AU2009201594A1

AU2009201594A1 - Building system

Info

Publication number: AU2009201594A1
Application number: AU2009201594A
Authority: AU
Inventors: Brett Preston
Original assignee: PRESTMAC Pty Ltd
Current assignee: PRESTMAC Pty Ltd
Priority date: 2008-04-21
Filing date: 2009-04-21
Publication date: 2009-11-05
Also published as: AU2009101337A4

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION Standard Patent Applicant(s): Prestmac Ltd Invention Title: BUILDING SYSTEM The following statement is a full description of this invention, including the best method for performing it known to me/us: P77451.AU.1 PtSetFilng Appication 2009-4-21.doc (P) -2 BUILDING SYSTEM Field of the Invention 5 The present invention relates to a building system to facilitate the construction of residential and commercial structures such as, but not limited to, patios, pergolas, carports, garden sheds, and fences. 10 Background of the Invention Many suburban and commercial structures are fabricated from steel posts and beams which are fixed to each other using corner fittings and/or brackets. The fittings and brackets 15 are in turn attached to the posts and beams by mechanical fasteners such as screws, bolts and rivets, or by welding. This process is time-consuming and labour-intensive, as many of the posts or beams may need to be supported during the fabrication process and many of the brackets are custom-made 20 on site or require a multi-step process to fit. Summary of the Invention In the statement of invention and description of the 25 invention which follow, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the 30 presence or addition of further features in various embodiments of the invention. One aspect of the present invention provides a building system comprising two or more elongated structural members, 35 and at least one joint adapted for connecting two or more of the structural members together, each joint having for each structural member a connector wherein the connectors of each N:\Perth\Cases\Patent\770O0-77999\P77451.AU. 1 \Specis\P77451 AU. 1 Specification 2009-4-15.doc 21/04/09 - 3 joint are attached together and wherein the connectors and the members are relatively configured such that either an individual connector is received by a respective member or a member is received by an individual connector. 5 An individual connector may be received by a member by fitting into an end of the member. A member may be received by an individual connector by fitting into or through the individual connector. 10 It is envisaged that this system may comprise joints of different configuration. For example: (a) different joints may have a different number of connectors (for example, from two to nine connectors); and/or, (b) the connectors in 15 different joints may extend at different angles from each other (for example, where a two connector joint may comprise two connectors extending at 300, 450, 90* or 1200 from each other). That is, the joints may be provided in a plurality of sets where joints in the same set have the same 20 configuration but joints in a different set have a different configuration. In one' embodiment of the system, the connectors are in the form of sleeves that fit over the ends of the members, i.e. 25 the members can slide into the sleeves. In this embodiment, the members, or at least the end of the members, may have a solid cross-section. However, in an alternative embodiment the connectors may be in the form of spigots that fit into the members. In this alternative embodiment, at least the 30 ends of the members are hollow, and the connectors may be either of a solid or hollow cross-section. The connectors and members may be made of similar cross sectional shape, but with different dimension to allow a 35 fitting of one in or through the other. These shapes may include, for example, square, rectangle, circle or oval. In addition, the connectors and members may be relatively N:\Perth\Cases\Patent\77000-77999\P77451.AU.1\Specis\P77451 AU.1 Specification 2009-4-15.doc 21/04/09 -4 configured to allow one to fit within the other to a distance of up to 150mm. In one embodiment, the members and the joints may be pre 5 formed with holes and/or slots at locations to allow mutual registration for receiving a mechanical fastener such as a screw or bolt. In a further embodiment, the members and joints may be 10 relatively configured so as to engage each other with a snap-fit. This may be achieved, for example, by the provision of a slot or recess formed in one of the member and a joint, and the provision of a protrusion on the other of the member and the joint, for seating in the slot or 15 recess. It is envisaged that the structural members and the joints be made from metallic materials such as steel, and treated steel, as well as suitable non-metallic materials such as 20 polyethelene or other plastic materials. The building system may be used for fabricating structures such as garden sheds, patios, pergolas, carports, fences and a roof. 25 Brief Description of the Drawings The preferred embodiments of the present invention will now the described, by way of example only, with reference 30 to the accompanying drawings, in which: Figure 1 is a schematic presentation of one form of a connecter utilised in an embodiment of the building systems; 35 Figure 2 is a schematic presentation of a second form of a connecter utilised in the building system; N:\Perth\Cases\Patent\77DOO-77999\P77451.AU.1\Specis\P77451.AU.1 Specification 2009-4-15.doc 21104/09 - 5 Figure 3 is a schematic presentation of a third form of a connector utilised in the building system. Figure 4 is a schematic presentation of a fourth form of a 5 connector utilised in the building systems; Figure 5 is a photographic representation of a mock building frame constructed using an embodiment of the building system; 10 Figure 6 is a schematic presentation of a further building frame constructed using the building structure in accordance with the present invention; 15 Figure 7 is a photographic representation from the front of a portion of a fence constructed using the building system; Figure 8 is a photographic representation of the fence 20 shown in figure 7 from a reverse angle; Figure 9 is a schematic representation of a fifth embodiment of the building system; 25 Figure 10a is an isometric view of a sixth embodiment of the building system; Figure lob is a front veiw of the connector shown in Figure 10a; 30 Figure 11a is a representation of a seventh embodiment of the building system; and, Figure bib is a representation of joints that may be used 35 in the building system shown in Figure 11a. N:\Perth\Cases\Patent\77000-77999\P77451.AU.1\Specis\P77451.AU.1 Specification 2009-4-15.doc 21/04/09 - 6 Detailed Description of the Preferred Embodiments of the Invention With specific reference to the accompanying drawings, and 5 in particular Figures 1-6, it can be seen that one embodiment of a building system 10 in accordance with the present invention comprises two or more elongated structural members in the form of a rectangular section, steel tubes (or posts) 12 and one or more joint 14 adapted 10 for connecting two or more of the tubes 12 together. As is apparent from the Figures, the joints 14 may be formed in many different configurations. Throughout this specification the term "joint 14" or "joints 14" is used in a generic sense to refer to all joints in accordance 15 with embodiments of this invention irrespective of their specific configuration. However joints of a specific configuration are denoted by the number "14" followed by an alphabetic letter. For example, Figure 1 depicts a joint 14a, figure 2 depicts a joint 14b, Figure 3 depicts 20 a joint 14c and Figure 4 depicts a joint 14d. Each joint 14 comprises a connecter 16i (where i = 1,2,3...) for each tube or structural member 12. The connectors 16i and the tubes 12 are relatively configured such that 25 either an individual connector 16i is received by a respective tube 12 or, a tube 12 is received by an individual connector 16i. Looking at the joints 14 in more detail, Figure 1 depicts 30 a joint 14a comprising three connectors, 161 162 and 163 which are all connected together to form a single integral unit. Each connecter 16i comprises a sleeve of the same shape as the tube 12 with a slightly larger dimension so that ends of respective tubes 12 can slide into a 35 corresponding connector 16i. This is depicted in Figure 5 which shows respective tubes 121, 122 and 123 fitting into the connector 16,, 162 and 163 respectively of joint 14a. N:\Perth\Cases\Patent\77000-77999\P77451.AU. 1Specis\P77451.AU.1 Specificaion 209--15.doc 21/04/09 -7 In joint 14a, the connectors 16, and 162 are in the same plane but are angled with respect to each other to form an included angle of approximately 1600, while the connector 5 163 extends centrally of the connectors 16, and 162 in a plane perpendicular to that containing the connectors 16, and 162 Figure 2 depicts the joint 14b comprising three connectors 10 161-163 wherein the connectors 16, and 162 are in the same plane and extend at an included angle T of approximately 1000 while the connector 163 extends in a plane perpendicular to that containing the connectors 16, and 162 and disposed so that its footprint lies over the connector 15 162 and with a face 18 co-planar with an edge 20 of the connector 162. The joint 14b is also depicted in use in the structure 10 of Figure 5. Figure 3 depicts the joint 14c having four connectors 161, 20 162, 163 and 164 in the general configuration of a cross. The connectors 16, and 162 lie in the same plane and form an included angle of approximately 160*. The connectors 163 and 164 are co-linear with each other and extend centrally of the connectors 161 and 162 in a perpendicular plane. 25 Two joints 14c are depicted in the structure 10 shown in Figure 5. Figure 4 depicts the joint 14d which also comprises four connecters 161, 162, 163 and 164 and may be considered as a 30 variation of the joint 14b shown in Figure 2 with the addition of the connector 164 which is co-planar with connector 163 but on an opposite side of the connectors 16, and 162. Four of the joints 14d are depict in the structure 10 shown in Figure 5. 35 The structure 10 in Figure 5 also comprises a joint 14e comprising three connectors 161, 162 and 163 arranged in a N:\Perth\Cases\Patent\7700O-77999\P77451.AU.1\Specis\P77451.AU.1 Specification 2009-4-15.doc 21/04/09 -8 mirror image of the joint 14b. Figure 6 depicts a structure 10 in the form of a frame for a 6m by 9m shed composed of a number of tubes 12 and 5 twelve joints 14. While there are twelve joints 14 in total, only five different configurations of joints 14 are required. In particular, there are two joints 14a; two joints 14c; four joints 14d; two joints 14f; and two joints 14g. The joints 14f and 14g each comprise four 10 connectors but arranged in a mirror image configuration with respect to each other. It would be appreciated that when constructing a structure 10 using embodiments of the present invention, the tubes 15 12 can be simply slid into the connectors 16i of the appropriate joint 14. A user can then either (a) fasten a tube to the connector, for example by use of a tek screw, bolt or rivet; or (b) slide in another one or more tubes 12 into other connectors 16i of the same joint and 20 subsequently fastened all the tubes to each of the connectors while making appropriate adjustments by sliding a particular tube within its corresponding connector to take account of building tolerances. The connectors 16i maybe joined together to form a joint 14 by any known 25 technique which provides sufficient strength and integrity required by the joint for its intended purpose and load. For example the connecters 16i may be attached together by welding, soldering, riveting or by the use of screws, bolts, or a combination thereof; or alternately by forming 30 the joints 14 as cast components. Figures 7 and 8 depict a structure in the form of a fence constructed using a second embodiment of the building system 10 which comprises a plurality of structural 35 members in the form of fence posts 22 and fence rails 24; and, joints 14h and 14i. N:\Perth\Cases\Patent\77000-77999\P77451.AU. 1\Specis\P77451.AU. 1 Specification 2009-4-15.doc 21/04/09 -9 Each of the joints 14h is a corner joint and comprises connectors 161 and 162 that extend at right angles to each other and receive respective fence rails 24; and, a connector 163 that is nestled in the right angle formed by 5 the connector 161 and 162 and is formed with open ends so that a fence post 22 can pass through the connector 163. The joint 14i comprises two connectors 16, and 162. The connector 16, is essentially in the form of a short sleeve 10 which is open at opposite ends and through which a fence post 24 can pass through. The connector 162 is fixed centrally of the connector 16, and is also open at opposite ends but extends perpendicular to the connector 16, to receive a fence post 22 which passes therethrough. 15 In the embodiment of the building system 10 shown in Figures 1-8, the elongate member 12 is received in a connector 16 of a joint 14. Typically the member 12 will be inserted into the connector 16 to a depth of about 20 50mm-150mm. This provides a user with a degree of flexibility and adjustment to take account of tolerances and imprecisions in the manufacturing process of the components of the system 10 and in the construction of the structure formed with the system 10. A close fit between 25 the member 12 and connector 16 is preferred so as to give the coupled components a degree of self locking when they are mutually engaged. Indeed, the member 12 and connector 16 may be relatively configured to provide a light or marginal interference fit. Once these components are 30 engaged to the appropriate extent having regard to the structure being constructed, they may be fixed together with mechanical fasteners such as tek screws 26 as depicted in Figure 7, although other mechanical fasteners or fastening systems may be used such as nuts and bolts, 35 rivets, welding and soldering. Figure 9 depicts a further embodiment of the building N:\Perth\Cases\Patent\770O0-77999\P77451.AU.1\Specis\P77451.AU.1 Specification 20094-15.doc 21/04/09 - 10 system where the member 12 and joint 14 are relatively configured to provide a snap fit. In this embodiment, the member 12 is provided with an elongated slot 28 in one surface while the connector 16, of a joint 14 is formed 5 with a depression 30 formed in an outside surface 32 and which on the inside of the surface 32 (ie on the inside of the connector 16,) forms a corresponding protrusion. When the member 12 is inserted into the connector 161, the protrusion will initially bear against the surface of the 10 tube 12 containing the slot 28 to provide an interference type fit, and subsequently snap into the slot 28 to provide a degree of self locking between the member 12 and the joint 14. 15 Figures 10a and lob depict a further joint 14j comprising nine connectors 161 -169. The connector 161-168 radiate outwardly and downwardly from a central connector 169. The joint 14i may be used for a pergola with the connector 16, 169 being used to connect to roof beams (not shown) and the 20 connector 16, used for connecting to a central support column or post(not shown). As previously mentioned, the connector 16,-168 are inclined or angled to form an included angle of less than 900 relative to the central connector 169. Thus, a building constructed with the joint 25 14i formed at a central location will have a roof having a highest point coincident with the location of the joint 14i with roof beams inclined downwardly therefrom to a peripheral wall of the building. 30 Figures lla and lb depicts a range further joint for use with a combination of circular post and rectangular tubes. Figure lla shows the building system 10 used for constructing a fence. Here the system incorporates joints 14k and 141 which joint structural members in the form of 35 circular posts 12, and rectangular tubes 122. The joint 14k which comprises three joints 16,, 162 and 163. The connectors 161 and 162 extend at right angles relative to N:\Perth\Cases\Patent\77000-77999\P77451.AU.1\Specis\P77451 AU.1 Specification 2009-4-15 doc 21/04109 - 11 each other from the connector 163. While the connectors 161 and 162 are in the form of rectangular sockets for receiving tubes or post of similar cross-sectional shape, the connector 163 is circular so as to receive a circular 5 post or beam. The connector 163 may be in the form of a circular band of metal so that the post can pass wholly through the connector 163, or can be in the form of a cylinder post at one end thus forming a cylindrical type socket. The joint 141 comprises only the circular 10 connector 163 and a single rectagular connector 16,. As shown in Figure 11b the number of the rectangular connectors and their spacing about the circular connector 163 can be varied depending on the application at hand. 15 Joint 14m provides three rectangular connectors 161, 162, 164 with connector 16, spaced 90* from connector 162, and connector 164 spaced 90* from connector 162. In joint 14n there are two rectangular connectors 16, and 162 spaced by 1350. In joint 140 there are two connectors 161 and 162 20 spaced by 1800 about the connector 163. As previously submission embodiments of the present building system maybe used to build a variety of different structures. Typically when building a enclosed structure 25 or partially enclosed structure such as a pergola or shed, as shown for example in figures 5 and 6, the structure may comprise one or more wall frames, where each wall frame comprises at least one column and a roof frame where the roof frame comprises at least one roof beam, and a 30 plurality of joints 14. The joint may be configured to have connectors that enable connection between a column of a wall frame and a beam of a roof frame. Naturally, the arrangement of the slot 28 and the 35 depression protrusion 30 may be swapped between the member 12 and joint 14. By forming the slot 28 of a length greater than the length of the depression/protrusion 30, a N \Perth\Cases\Patent\77000-77999\P77451 AU.1\Specis\P77451.AU.1 Specification 20094.15.doc 21104/09 - 12 degree of adjustment is provided between the member 12 and the joint 14. Now that various embodiments of the invention have been 5 described in detail it will be apparent to those skilled in the relevant arts that numerous modifications and variations may be made without departing from the basic inventive concepts. For example, while in the above described embodiments, the joints 14 and structural 10 members 12 are relatively configured so that the structural members 12 fit in or through the joints 14 and they may have an opposite configuration so that the joints 14 in particular the connectors of the joints 14 fit inside ends of the structural members 12. Also, while the 15 structural member 12 and the connectors 16i of the joints 14 are depicted as having a rectangular cross-section, different cross-sectional shapes are possible. For example, the member 12 and connectors 16i may have circular, square or oval cross-sections. Further, while 20 in the embodiments described, approximate included angles between connectors are specified (e.g. 1600 between connectors 161 and 162 in joints 14a and 14c) these angles will be dictated by the application at hand and be varied accordingly anywhere between 00 and 1800 to suit. Such 25 modifications and variations, together with others that would be obvious to persons skilled in the art are deemed to be within the scope of the present invention, the nature of which is to be determined from the above description and the appended claims. N:\Perth\Cases\Patent\77000-77999\P77451.AU.1\Specis\P77451.AU.1 Specification 2009-4-15.doc 21/04109

Claims

1. A building system comprising two or more elongated structural members, and at least one joint adapted for 5 connecting two or more of the structural members together, each joint having for each structural member a connector wherein the connectors of each joint are attached together and wherein the connectors and the members are relatively configured such that either an individual connector is 10 received by a respective member or a member is received by an individual connector.

2. The building system according to claim 1, wherein at least one connector is received by a member by fitting 15 into an end of the member.

3. The building system according to claim 1, wherein at least one member is received by an individual connector by fitting into or through the individual connector. 20

4. The building system according to any one of claims 1 3, wherein the joints are provided in a plurality of sets where joints in the same set have the same configuration but joints in a different set have a different 25 configuration.

5. The building system according to claim 1, 2 or 4, wherein the connectors are in the form of sleeves that fit over the ends of the members. 30

6. The building system according to any one of claims 1 5, wherein the connectors and the members are made of similar cross-sectional shape, but with different dimension to allow a fitting of one in or through the 35 other.

7. The building system according to any one of claims 1 N:\PerthCases\Patent\7700077999\P77451.AU.1\Specis\P77451.AU.1 Specification 2009-4-15.doc 21/04109 - 14 6, wherein the connectors and members are relatively configured to allow one to fit within the other to a distance of up to 150mm. 5

8. The building system according to any one of claims 1 7, wherein the members and joints are pre-formed with holes and/or slots at locations to allow mutual registration for receiving a mechanical fastener. 10

9. The building system according to claims 1-7, wherein the members and joints are relatively configured so as to engage each other with a snap-fit.

10. The building system according to claim 9, wherein the 15 snap-fit is formed by the provision of a slot or recess formed in one of the member and a joint, and the provision of a protrusion on the other of the member and the joint, for seating in the slot or recess. 20

11. The building system according to any one of claims 1 10, wherein the members and the joints are made from metallic materials such as steel, and treated steel.

12. The building system according to claims 1-11, wherein 25 the building system is used for fabricating structures such as garden sheds, patios, pergolas, carports, fences and a roof.

13. A building frame comprising: 30 one or more wall frames; a roof frame wherein the or each wall frame comprises at least one column member and the roof frame comprises at least one roof beam; and, 35 at least one joint for connecting at least one of the column members to at least one of the roof beams, each joint having for each member to which it is connected, a N:\Perth\Cases\Patent\77000-77999P77451.AU.1XSpecis\P77451.AU.1 Specification 2009-4-15.doc 21/04/09 - 15 connector wherein the connectors of each joint are attached together and wherein the connectors and the members are relatively configured such that either an individual connector is received by a respective member or 5 a member is received by an individual connector.

14. The building system or the building frame according to any one of claims 1-13 wherein at least two of the connectors for at least one joint extended out an inclined 10 angle of less than 900 from each other.

15. The building system substantially as herein described with reference to and as illustrated in the accompanying drawings. N.\Perth\Cases\Patent\77000-77999\P77451.AU.1\Specis\P77451.AU.1 Specification 2009-4-15.doc 21/04/09