AU620817B2 - Improvements in or relating to a jig and a method of forming a panel for a building - Google Patents

Description

S F Ref: 70414 FORM COMMONWEALT JF AUSTRALI PATENTS ACT 1952 V COMPLETE SPECIFICATION

(ORIGINAL)

FOR OFFICE USE: Class Int Class 9

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Complete Specification Lodged: Accepted: Published: Priority: Related Art: Name and Address of Applicant: William Murphy 25 Pohutukawa Avenue Howick, Auckland NEW ZEALAND Spruson Ferguson, Patent Attorneys Level 33 St Martins Tower, 31 Market Street Sydney, New South Wales, 2000, Australia Address for Service: 9* S

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@5 Complete Specification for the invention entitled: Improvements in qr Relating to a Jig and*er a Method of Forming a Panel -i4er a Building The following statement is a full description of this invention, including the best method of performing it known to me/us This invention relates to a jig and/or apparatus for construction and/or a method of forming a panel and/or a building.

It is an object of the present invention to provide a jig and/or apparatus for construction and/or a method of forming a panel and/or a building which will at least provide the public with a useful choice.

Accordingly in one aspect the invention consists in a jig comprising a platform, a pair of spaced apart substantially parallel side members mounted on said platform, the distance between said side members being a multiple of a selected length, and a base member at or adjacent one end of said platform and substantially at right angles to said side members, so that a panel of predetermined width may be formed in said jig by first members and second members, said first members being positioned parallel to said side members and extending from said base member and being spaced apart by said second members.

In a further aspect the invention consists in a jig as described in the preceding paragraph and a further jig, said further jig including a channel itherein, distance indicators being associated with said channel, the dimensions of Ssaid channel being such that a plurality of lengths of timber may be positioned therein in side by side relationship to be cut to length.

In a still further aspect the invention consists in a method of forming a panel comprising the steps of providing a jig accordingly to any one of claims 1 to 4, positioning a selected first member in said jig adjacent one side member and substantially abutting said base member, positioning one or more second members at right angles to said first member, positioning a further first member at right angles to said second member and so on until a second member is positioned adjacent the other said side member, the connecting adjacent members one to the other.

In a still further aspect the invention consists in a building formed from panels constructed according to a method according to the preceding paragraph in a jig according to the preceding but two paragraph.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are "purely illustrative and are not intended to be in any sense limiting.

The invention consists in the foregoing and also envisages constructions of which the following gives examples.

One preferred form of the invention will now be described with reference to the accompanying drawings in which, :Figure 1 is a diagrammatic perspective view of a jig according to one S" preferred form of the invention, Figures 2 to 6 are diagrammatic representations showing the use of limit members in the jig of Figure 1, ~1 Figure 7 is a diagrammatic perspective view of a further jig according to one preferred form of the invention, Figure 8 is a diagrammatic perspective view of a saw guide for use with the jig of Figure 7, Figure 9 is a cross-section on A-A in Figure 8, Figure 10 is a view of a clamp usuable with jig of Figure 7, Figure 11 shows a ship-lap joint between panel claddings, f Figure 12 is a diagrammatic side elevation of an alternative joint between cladding members, *o Figure 13 is a diagrammatic pictorial view of a first eeeee Stype of corner panel, Figure 14 shows the panel of figure 13 during construction, *.5 e• S Figure 15 is a diagrammatic pictorial view of a second type of corner panel used in conjunction with the panel of figure 13, Figure 16 shows a step in forming the corner panel of "'figure Figure 17 is a diagrammatic pictorial view of a step in a potential method of forming a split panel, Figure 18 is a pictorial view of the split panel so formed, Figure 19 is a pictorial diagrammatic view of a balloon frame gable end split panel formable in the jig of the -4invention, Figure 20 shows a plan view of a flooring panel during construction with a section of S S1 and a side elevation alsd being shown, the panel being formable in the jig of the invention, Figure 21 is a plan view of a possible wall panel for formable in the jig of the invention, Figure 22 shows a possible ceiling panel formable in the jig of the invention, and Figures 23 to 27 are cross-sections of interior and exterior joints formed from panels formed in a jig according to the invention used in a building.

Referring to the drawings a jig and/or apparatus for construction and/or a method of forming a panel and/or a building are provided as follows.

Referring to Figure 1 a jig 1 is provided which comprises a platform 2 which may be formed for example of a sheet of material which can be scrap or demolition material. The platform 2 can be placed on a support or stand for example legs (not shown) so that it is raised to a suitable height for example i knee height.

Onto the platform or deb 2 is provided a first side member 3 which in the coo.

construction shown in Figure 1 extends from adjacent one end 4 of the bed 2 to a position adjacent the other end 5 of the bed 2. Spaced from the side 3 is a second side 6 which is substantially parallel to the side 3 and is separated by a distance, the module width which is selected to form the basis of the panel width for example 2,400mm. This length is a multiple of a selected length, preferably 0 i I r x 4 r i a basic module size or multiple of a basic module for example a width of 2,400mm readily receives a standard cladding dimension of 1,200mm.

The length of the bed 2 can be any further selected length for example 4,000mm.

A third member is provided at or adjacent the end 4 and forms a base member 7.

A further jig can be formed to provide a cutting platform in the form of a channel 8 which can be formed for example between a side member 9 and a further side member 10 positioned for example on a further platform 11. The 1 10 members 9 and 10 are substantially parallel one to the other. A stop 12 can be I provided which is positionable into the channel 8 for example by providing a downwardly depending portion 13 which extends into the channel 8 and a crosspiece 14 which is able to rest on the upper faces of the members 9 and 11.

a The stop 12 can be fixed into position and is useful when many equal lengths are being cut. This occurs for example during pre-cutting operations. distance S* V.

indicating marks 15 can be provided on side members 9 and 10 to provide a reference for cutting unequal lengths at the same time.

The width of the channel 8 is selected so that for example a plurality of timber members to be cut to length can be positioned therein so as to be relatively tight to 0 SS

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allow easy and relatively accurate cutting. A clamp 16 can be provided to press the timbers together and against one edge 10 of the jig. The clamp 16 may be a quick release adjustable type the jaw 17 of which presses against a pin 18 passing through an aperture 19 in the side member 9.

A saw guide 20 can also be provided which is able to be positioned across the end of the channel 8.

The saw guide preferably comprises a relatively stiff but flexible sheet of material 21 such as plywood. Other 10 materials may be used. A slot 22 is provided in the material. This may be made by an initial cut in use.

Below end 23 an end cross member 24 is positioned and the slot 22 may extend into but not fully through the member 24. At the other end 25 a further end cross member 26 is 15 provided. This may be and preferably is above sheet 21.

This holds the sheet 21 together. The side edges of the saw guide 20 are stiffened for example by channel members 27 the outer edge of which is returned under the sheet 21 by extension 28. The shaped edges 28 provide stiffness and the extension 28 provides a wear surface under the sheet 21. By suitable positioning of the channel members 27 on the sheet the space between inner edges 28 can be made substantially equal to the width of a hand held circular saw to provide a guide for the saw.

The saw guide 20 can be positioned across the member 9 and 10 for example by passing a pin 30 through an aperture 31 in the saw guide or otherwise as desired. A stop 32 can -7be provided on the upper side members. The stop 32 may carry pins positionalbe in holes 33 in that side member.

Also further apertures can be provided on the saw guide By suitably selecting apertures on the saw guide and apertures 33 selected angles of cut of member in channel 8 can be provided. Slots can be cut in side members 9 and as required to allow the saw blade to pass.

Assuming the cutting of the platform is to cut five timber lengths of for example 100 x 50 timber (94 x 47 when dressed) then the width of the channel forming the cutting see*-platform would be 470mm. Where 75 x 50 (69 x 47) is to be S" provided the width of the cutting platform should be 345mm.

Thus T..;here timber is to be cut to length the timber ee00o pieces are positioned into the cutting platform as seen in figure 1 with the adjustable stop 12 positioned against selected stops 15 so as to provide the correct length and

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5 S.o the saw guide positioned for example as shown in figure i.

A saw is then passed along the saw guide 16 to cut the timbers. Once the timbers have been cut to the desired lengths panels can be provided as follows for example to provide a flooring panel such as shown in figure 12 of a length of for example 3,900mm a limit member (figure 1) is placed into the jig, for example, the limit member 40 with its edge 41 a distance of 3,947mm from the edge 42 of the base 7, joist 50 (figure 20) is then placed hard up against the base 7 and the floor joists 51 placed into the suitable positions. Noggins such as noggins 52 are then placed -8against the edges 41 and 42 to correctly space the joists 51. The joists 50 are then nailed to the joists 52 for example by nails passing transversely through the joists into the ends of the joists 51 for example in pairs. The doubled joists can then be nailed together for example by skew nailing. The noggins 52 are then removed and spacers of the correct length (not shown) placed against the joists allowing the noggins to be placed in the correct position followed by further spacers and further noggins and so on till the end. The noggins can then be nailed to i:o the joists 51. The frames so formed can then be clad for S, example by material such as particle board which is placed on top of the frame forms and nailed through to the joists ro0 S, and noggins. Of course all joists and noggins can be placed then all nailed. Usually this is the preferred procedure.

e, In figure 2 the limit member 40 is positioned to form a rectangular panel. Pecked lines 52 indicate that other positions are available. In figures 3 and 4 the limit member 40 is positioned to form parts of gable ends and in 4 figure 5 the limit member 53 is positioned to form the If centre panel of a gable. In figure 6 the limit member 54 is positioned to form trusses.

The wall panel of figure 20 is formed in a similar manner with the limit member 40 being set for example at 2412mm. The top and bottom plates 60 and 61 are then placed against the base and the limit and stud 62 placed on -9edge against side member 3. Stud 63 is placed on edge against the stud 52 and the remainder of the studs 64 placed in their approximate position. Noggins are again positioned against the members 7 and 40 and substantially the same method pursued as to form the floor panels shown in figure The frame so formed can be covered in horizontal rows by building paper which shouldbe overlapped and then o. cladding placed onto the frame as required.

oooo The panels if provided with a ship-lap as shown in

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off figure 11 are overlapped substantially as shown so that panel 7 and 71 are overlapped in a ship-lap form. Where no ship-lap is provided the panels 72 and 73 can be brought together and a weather shield 74 with capillary grooves 15 can be provided to seal the edge.

g" The ceiling panels are formed in substantially the same manner.

.o Half panels can be formed by providing a member o against the base member 7. Members 81, 82, 83, 84, 85 and S. 20 86 are positioned by use of noggins as previously described. Lines can be drawn down the centre of joists 83 and 86 as indicated and cladding members such as particle board can be placed on this line and in line with the edge 42 of base 7. The board is then nailed as required. By cutting the boundary joists at the two ends half panels are able to be formed which in fact are light enough to lift.

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I o r Referring now to Figures 13 and 14 corner members can be provided by providing in a panel 100 a tongue 101. This can be achieved by providing the stud 101 on edge and cutting away the corner parts 102 of the top and bottom plates 103 and 104. A second corner member is provided by providing a member having a pair of studs 105 and 106 the distance apart of which can be set by a dummy stud 107 which is removed once the panel is taken from the jig.

This provides a slot 108 into which the tongue 101 can be positioned in use.

Split panels can be formed by providing a panel 110 which can be cut at positions 111 and 112 so as to provide the half panels 113 and 114 to which tongues 115 and 116 are attached by providing two studs on edge at 117. One stud is nailed to each half panel while the half panels are in the jig 1.

Construction of half panels in jig 1 allows cladding such as ceiling covering to be neatly applied. If a series of five double half panels are to be made the half panels can be numbered say one to ten. If the fifth and sixth half panels are made first say the fifth half panel on the left and the sixth half panel on the right, the fifth and sixth half panels are made and clad with any required gap 3m) between the cladding positioned on the half panels. The cladding may overlap onto the side members 3 and 6, the fifth half panel can be removed and the sixth half panel moved to the left. The seventh half panel is then made and clad leaving the required gap between the cladding. The sixth half panel -11- 0 I ~1 I -I i is removed and the seventh half panel is moved to the left. This is continued until all half panels are made. The excess is then cut from the last panel. The fifth panel is then inserted in the right of the mould and the fourth half panel made and clad. This process is repeated until all panels are made. Thus only two cuts to remove excess cladding material are required and these cut edges are at the ceiling end where this will be covered during finishing.

A balloon gable end panel substantially as shown in Figure 22 can be provided by repositioning the limit member 40 to correctly position the angled end members 120. The half panels so formed can be bolted for example by bolts such as at position 121 to form the two panels into a single panel.

|ij i In use the panels are formed substantially as above described and from the ii panels so formed a building can be erected by interconnecting the panels to form flooring walls &nd a ceiling and roof. By use of the cutting jig even unskilled people can dimension the timbers squarely and accurately to length |1 *5 I without requiring industrial machinery. The use of a small light power circular saw assists. Once cut to length the platform jig uses the previously cut framing I timber set out in particular ways such that the fabricated panels will fit together accurately when assembling the house or other building. In particular the relationship between the module size and the width and thickness of the timber is expressed on the jig ;1 n allowing accurate interlocking panels to be made. This is a significant factor for the interlocking panels as well as maintaining module length will also be self-plumbing within any allowable limits for a successful house. Also the jig is able to be used as a sawstool with stops cut to length accurately. The construction will work even if an inexperienced person measures the distances only reasonably accurately. Also where openings for doors and windows are in panels in the sill or bottom trimmers become spacing 1. I0 lengths for the openings and most of the openings are standardized for doors and windows. The system can be *fee extended however to the use of non-standard, for example, *recycled windows and doors so as to reduce prices to an 4 i even greater level than possible.

By the use of two half panels or multiples of other fractional panels, eg. three one third panels, the position of doors, windows and interior joints can be varied whilst remaining within an overall modular construction. That is to say that modules can be shifted within an overall wall 0000 length.

In modular constructions module creep can occur due to, for example bent timber, proud knots, imperfect gauging or material between studs, such as building paper for a weatherproof seal or the use of rough sawn timber. Figure 23 shows a joint where tongue 140 extends from panel 141 and slides in slot 108 in panel 142 which includes studs 143 and 144. The studs 143 and 144 are connected by the -13top and bottom plate. The interior corner so formed readily receives interior lining.

In figure 24 tongue 150 on panel 151 enters slot 152 in panel 153 at a point between the ends of the panel. In figure 25 tongue 160 on panel 161 is positioned in slot 108 in panel 162 having studs 163 and 164. Panel 165 butts against panel 162. Figure 26 shows a joint between four panels in which tongues 170 and 171 on panels 172 and 173 enter a slot as indicated in figure 24 in panel 153. The i0 construction of figure 27 is an alternative to the construction of figure 26 where tongues 180 and 181 extend Does from panels 182 and 183.

:Thus it can be seen that at least in the preferred form of the invention a jig and/or a method of erect 15 constructing a panel and/or a building are provided which allows at least in the preferred form of the invention a self built extremely low cost house to be provided using conventional materials but which apply a building technology allowing unskilled people to achieve a 20 relatively high quality home even using rough sawn framing timber. It is a particular advantage that the buildings can be prefabricated virtually anywhere and with few conventional tools. One size of timber can be used for up to 95% of the building and the jig can be simply constructed and made out of for example demolition materials. The size of the jig is such that it can be fitted into a small garage or workshop. The jig and method -14- C Li are also suitable for the provision of a simple step by step guide to enable the constructions to be put into effect. The construction also allows the building to be prefabricated so that building can be spread over a period of time to allow ease in funding. It is a particular advantage of the jig of the invention that use can be made of dummy studs either on edge or on the flat for the purposes of creating spaces for tongues to fit into in a manner such that the tolerance of the space is set by the s•.•lO1 dummy stud. A feature of the jig is the way in which full top and bottom plates are used in the jig but later by the use of saw cuts parts of top and bottom plates are removed o• to enable interlocking of panels or the formation of split panels.

Also each panel if correctly constructed has its studs and nogs on the same basic matrix. Also the module length is maintained for the length and breadth of the building constructed from panels made in the jig of the invention.

This can be achieved because the jig of the invention 5550 .o 20 defines the boundaries of each panel rather than the fixing the position of each member forming the panel frame.

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Claims (7)

1. A jig comprising ,a platform, a pair of spaced apart substantially parallel side members mounted on said platform, the distance between said side members being a multiple of a selected length, and a base member at or adjacent one end of said platform and substantially at right angles to said side members, so that a panel of predetermined width may be formed in said jig by first members and second members, said first members being positioned parallel to said side members and extending from said base member and being spaced apart by said second members.

2. A jig as claimed in Claim 1 wherein said platform also mounts a moveable limit member positionable on said platform and displaced from said base member.

3. A jig as claimed in either Claim 1 or Claim 2 wherein said jig is formed on a support to position said jig at a desired height.

4. A jig substantially as herein described with reference to the accompanying drawings.

5. Apparatus for construction comprising a jig as claimed in any one of the preceding claims and a further jig, said further jig including a channel therein, distance indicators being associated with said channel, the dimensions of said channel being such that a plurality of lengths of timber may be positioned therein in side by side -16-

11- L i relationship to be cut to length. 6. Apparatus for construction comprising a jig as claimed in any one of the preceding claims and a further jig all substantially as herein described with reference to the accompanying drawings. 7. A method of forming a panel comprising the steps of providing a jig accordingly to any one of Claims 1 to 4, positioning a selected first member in said jig adjacent one side member and substantially abutting said base member, positioning one or more second members at right angles to said first member, positioning a further first member at right angles to said second member and so on until a second member is positioned adjacent the other said side member, then connecting adjacent members one to the other. o 0 S: 8. A method of forming a panel as claimed in Claim 7 wherein said method Sfurther includes the step of adding cladding to said members as necessary. 9. A method of forming a panel as claimed in either Claim 7 or Claim 8 wherein said method further includes the step of placing spacers between selected adjacent first members of some panels and removing said spacers after connection of the remaining members to thereby form a slot, and forming a tongue on other selected panels which tongues on erection of a building enter appropriately positioned slots in other panels to form a corner joint. A method of forming a panel substantially as herein described with reference to the accompanying drawings. 11. A building formed from panels constructed according to -17- I a method according to any one of Claims 7 to 10 in a jig according to any one of Claims 1 to 4.

12. A building formed from panels substantially as herein described with reference to the accompanying drawings. DATED this ELEVENTH day of DECEMBER 1991 William Murphy Patent Attorneys for the Applicant SPRUSON FERGUSON o *oo -18-