CA2804407C - Log wall connector system - Google Patents

Abstract

A building structure comprises a post having a vertically extending longitudinal face. A plurality of horizontal logs extends from said longitudinal face and has an end face in abutment with said longitudinal face. The post having an undercut channel in said longitudinal face and extends along said post. At least one of said end faces has a recess aligned with said undercut channel, and a spline assembly extends between said post and said log to secure said log to said post. The spline assembly includes a key located in and extends between said channel and said recess and an insert in one of said undercut channel and said recess. The insert co operates with said key to facilitate relative sliding movement therebetween.

Description

2

3 CROSS-REFERENCE TO RELATED APPLICATIONS

4 [0001] This application claims priority from United States Application No. 13/364,283 filed on February 1, 2012.

7 [0002] The present invention relates generally to wall structures and in particular to log 8 wall structures.
9 [0003] Log construction has been known for many decades as typified by the log cabin.
For many years the logs have been notched so that at a corner, logs forming one wall of a 11 structure can be laid on top of and at an angle alternating with logs from an intersecting 12 wall. Although a number of materials may be used to form the "logs" used as wall 13 members, including various types of composite materials, the wall members are typically 14 milled from wood. The term "logs" will be used throughout this disclosure to include all types of materials that simulate a horizontal wooden log and includes different cross 16 sections, either machined, hand-hewn or in a natural state.
17 [0004] The assembly of buildings from logs has been performed using traditional 18 techniques. Where hand hewn logs are used, the builder individually fits each log to ensure 19 a proper fit. Whilst this is traditionally done at the final site of the building it has become more common to assemble the shell of the building at a convenient remote location and 21 then disassemble the logs for transportation. The building is then reassembled at the 22 intended site and finished.
23 [0005] Log buildings using manufactured logs have the logs machined and cut at the 24 factory to provide the desired floor plan. The logs are then transported to the site where the building is assembled.
26 [0006] In either case, assembly of the building at the final site requires the relocation of 27 skilled workmen, the provision of tools and equipment for assembly at the site and the 28 exposure of the partially assembled structure to a potentially inclement environment.
- -22337767.1 1 [0007] In practical use, traditional construction is usually limited to right angle corners 2 because of the complexity of the angled notches required for non-right angle corners. More 3 recently, posts have been introduced that can be milled with longitudinal faces at a range of 4 desirable angles such that wall members having square-cut ends can be attached by spikes to the posts to form right-angle or non-right angle corners.
6 [0008] To form a tight connection between the logs and the posts, split key members 7 have been used that engage cooperating undercut recesses in the end of the log and a face 8 of the post. In US Patent 6,050,033 there is disclosed a spline arrangement in which the log 9 and post are connected by a key formed by a pair of wedges. The key is expandable and secures the log to the post. A first section of the key member is fitted into place to engage 11 the recesses in the post and the log and then a second section of the key member is inserted 12 and tapped into place beside the first section of the key member. The cross-sections of the 13 split key member are wedge-shaped and tighten the joint as the second portion of the key 14 member is tapped into place.
100091 It is necessary to ensure that the interconnecting butt joints are tight and provide 16 an effective seal, but at the same time accommodate relative movement between logs whilst 17 maintaining the seal. This is particularly an issue in wooden log construction because of 18 the shrinkage of the logs as they dry. This causes the logs to settle and move vertically 19 down. However, in some circumstances the connection of the key to both the log and the post as shown in US Patent 6,050,033 may inhibit such movement and as a result a gap is 21 created between adjacent logs in the log walls.
22 [0010] Similar considerations apply where a pair of walls intersect, such as where an 23 internal wall meets an external wall. This may occur between the locations of the posts and 24 a secure butt joint between the intersecting walls is required.
[0011] It is an object of the present invention to obviate or mitigate the above 26 disadvantages.

22337767.1 2 [0012] According to one aspect of the invention, a building structure comprises a 3 vertically extending longitudinal face, a plurality of horizontal logs extending from said 4 longitudinal face and having an end face in abutment with the longitudinal face. An undercut channel is provided in the longitudinal face and extends along the face. At least 6 one of the end faces has a recess aligned with the undercut channel and a spline assembly 7 extends between the longitudinal face and the log to secure the log to the post. The spline 8 assembly includes a key located in and extending between the undercut channel and the 9 recess and a slide member in one of the undercut channel and the recess.
The slide member co-operates with the key to facilitate relative sliding movement of the logs and the post.
11 [0013] A further aspect of the invention provides a spline assembly to secure a log to a 12 face of a log wall of a building. The spline assembly includes a slide member for insertion 13 into an undercut channel in a vertical face and a key for insertion into said slide member 14 and a recess in said log to extend between said log and inhibit separation thereof.
[0014] A still further aspect of the invention provides a method of assembling a log to a 16 vertically extending face comprising the steps of providing an undercut channel in a 17 longitudinal face, inserting a slide member in the undercut channel providing a recess in the 18 log, aligning the recess with the slide member undercut channel, inserting a key into the 19 key slide to extend between the post and the log, and securing the key to the recess, whereby relative movement between the log and the post is accommodated by relative 21 sliding movement between the key slide and the key.
22 [0015] The face may be provided as a face of the post or as a face of an intersecting 23 wall.
24 [0016] A further aspect of the invention is the provision of a building having walls formed from one or more wall sections. At least one of the wall sections has a plurality of 26 logs interconnected at opposite ends by a respective post. A spline assembly secures the 27 posts to the logs. The wall section is secured to an adjacent wall section by spline 28 assemblies connecting the posts of the adjacent wall sections.

22337767.1 2 [0017] The principles of the various aspects of the invention may better be understood 3 by reference to the accompanying illustrative drawings which depict features of examples 4 of embodiments of the invention, and in which:
[0018] Figure 1 is a perspective view of a building.
6 [0019] Figure 2 is a view on the line II-II of Figure 1 showing components as 7 assembled.
8 [0020] Figure 3 is a view similar to Figure 2 with the components in a expanded 9 position.
[0021] Figure 4 is an exploded perspective view of the components shown in Figure 3.
11 [0022] Figure 5 is a perspective view of a key member used in the embodiment of 12 Figures 1 to 4.
13 [0023] Figure 6 is a rear perspective of the key member of Figure

5.
14 [0024] Figure 7(a)-(k) is a schematic representation of the steps of assembling the building of Figure 1.
16 [0025] Figure 8 is an exploded view of components used at a corner of the building of 17 Figure 1.
18 [0026] Figure 9 is an exploded perspective view of an alternative embodiment of the 19 building.
[0027] Figure 10 is an enlarged view of the assembly shown in Figure 9.
21 [0028] Figure 11 is a view in the direction of arrow XI-XI of Figure 10.
22 [0029] Figure 12 is a exploded perspective view of a further embodiment of building 23 structure.
24 [0030] Figure 13 is a plan view of Figure 12 in the direction of arrow XIII-XIII.
[0031] Figure 14 is a plan view similar to Figure 13 showing a further step in the 26 assembly of the building.

22337767.1 1 [0032] Figure 15 is a view similar to Figure 14 showing a yet further step in the 2 assembly of the building.
3 [0033] Figure 16 is a view similar to Figure 15 showing a still further step in the 4 assembly of the building.
[0034] Figure 17 is an enlarged plan view of a component used in the building of

6 Figures 12 to16.

7 [0035] Figure 18 is a view similar to Figure 17 showing the component of Figure 17 in

8 an expanded position.

9 [0036] Figure 19 is a view similar to Figure 17 of an alternative embodiment of the component.
11 [0037] Figure 20 is a view similar to Figure 17 of a further embodiment of the 12 component shown in Figure 17.
13 [0038] Figure 21 is a still further alternative embodiment of the component shown in 14 Figure 17.
[0039] Figure 22 is a view similar to Figure 12 showing a further step in the assembly 16 of a building.
17 [0040] Figure 23 is a perspective view of a further embodiment of a building.
18 [0041] Figure 24 is a view on the line XXIV ¨ XXIV of Figure 23.
19 [0042] Figure 25 is a perspective view of a yet further embodiment of building.
[0043] Figure 26 is a view on the line XXVI ¨ XXVI of Figure 25.
21 [0044] Figure 27 is a schematic plan view of a building assembled from the 22 embodiments shown in the proceeding figures.
23 [0045] Figure 28 is a section through an alternative embodiment of post used in the 24 building structures in the proceeding figures.
[0046] Figure 29 is a plan view of the post of Figure 28 assembled into a wall structure.
26 [0047] Figure 30 is a plan view of a pair of wall structures utilizing the post of Figure 27 28 being connected.

22337767.1 2 assembly of a building structure.
4 assemble.
6 building structures shown in the proceeding embodiments.
8 manufacturer.
stage of manufacturer.
12 Figure 35.
14 36.
16 of the wall sections.
18 of wall sections.
using the post sections described with respect to Figures 28 through 39.
23 Figure 41.
detail P.
27 Figure 41.

22337767.1 1 [0062] Figure 45 is a detailed perspective view of a portion of the wall section within 2 circle H of Figure 42.
3 [0063] Figure 46 is a detailed perspective view of the portion of the wall section within 4 the circle J of Figure 42.
[0064] Figure 47 is a plan view of the wall section of Figure 41.
6 [0065] Figure 48 is a perspective view of a pair of wall sections as shown in Figure 41 7 joined end-to-end.
8 [0066] Figure 49 is a section on the line AA of Figure 48.
9 [0067] Figure 50 is a section on the line BB of Figure 48.
[0068] Figure 51 is a section on the line CC of Figure 48.
11 [0069] Figure 52 is a perspective view showing a pair of wall sections of Figure 41 12 during assembly.
13 [0070] Figure 53 is a detailed perspective view from above of the connection between 14 the wall sections in the position shown in Figure 52.
[0071] Figure 54 is a perspective view of a corner assembly.
16 [0072] Figure 55 is a plan view of the corner assembly of Figure 54.
17 [0073] Figure 56 is a detailed view of the corner assembly of Figure 55.
18 [0074] Figure 57 is a front elevation of an alternative wall configuration.
19 [0075] Figure 58 is an enlarged view, partly in section, of an upper portion of the wall figure 57; and 21 [0076] Figure 59 is an enlarged view of a lower portion of the wall of figure 57.

24 [0077] The description that follows and the embodiments described therein are provided by way of illustration of examples of particular embodiments of the principles of 26 the present invention. These examples are provided for the purposes of explanation, and not 27 of limitation, of those principles and of the invention. In the description, like parts are 22337767.1 1 marked throughout the specification and the drawings with the same respective reference 2 numerals. The drawings are not necessarily to scale and in some instances proportions may 3 have been exaggerated in order more clearly to depict certain features of the invention.
4 [0078] Referring therefore to Figure 1, a building 1 includes log walls 2 that intersect at a corner 6. The log walls 2 are supported on a foundation wall 3, that may be poured 6 concrete or laid cement block, and have openings for windows 4. The log walls 2 will 7 support a roof or additional framed storey in a conventional manner. Each of the log walls 8 2 is formed from logs 11 that are laid horizontally one on top of the other and are secured to 9 posts 10 to form an integral structure. The posts 10 may be located at corners 6 and at intermediate locations 7 along the log walls 2, depending on the overall plan of the building 11 1.
12 [0079] Each of the logs 11 is machined to an uniform cross section and have 13 complementary tongues and grooves formed on abutting upper and lower faces 13a, 13b 14 (Fig. 4). A sealant, typically in the form of a mastic tape, or foam tape is located between the tongue and groove and compressed by the log to form an effective seal. The particular 16 form of tongue and groove forms no part of the present invention and a variety of 17 configurations may be used, such as that shown in US Patent 5,020,289.
18 [0080] It will be appreciated that the log walls 2 extend along the periphery of the 19 building 1 and the logs 11 are cut to the required length to conform to the desired floor plan.
21 [0081] Each of the posts 10 extends vertically the height of the log wall 2 and each post 22 10 has a pair of generally planar faces 12, 14, that are disposed at the required included 23 angle. Where the post 10 is located at the corner 6 of the building 1, typically, the planar 24 faces 12, 14 intersect at right angles but other included angles can be provided, as shown in Figure 7. Where the posts are at intermediate locations the planar faces 12, 14 are 26 oppositely directed.
27 [0082] As can best be seen in Figure 2 and Figure 4, which illustrates a corner 6, each 28 of the logs 11 has an end face 16 that extends between the upper and lower faces 13a, 13b 29 to butt against one of the planar faces 12, 14 of the post 10. The end face 16 has a part 22337767.1 1 cylindrical slot 17 extending between the upper and lower faces 13a, 13b of the log 11 and 2 intersecting the end face 16 so as to define a re-entrant recess in the end face 16.
3 [0083] Sealant slots 18 are provided along the length of each of the planar faces 12, 14 4 of post 10. The sealant slots 18 are dimensioned to accept sealant materials, typically in the form of butyl or impregnated foam tapes 19 that are exposed to the end face 16 when a log 6 11 is butted against post 10.
7 [0084] Each of the planar faces 12, 14 has an undercut channel 20 extending along the 8 length of the post 10. The undercut channel 20 has a parallel sided body portion 22 which 9 opens to an enlarged socket 24. Inclined flanks 26 connect the body portion 22 to the enlarged socket 24. The width of the body portion 22 corresponds to that of the opening of 11 part cylindrical slot 17 at the end face 16.
12 [0085] The logs 11 are held against the respective planar face 12, 14 by the spline 13 assembly generally indicated at 30 in Figure 4. The spline assembly 30 includes a key 32 14 and a slide member, referred to as key slide 70. The key 32 has a pair of key members 33 that are identical to one another and have a length slightly less than the corresponding 16 height of the log 11. For example, with a log of nominal 12" height, the key 32 will 17 typically be 10" in length.
18 [0086] The key members 33 are best seen in Figures 5 and 6. Each key member 33 is 19 molded from a plastics material and has an outer shell 34 with a hollow interior 36 with reinforcing ribs 38 integrally molded with the outer shell 34. In cross section, each of the 21 key members 33 is similar to one half of the void formed between the part cylindrical slot 22 17, undercut channel 20 and the key slide 70 so that a pair of key members 33 may be 23 inserted within the void.
24 [0087] Each of the key members 33 has an enlarged head 40 connected by a neck 42 to a flared shoulder 44. The enlarged head 40 has an arcuate undersurface 46 terminating in 26 radial step 48. Each end of the key members 33 has a tapered terminal section 50 on the 27 neck 42 and the flared shoulder 44 to facilitate insertion in to the key slide 70. End walls 28 52 enclose the shell at each end up to a median plane 54. A flange 56 projects outwardly 29 from the median plane 54 at one end and extends one half the length of the key member 33.
A slot 58 having a depth slightly greater than that of the flange 56 is molded into the key 22337767.1 1 member 33 in alignment with the flange 56 over the balance of the length of the key 2 member 33. A notch 59 is formed in each end wall 52 beside the flange 56 and slot 58 3 respectively.
4 [0088] The flange 56 and slot 58 are arranged such that when two key members 33 are placed back to back, that is with the interior of the shells 34 facing one another, the flange 6 56 of one is received in the slot 58 of the other, so a continuous barrier is provided along 7 the length of the key members 33. It will be noted from Figure 5 that the arcuate 8 undersurface 46 has embossments 60 molded along its length. The embossments 60 are in 9 the form of letters in the embodiment shown that project slightly above the arcuate undersurface 46. Similar embossments 62, 64 are molded on the neck 42 and above the 11 radial step 48.
12 [0089] As can best be seen in Figures 2, 4 and 8, the slide member or key slide 70, is 13 provided to promote relative sliding movement between a log and the post. As shown, the 14 key slide 70 of the spline assembly 30 is an elongate channel member arranged to be a sliding fit within the enlarged socket 24 of the undercut channel 20. The key slide 70 16 generally extends the full height of the post 10 as a continuous member, although it could 17 made from multiple shorter pieces arranged end to end, and is inserted into the enlarged 18 socket 24 of undercut channel 20 after machining of the post 10. The key slide 70 is 19 dimensioned to have contact with the parallel sided body portion 22 of the undercut channel 20, inclined flanks 26 and enlarged socket 24 in its free body state so as to be retained 21 within the undercut channel 20 during transport of the post 10 and subsequent assembly of 22 the log walls 2 and the post 10.
23 [0090] As can best be seen in Figure 2, 3 and 8, the key slide 70 has an outer surface 24 that conforms substantially to the enlarged socket 24. The key slide 70 has a base 71 with upstanding walls 72 projecting from opposite sides of the base 71. The upstanding walls 72 26 project to form a throat 74 that extends into the body portion 22 with the inwardly directed 27 surfaces of the throat 74 radiussed so as to provide a rolling contact between the junction of 28 the neck 42 and the flared shoulder 44 of each of the key members 33 (Figure 3). The key 29 slide 70 is of substantially uniform thickness so as to be a snug sliding fit within the

- 10 -22337767.1 1 enlarged socket 24 and allow the neck 42 and flared shoulder 44 of key 32 to be a sliding fit 2 within the key slide 70.
3 [0091] The key slide 70 is formed of a suitable material having the requisite thermal 4 insulation qualities, low surface friction, hardness and durability. A
thermo-plastic material such as polyethylene or polypropylene is suitable. Polypropylene has a relatively low 6 surface friction to facilitate insertion and to provide a smooth sliding surface between the 7 key 32 and the key slide 70.
8 [0092] The assembly of the log walls 2 shown in Figure 1 is best seen with reference to 9 the sequence represented in Figure 7 where the walls intersect at an obtuse angle, rather than right angle. Initially, a flashing F is secured to the foundation wall 3 and two rows of

11 butyl tape 80 are applied toward the exterior of the building. The paper covering found on

12 the butyl tape 80 is left in situ to allow for slight adjustment of the initial course of logs 11.

13 [0093] With the two rows of butyl tape 80 installed on the flashing F, the post 10 with

14 the key slide 70 inserted in the channel 20 is placed on the foundation wall 3 and foam tape 19 inserted into each of the sealant slots 18 on one planar face 12 of the post 10 (Figure 7b).
16 The surface of the foam tape 19 immediately adjacent the work area is revealed by removal 17 of the paper covering, which progresses along the length of the post 10 as the log wall 2 is 18 assembled.
19 [0094] The initial log 11 is then placed against the post 10 with the end face 16 in abutment with the planar face 12 (Figure 7c). In this position, the part cylindrical slot 17 is 21 aligned with the undercut channel 20. An asphalt impregnated foam pad 82 conforming to 22 the shape of the part cylindrical slot 17 and undercut channel 20 is inserted from the top of 23 the log 11 (Figure 7d) and pushed down in the part cylindrical slot 17 until it reaches the 24 top of the foundation wall 3.
[0095] To secure the log 11 to the post 10, a key member 33 is inserted, as shown in 26 Figures 7e to 7g. Prior to insertion of the key member 33 lengths of sealant tape 84, 86 are 27 applied to the neck 42 directly on embossment 62 and to the enlarged head 40 directly on 28 embossment 64 of each key member 33 (Figure 5). The sealant tape 84, 86, is not initially 29 in engagement with the parallel sided body portion 22 or the part cylindrical slot 17 during insertion and the sealant tape 84, 86 therefore remains in situ during insertion of the key 22337767.1 1 member 33. The sealant tape 84,86 is held in situ during insertion by the inherent 2 adhesiveness of the surface of the sealant tape 84,86 that is against the key member and by 3 engagement with the embossments 62,64 molded on the surface of the outer shell 34. When 4 initially placed on the key member 33, the sealant tape 84, 86 is in a compressed state as it has been removed from a roll of tape and progressively expands to its free body state. Each 6 of the key members 33 is inserted into the key slide 70 in post 10 individually such that the 7 flared shoulder 44 may pass through the throat 74 of the key slide 70 (Figure 7e and 7f).
8 The first of the key members 33 is inserted with the flange 56 lower most. The other of the 9 key members 33 may then be inserted into the key slide 70 above the first key member 33 and the two key members 33 slid together axially. The flange 56 on one key member 33 is 11 received in the slot 58 of the other key member 33 as the key members 33 slide together to 12 form the key 32.
13 [0096] With the key members 33 assembled, they form the key 32 and may be pushed 14 as a unit into the part cylindrical slot 17 (Figure 7g) until they are flush with the bottom of the grooves provided in the top surface 13a of the log 11. At this time, the sealant 84, 86 16 has not expanded to its free body state, thereby avoiding contact with the walls of the part 17 cylindrical slot 17 or parallel sided body portion 22 of the undercut channel 20. The key 18 members 33 and key slide 70 are dimensioned such that the key 32 may slide relatively 19 easily along the key slide 70 and into the part cylindrical slot 17.
Typically a clearance in the order of 1/8 of an inch on the diameter is provided between the arcuate undersurface 46 21 and the cylindrical wall of the part cylindrical slot 17. However, the flared shoulders 44 22 extend laterally into key slide 70 within the enlarged socket 24 so as to inhibit removal of 23 the key 32. With the key 32 correctly positioned, the key members 33 are forced apart 24 within the part cylindrical slot 17 by insertion of a spike 88 along the length of the key member 33 (Figure 7h). The spike 88 is inserted into the notch 59 provided adjacent the 26 flange 56 and acts as a wedge to separate the key members 33. The enlarged head 40 is 27 dimensioned to prevent removal from the part cylindrical slot 17 in the locked condition as 28 seen in Figure 3. The flanges 56 act as a barrier to prevent lateral movement of the spike 29 88 from between the key members 33 and to cause a uniform spreading of the key 32 within the part cylindrical slot 17. The relatively small surface area of the reinforcing ribs 31 38 reduces the friction on the spike 88 and reduces the downward force transferred to the - U -22337767.1 1 key members 33 by the spike 88. The initial spreading of the key 33 members also brings 2 the embossments 60 in to engagement with the walls of part cylindrical slot 17 to inhibit 3 further upward or downward movement.
4 [0097] The spike 88 separates the key members 33 within the part cylindrical slot 17 but the inner edges of the flared shoulders 44 within the key slide 70 remain in contact with 6 one another. As can be seen from a comparison between Figures 2 and 3, spreading of the 7 key members 33 causes a rolling action about the curved surfaces of the throat 74 of the 8 key slide 70 so as to provide essentially an outward force that is readily resisted by the 9 material in the post 10, as opposed to a torque acting so as to break off the material at the body portion 22 of the undercut channel 20. At the same time, the sealant tape 84, 86 11 expands and is compressed against the enlarged head 40 and part cylindrical slot 17 as well 12 as the neck 42 and undercut channel 20 to provide a continuous uniform seal within the 13 undercut channel 20 and part cylindrical slot 17 respectively. The spreading of the key 14 members 33 as shown in Figure 3 causes the log 11 to be drawn tightly against the face of the post 10 causing the foam tape 19 in sealant slots 18 to be similarly compressed to form 16 a continuous seal. An asphalt impregnated foam pad 90 is then placed onto the top of the 17 key 32 to ensure a proper seal between adjacent key 32 (Figure 7i).
However, the reduced 18 spreading within the key slide 70 in combination with the low friction material of the key 19 slide 70 facilitates sliding movement of the key 32 down the key slide 70.
[0098] With the initial log in situ, a similar procedure is followed with the log on the 21 opposite planar face 12 of the post 10 to provide the first row of logs 11 (Figure 7j-7k).
22 The upper surface 13a of the log 11 is then prepared by applying sealant strips 87 to the 23 sealant grooves on the upper surface 13a of each log 11 and the next log 11 placed in 24 position. The key 32 is then inserted as described above and the process continues up each side of the post 10 until the full height of the log wall 2 has been attained.
26 [0099] During assembly, the weight of each of the logs 11 is sufficient to induce sliding 27 between the key 32 and the key slide 70 to accommodate downward vertical sliding 28 movement of the logs 11 and compression of the sealant strips 87.
Optionally, a thru-bolt 29 may be inserted vertically through the log walls 2 and tensioned to force the logs 11 together. As the logs dry, the weight of the logs 11 and the tension in the thru bolt if used, 22337767.1 1 is sufficient to force the key 32 to slide within the key slide 70 and maintain a sealed 2 relationship with the adjacent log 11 and the post 10. The engagement of the embossments 3 60 with the part cylindrical slot 17 ensures the key 32 moves with the logs 11 and slides 4 within the key slide 70.
[00100] Thus, the spline assembly 30 provides a relatively low friction slide member in 6 the post 10 that permits key 32 to slide in a controlled manner within the key slide 70. The 7 key 32 is secured to respective ones of the logs 11 by expansion of the key members 33 so 8 as to move with the logs 11 relative to the post 10. In this manner, the integrity of the log 9 walls 2 is maintained by inhibiting gaps from opening between the logs 11. As well as maintain a seal between planar face 12 and the end face 16.
11 [00101] The above embodiment is described in the context of securing a vertical post 10 12 to logs 11 to form a corner 6. A similar arrangement may be used where a pair of log walls 13 intersect at a location other than where a post 10 is provided.
Typically this would be 14 where an interior log wall intersects an exterior log wall although it will be appreciated that the technique may be used to interconnect two exterior walls or two interior walls.
16 [00102] Referring therefore to Figures 9 through 11, in which like components are 17 identified with like reference numerals to the embodiment of Figures 1 through 8 but with a 18 suffix "a" added for clarity, an intersecting log wall 90 made from logs lla is perpendicular 19 to the length of the logs lla of an exterior log wall 2a. A vertical recess 92 is formed in the exterior log wall 2a extending the full height of the intersecting log wall 90. Typically this 21 will be the full height of the log wall 2a, but in some applications the intersecting wall 90 22 may terminate at less than the full height of the exterior wall 2a. The recess 92 has a 23 minimum width corresponding to the width of the logs 11a of the intersecting wall 90 and 24 has a depth sufficient to extend into the log lla beyond any surface formations such as bevels formed on the edge of the logs 11a.
26 [00103] An undercut channel 20a is cut in the logs 11 a at the base of the recess 92 and 27 has a profile corresponding to that of the channel 20 formed in the post 10 described above 28 with respect to Figures 1 through 8. Similarly, end faces 16a of the logs 11 a of the interior 29 wall 90 are formed with part cylindrical slots 17a that, when assembled, are aligned with the undercut channel 20a.

22337767,1 1 [00104] In the preferred embodiment, a key slide 70a is inserted into the enlarged socket 2 24a of the undercut channel 20a to receive a key 32a. The key slide 70a may be inserted 3 from the top of the wall 2a if space permits. However, to facilitate assembly of the 4 intersecting wall 90 after the exterior walls 2a are capped with a roof or second storey, the key slide 70a is modified to facilitate insertion into the enlarged socket 24a. As can be seen 6 from Figures 9 and 11, base 71a has a central groove 102 that provides a living hinge at the 7 midpoint of the base 71a. The groove 102 permits the base 71a to be folded at the hinge 8 and thereby reduce the lateral extent of the key slide 70a so it may pass through the body 9 portion 22a of the undercut channel 20a. Once inserted, the base 71a may be unfolded and force the wall 72a of the key slide 70a into the enlarged socket 24a.
11 [00105] With the key slide 70a inserted in the enlarged socket 24a of the undercut 12 channel 20a, the intersecting wall 90 may be assembled by positioning the end faces 16a of 13 the logs 11 a against the base of the recess 92. The keys 32a may then be inserted to bridge 14 the undercut channel 20a and part cylindrical slots 17a and expanded to lock the keys 32a in situ as described above. It will be understood that the foam tapes 19a may be placed in 16 the sealant slots 18a in the recess 92 of the logs lla and the keys 32a in a similar manner to 17 that described above to ensure an air tight connection between the walls.
18 [00106] The recess 92 may be formed in individual logs 11 a of wall 2a prior to assembly 19 or may be routed after the exterior walls 2a have been assembled. This latter arrangement increases the flexibility of modifying the building after its initial assembly although the 21 routing of the recess 92, the sealant slots 18a and the undercut channel 20a during 22 manufacture of the logs 1 1 a is to be preferred.
23 [00107] It will also be appreciated that where the intersecting wall 90 is intended as an 24 interior wall, maintaining a seal between adjacent logs is not as critical as where it is an exterior wall. In this case, the key slide 70a may be omitted allowing for the direct 26 connection between the wall 2a and the wall 90 using the keys 32a.
27 [00108] A further application of the connection between the post 10 and logs 11 forming 28 a wall 2 is shown in the embodiment of Figures 12-17, in which like components will be 29 identified with like reference numerals with a suffix "b" added for clarity.

- 15 -22337767.1 1 [00109] In the embodiment of Figures 12-17, the connection is formed at an intermediate 2 location 7 on the wall, as shown in Figure 1. Referring therefore to Figure 12, the wall 2b 3 is formed by a pair of log wall sections 100 are each formed from logs lib connected at 4 each end to a post 10b using the key 32b as described above with respect to Figures 1-8.
Each of the wall sections thus comprises a pair of posts 10b with logs lib extending 6 between them and secured thereto. The wall sections 100 may be connected end to end to 7 one another when an extended wall 2b is required for the building 1. As can be seen in 8 Figure 22, each wall section 100 is assembled with the logs lib extending slightly above 9 the post 10b to allow for shrinkage as the logs lib dry. Where thru bolts are used they may be installed during assembly of the section 100 to enhance the integrity of the wall section.
11 [00110] As shown in Figure 13 each of the posts 10b has a planar face 12b that abuts the 12 end face 16b of the logs 11 b and an oppositely directed planar face 14b that is designed to 13 abut a corresponding face 14b of a post 10b of an adjacent wall section 100. The planar 14 face 14b of post 10b is formed with a part cylindrical slot 103 (similar to the part cylindrical slot 17b formed in the planar face 16b in log 11 b) so that when the faces 14b

16 abut, the part cylindrical slots 103 are aligned and define a waisted void 110 having a

17 "figure of 8" cross section.

18 [00111] To secure the posts 10b to one another, an elongate "figure of 8" shaped key 112

19 is inserted into the void 110. The elongated key 112 can best be seen in Figures 17 and 18.
[00112] The elongated key 112 is formed from two identical key members 113 that 21 extend the full length of the post 10b. Each of the key members 113 has a pair of enlarged 22 heads 40b extending to either side of a waisted central portion 114 so that, in cross section, 23 each of the key members 113 is similar to one half of the waisted void 110 formed between 24 the abutting part cylindrical slots 103 in the posts 10b.
[00113] A pair of flanges 56b project outwardly from the key members 113 and a pair of 26 slots 58b having a depth slightly greater than that of the flange 56b are molded into each of 27 the key members 113. As shown in Figure 17, the key members 113 may be placed back to 28 back with the flanges 56b of one of the key members engaging the slots 58b of the other of 29 the key members. Each of the enlarged heads 40b is formed with a radial step 48b. The key members 113 are preferably extruded from a plastics material and so have a uniform 22337767.1 1 cross section. Alternatively, the key members may be formed from wood or plywood 2 without flanges.
3 [00114] To assemble the wall 2b from wall sections 100, the sections 100 are placed end 4 to end, as shown in Figure 12, with the faces 14b of posts 10b in alignment. Sealant tape 19b is applied in the sealant slots 18b on the face of one of the posts 10b to form an 6 effective seal as the faces 14b are drawn together. The key members 113 are prepared, by 7 applying the sealant tape 86 to the enlarged head 40b above the radial step 48b and the key 8 112 is inserted between the posts 10b with the sealant tape in a compressed state. Once 9 inserted, spikes 88b are inserted between the key members 113 and driven downward as shown on Figure 16 to separate the key members 113 and thereby spread key 112 as shown 11 in Figure 18. Whilst it is theoretically possible to insert two elongated single spikes 88b 12 along the entire length of the key 112, in practice, it is easier to insert a series of spikes 88b 13 end to end. To facilitate the insertion of such spikes 88b, each of the spikes 88b is formed 14 without a head and with a countersink to receive the pointed end of a subsequent spike 88b.
Therefore, the spikes 88b may be inserted progressively between key members 113, to 16 spread the key 112 over the entire length of the post. The outer surface of the spikes 88b 17 may be coated with a lubricant, such as a "wax" if required, to facilitate insertion over the 18 entire length of the key 112. The key members 113 may be extruded from a relatively low 19 friction material. The spreading of the key 112 causes the posts 10b to be drawn toward one another and abut along the opposed faces 14b.
21 [00115] It will be appreciated that it is not necessary to form the key members 113 as a 22 single component and shorter lengths of key member 113 may be stacked in the void 110 23 without jeopardizing the integrity of the connection between the posts 10b. However, the 24 insertion of multiple spikes 88b suggests that a continuous key members 113 is to be preferred.
26 [00116] With the wall sections 100 aligned and connected to one another, as shown in 27 Figure 22, the rigidity of the exterior wall 2b is increased by placement of straps 120 across 28 the posts 10b. The steel straps 120 extend along the upper surface of the logs lib and are 29 secured by nails or screws to the logs 11 b to inhibit a hinging action about a vertical axis at the posts 10b. Clearance is provided between the strap 120 and the upper end of the posts 22337767.1 1 10b, to facilitate log wall shrinkage and settlement. A foam pad 125 is placed between the 2 strap and the post 10b to inhibit air movement over the top of the post.
3 [00117] The strap 120 may also provide a support for additional structural members, 4 such as a joist or rafter. A yoke 122 attached to strap 120 may be dimensioned to receive standard section lumber and provides a nailing point to secure the structural member. The 6 yoke 122 is maintained in alignment with the upper surface of the logs lib as they shrink 7 by virtue of the strap 120.
8 [00118] Alternative embodiments of the key 112 are shown in Figures 19,

20 and 21. In 9 the embodiment of Figures 19, each of the key members 113 has a pair of flanges 56b to one side of the waisted central portion 114 and a pair of grooves 58b to the other side. This 11 still permits the key members 113 to be placed back to back and to constrain the spikes 88b.
12 [00119] In the embodiment of Figure 20, the end face of the body is offset with 13 projecting flanges 115 that serve to define an air cavity between the post 10b and the key 14 member 113. This enhances the insulative properties to reduce heat transfer across the posts 10b.
16 [00120] Similarly, in the embodiment of Figure 21, the key members 113 are formed to 17 provide a void between them when assembled to provide a further air cavity in the key 112.
18 [00121] In some buildings, it is necessary to integrate conventional frame construction 19 with log construction. The connection system described above can be adapted for these circumstances, as illustrated in Figures 23 to 26.

21 [00122] Referring firstly to the embodiment of Figures 23 and 24, in which like

22 reference numerals will denote like components with a suffix 'c' added for clarity, a wall

23 section 100c, formed by posts 10c and logs lie, is connected to a framed wall section 200

24 of conventional construction and having a top plate 202 and studs 204, 206 and a post 10a.
It will of course be appreciated that the framed wall section 200 includes the additional 26 components normally associated with frame construction, such as a bottom plate, lintels 27 and the like.
28 [00123] The end stud 204 is nailed to a post 10c, that has a part cylindrical slot 17c along 29 the face 14c. The posts 10c of the wall section 100c and framed wall section 200 are 22337767.1 1 aligned with the respective faces 14c in abutment and a key 112c inserted to connect the 2 wall section 100c to wall section 200.
3 [00124] In the embodiment of Figures 25 and 26, an elongated keyspline 32d and 4 keyslide 70d is used to connect a framed wall section 200d to a post 10d.
The wall section 100d has a recess 92d corresponding in width to the width of the post 10d. An undercut 6 channel 20d is formed in each of the base of recess 92d and a part cylindrical slot 17d 7 formed in the post 10d. A key 32d is inserted and spread to secure the wall sections 100d, 8 200d, to one another.
9 [00125] If required, a post 10 may be secured to the wall section 100 as shown in Figures 25 and 26 to stiffen the wall along its length. In this case, a stud wall 200 would 11 not be utilised so as to minimise the protrusion in to the room.
12 [00126] It will be seen from the above that embodiments are provided to form a corner 13 between a post and two walls, to connect walls that intersect between posts and to connect 14 walls end to end.
[00127] The arrangement of connections between the post and logs may be integrated 16 into a single building as illustrated schematically in Figure 27 to permit a panelised 17 construction technique to be used. In this arrangement, a corner unit indicated at 300 18 consists of a post 10 with logs 11 connected to its oppositely directed faces 12, 14. The 19 logs 11 extend to and are secured at opposite ends to a face of the posts 10b that is directed toward the post 10 in the manner shown in Figures 1-4 so that the unit 300 defines a 21 panelised comer unit. The intermediate wall indicated at 302 is formed by a wall section 22 100 constructed as shown in Figure 12 to 16 and has a pair of posts 10b with a logs 11 b 23 extending between opposed faces. The post 10b of the wall section 100 is joined to the post 24 10b of the corner unit 300 using the formations in the form of recesses 17 and keys 112 to form an integral exterior wall 2. A further comer unit 300 is connected at the opposite end 26 of the wall section 100. The exterior periphery of the building shown in Figure 27 may 27 thus be built from four comer units 300 and a pair of wall sections 100, which may be 28 either log or frame construction.
29 [00128] An interior wall 304 may be joined to the exterior wall section 100 using the connection as shown in Figures 9 through 11. A further connection in the exterior wall is 22337767.1 1 made at the post 10 connecting the two corner units 300 using a connection similar to that 2 shown in either Figures 9 through 12 or Figures 13 through 18.
3 [00129] It will be seen that the arrangement of self contained wall units permits a 4 panelised building to be assembled from previously constructed wall units each of which utilizes formations in the posts and a key to connect logs to posts or post to post or log 6 walls to log walls or framed walls to log wall. In each case, provision is made for proper 7 sealing between the keys and the logs to maintain the integrity of the walls and where key 8 slides are used, relative movement between the logs is facilitated.
9 [00130] A further embodiment particularly suitable for providing a panelized construction technique is shown in Figures 28 through 40, although it will be appreciated 11 that the components illustrated in these figures may be utilized in the construction of a non-12 panelized building as illustrated for example, in Figure 7.
13 [00131] Referring to Figure 28, the post 10d is formed from laminations of different 14 lumber for stability and economy of manufacturer. As shown in Figure 28 outer laminations 400 are machined from a premium quality wood, such as a white pine or cedar, 16 and the balance of the laminations 402 are machined from a lower premium wood, such as 17 construction grade spruce/pine/ fur. The faces 12d, 14d extend between the laminations 400 and have formations machined in them to provide the re-entrant part cylindrical recess .
19 17d in the face 14d and the undercut channel 20d in the face 12d. The face 14d is also machined to have an upstanding tongue 404 to one side of the recess 17d and a 21 complimentary groove 406 to the opposite side. Sealant grooves 408, 410 are provided 22 adjacent the tongue 404 and groove 406 respectively. The sealant grooves 412 are also 23 provided on the face 12d to either side of the channel 20.
24 [00132] The post 10d is secured to logs lid by a spline assembly 30d as shown in Figure 29. A key slide 70d is inserted into the channel 20d and the key 32 inserted after placement 26 of the end face 16d of each of the logs lid against the face 12d. The key 32d is expanded 27 by means of the spike 88d as described above to secure the logs lid to the post 10d. A post 28 10d may be connected at opposite ends of the log lid such that the logs lid and posts 10d 29 form a self contained wall unit 100d.

22337767.1 1 [00133] To facilitate transportation of the units 100, the lower most log lid is secured to 2 the posts 10d by screws driven through the post and into the log. This inhibits the relative 3 movement between the lowermost post and log while still permitting such movement with 4 the balance of the logs.
[00134] Where tie bolts are used, as described above, they are inserted and provide 6 convenient locations to permit hoisting of the wall units during transportation and 7 assembly.
8 [00135] To assemble a pair of wall units 100d, the units are oriented such that the faces 9 14d are opposed. In this position, as can be seen in Figure 30, the tongue 404 of one post 10d is aligned with the groove 406 of the opposed posts 10d and the recesses 17 are 11 aligned. Sealing strips are located in the grooves 408,410 and the post 10d brought into 12 abutment as shown in Figure 31.
13 [00136] With the post 10d abutting, an elongate "Figure of 8" shape key 112d is inserted 14 to bridge the aligned recesses 17d. Any suitable form of key 112 may be used, such as one of the embodiments shown in figures 17 ¨ 21 and preferably is similar to that shown in 16 figure 14 or 15 with notches for the spikes 88. The key 112d can then be expanded using 17 spikes 88 as described above with respect to Figure 12 to 15. The key 112d may be either a 18 single continuous extrusion extending the full length of the post 10d or may be individual 19 shorter lengths of key, again as described above with respect to Figures 12 through 15.
[00137] With the key 112d expanded as shown in Figure 32 a secure connection is made 21 between the wall sections 100. The engagement of tongue 404 and groove 406 locates the 22 posts 10b in a lateral direction as well as providing a more tortuous path to inhibit air 23 infiltration. The seals located in the grooves 408, 410 also enhance the air tightness of the 24 connection between the walls.
[00138] It will be noted from Figure 32 that with the posts 10d secured to one another, 26 the outer laminations 400 cover the joint between the posts and thereby provide a 27 continuous pleasing appearance to the exterior surface of the post.
28 [00139] The manufacturer and use of the posts 10e used at the corners 6 may also be 29 enhanced to facilitate the panelized construction of the building. As shown in Figure 33, a post 10e is formed with undercut channels 20e on opposite faces. The post 10e is again 22337767.1 1 laminated from exterior laminations 400e and internal laminations 402e as described above 2 with respect to Figure 28. Sealant grooves 412 are machined into the faces 12e, 14e to 3 accommodate sealing strips upon further assembly.
4 1001401 The post 10e is then slit into two components 510 along a separation plane inclined at 45 degrees to the median plane of the post. The inclination of the cut will vary 6 depending upon the included angle of the corner to be formed, but for a 90 degree corner, 7 = the 45 degree cut is required. After cutting, two corner posts 510 are formed that are 8 identical in section. Inversion of one component end over end provides two components 9 that when assembled with the cut faces in abutment, define a 90 degree corner post, as described below. A different angle of cut will of course provide a different inclined angle.
11 As shown in Figure 35, each has a part cylindrical re-entrant recess 17e machined along its 12 cut face. This recess 17e may be machined using a cannon ball router bit with the recess 13 17e located at the mid point of the cut face 512. The corner post components 510 can be 14 connected at opposite ends of logs lie as shown in Figure 36 using spline assemblies 30e installed as described above. The logs lie and the post components 510 form a wall unit 16 100e that can be assembled with like wall units to form a corner. Again, the lowermost log 17 is secured to the post component with screws to inhibit sliding movement and the tie bars 18 used as hoist points.
19 1001411 To form a corner 6, as shown in Figure 37, a pair of wall units 100 each having a corner component 510 at one end are brought into alignment such that the cut faces 512 21 abut. Sealant grooves are machined into the cut face to receive sealant strips and are off set 22 from adjacent strips so as to provide four separate seal locations along the cut face 512.
23 With the corner units in abutment as shown in Figure 38, a key 112e is inserted to bridge 24 the aligned recesses 17e and connect the sections 100e at right angles to one another.
Thereafter, spikes 88e may be inserted into the key 112e to expand the key and secure the 26 corner components 510 into a unitary post 10e at a corner.
27 1001421 It will be noted with respect to Figures 37 through 39 that the exterior 28 laminations 400 extend around both exposed surfaces of the corner and thereby enhance the 29 aesthetics. At the same time, it will be appreciated that the wall units 100 may be made as 22337767.1 1 linear units for ease of transportation and subsequently assembled at corners by the 2 insertion of the spikes 100.
3 [00143] With the arrangement shown in Figures 28 through 39, it is apparent that a 4 panelized structure may be assembled readily as shown schematically in Figure 40. Each of the wall units is formed by a pair of posts 10 connected by logs 11 which extend between 6 the faces of the posts directed toward one another. The formations provided on the other 7 face facilitates connection to an adjacent post through the "figure of eight keys 112." The 8 wall units 100 are therefore flat self contained units that are readily transported and 9 assembled into the required configuration at the site.
[00144] In the above embodiments, the posts 10 of the wall sections 100 are 11 interconnected by the keys 112 which are expanded within the part cylindrical slots 103.
12 The expansion pulls the faces 14 of the posts in to engagement. An alternative arrangement 13 for connecting the faces 14 of the post 10 is shown in Figures 41 through 53, in which like 14 reference numerals will be used to denote like components with a suffix "f" added for clarity.
16 1001451 Referring therefore to Figure 41, a wall section 100f includes a pair of posts 10f 17 with logs llf extending between them. The logs llf are connected to the posts 10f using 18 the key 32f as described above with respect to Figures 1 through 8.
19 [00146] As shown in Figure 47, each of the posts 10f has an outwardly directed end face 14f with a tongue 404f and a complimentary groove 406f. A rabbet 600 is formed in the 21 end face 14f of one of the posts 10f between the tongue 404f and the groove 406f.
22 [00147] The face 14f of the other of the posts 10f is planar between the tongue 404f and 23 groove 406f with a pair of recess channels 602 to receive sealing strips.
24 [00148] A dovetail assembly 608 is located between the opposed faces 14f to secure the posts 10f to one another. The dovetail assembly 608 includes a pair of pins 610, which are 26 located in spaced relationship within the rabbet 600. As can be seen in Figures 43 and 44, 27 each of the pins 610 extends along the vertical extent of the post 10f and is secured to the 28 post at spaced intervals by screws 622.

22337767.1 1 1001491 Each of the pins 610 has an inwardly directed inclined face 614 that, in 2 combination with the adjacent pin 610, defines a re-entrant dovetail channel 616 (Figure 3 47) within the rabbet 600.
4 1001501 A comparison of Figures 49 to 51 shows that each of the pins 610 also tapers laterally from one end to the other so that a mouth 618 of the dovetail channel 616 narrows 6 from the vertically upper end of the post 10f to the lower end of the post 10f.
7 [001511 A tail 620 is secured to the planar face 14f of the other of the posts 10f through 8 screws 622. The tail 620 has a pair of convergent faces 624 directed toward the face 14f.
9 The tail 620 is of complementary cross section to the channel 616 and so similarly tapers from one end to the other.
11 [001521 In a typical installation, the lateral dimension of the rabbet 600 is 3.5 inches 12 with a depth of 1/2 an inch or 3/4 inch. The maximum width of the mouth 618 is 1 7/8 13 inches which progressively reduces along the vertical extent of the post 10f to a minimum 14 of 7/8 of an inch.
1001531 Similarly, the tail 620 has a maximum width of 2 3/4 inches and a minimum 16 width of 1 3/8 inches. The inclination of the faces 614 to the plane of the face 14f is 450 17 and the included angle of the taper of the tail and pins is in the order of .25 .
18 [001541 The groove 616 and tails 620 are dimensioned relative to one another so that 19 when the posts are abutting and aligned horizontally, the tail 620 is fully engaged with the pins 614.
21 [001551 In order to assemble a pair of adjacent wall sections 100f, sealing strips are 22 inserted in the grooves 602 and the two wall sections brought in to alignment for assembly.
23 One of the wall sections 100f is elevated so that its lower edge is aligned with the upper 24 edge of the adjacent panel. In this position, the tail 620 may be inserted in to the dovetail channel 616.
26 [00156] With the tail 620 aligned with the recess 616, the elevated wall section 100f may 27 be slid vertically. As can be seen in Figures 52 and 53, the mouth 618 is sufficiently 22337767.1 1 narrow to inhibit separation of the sections 100f as they are slid, but at the same time, the 2 taper of the tail and recess 616 allows relatively free sliding movement.
3 [00157] As the section 100f reaches the horizontal alignment with the other wall section 4 100f, the tail 620 is snugly received within the recess 616 and pulls the faces 14f in to abutment. The seals in the grooves 602 are compressed between the faces 14f and the 6 tongue and grooves 404f, 406f engaged.
7 [00158] With the tail engaged within the recess 616, separation of the post is inhibited in 8 the direction of the wall formed by the wall sections 100f.
9 [00159] The tail 620 and pins 614 may be made from a suitable material including metal or plastic mouldings having sufficient rigidly to pull the faces 14f in to engagement.
11 [00160] It will be apparent that the arrangement of tail and pins may be used in the 12 different configurations of corner shown in the previous embodiments.
13 [00161] An example of a comer construction as shown in Figure 54 through 56 which is 14 similar to the construction shown in Figures 33 through 39.
[00162] Referring therefore to Figure 54, walls sections 100g consisting of logs llg and 16 posts lOg intersect at a comer 6g. The post lOg is formed from a pair of components 510g 17 obtained by slitting a rectangular post 1 Og along a separation plane, as described above 18 with respect to Figure 33. Each of the components 510g has a cut face 512g that abut to 19 define the required included angle for the post. The logs llg are connected to the components 510g by the key assembly 30g, as described above.
21 [00163] To connect the faces 512g in abutment and provide a stable post 10g, a recess 22 600g is machined in the cut face 512g of each of the components.
23 [00164] A pair of pins 610g is secured within one of the recessess 600g and a tail 620g 24 secured within the other of the recesses. The dimensioning and interaction of the tail and pins is described above with respect to Figures 41 through 53.
26 [00165] To assemble the walls 100g at the corner 6g, each wall unit 100g is assembled 27 with the components 510g positioned adjacent to the comer. The wall unit to which the tail 28 620g is secured is elevated and slid in to the re-entrant channel provided by the pins 610g.
29 As the wall is lowered, the tail 620g engages the pins 610g and pulls the faces 512g in to

-25 -22337767.1 1 abutment and a stable connection. Sealing strips are of course provided between the faces, 2 as described above, to ensure an air tight construction.
3 [00166] As shown in Figure 56, the cut faces are disposed at a 45 angle relative to the 4 exterior faces of each of the posts so that an included angle of 90 is provided at the post 10g. Other angles may be adopted to provide different included angles.
6 [00167] The connection of the logs 11 to the post 10 facilitates assembly of the walls 2 7 of the building, and also accommodates the relative movement between the logs and posts 8 as the logs dry and shrink. Typically, clearance is left above windows and door openings to 9 accommodate such shrinkage. In the arrangement shown in figures 1 to 56, shrinkage of the logs will produce cause the upper end of the posts to project above the top course of logs.
11 Accordingly, the structure above the wall, typically the roof trusses, must be supported on 12 either the logs or the posts.
13 [00168] The arrangement of connection of the log to the posts provides an alternative 14 configuration, as shown in figures 57 to 59. Like components will utilize like reference numbers with a suffix "g" added for clarity.
16 [00169] Referring therefore to figure 57 to 59, wall sections 2g are formed from logs hg 17 connected to posts lOg as described above. The posts lOg are connected to one another on 18 their abutting faces, 14g, again as described above.
19 [00170] As shown in figure 58, the upper most log llg is connected to the post lOg by lag screws 700, so that the upper log hg is flush with the upper face of the post 10g. The 21 lag screws 700 are located on either side of the dovetail connection 608 and typically will 22 be 4 in number.
23 [00171] The length of post lOg is less than the height of the wall 2 so that the lower most 24 log llg extends below the post 10g. A seal 702 is located between the post lOg and the sub floor, on which the log rests.

26 [00172] The upper most log Hg is supported by the stacked logs below and the post lOg

27 suspended from the upper most log. The balance of the logs are in sliding contact with post

28 in the manner described above, so that as the logs shrink, the post move downwardly to

29 compress the seal 702.

22337767.1 1 [00173] The connection of the post to the upper most log maintains alignment on the top 2 edge, thereby allowing the structure to be supported on both the post and the log. A
3 modular structure is thus provided with versatility in the placement of supported structure.

22337767.1

Claims (25)

Claims

1. A self-contained wall unit for forming a wall section of a building said wall unit comprising a pair of posts each having a longitudinal axis, said posts being spaced apart and each having an abutment face directed toward the other of said posts, at least one log extending between each of said abutment faces and being secured thereto to form with said posts said self-contained wall unit, at least one of said posts having another face different to said abutment face and configured to abut an exposed face of an adjacent portion of said wall section, said other face of said one of said posts having a formation thereon extending along said longitudinal axis to facilitate connection to said exposed face, said formation including a pair of laterally spaced convergent flanks, the lateral spacing between said flanks varying progressively along said longitudinal axis to provide a tapered formation of progressively reducing width.

2. A wall unit according to claim 1 wherein said formation is located in a recess extending along said other face.

3. A wall unit according to claim 1 wherein said other face lies in a plane inclined to said abutment face.

4. A wall unit according to claim 3 wherein said plane is at right angles to said abutment face.

5. A wall unit according to claim 1 wherein said log is secured to said post to permit relative sliding movement there between.

6. A wall unit according to any one of claims 1 to 5 including a seal located on said other face and extending along said longitudinal axis.

7. A wall unit according to claim 6 wherein a seal is located on either side of said formation.

8. A wall unit according to claim 7 wherein a tongue is formed on said other face parallel to said longitudinal axis.

9. A wall unit according to claim 7 wherein a groove is formed on said other face parallel to said longitudinal axis.

10. A wall unit according to any one of claims 1 to 9 wherein said flanks converge toward said other face.

11. A wall unit according to claim 10 wherein said flanks are planar.

12. A wall unit according to any one of claims 1 to 9 wherein said flanks converge away from said other faces.

13. A wall unit according to claim 12 wherein said flanks are planar.

14. A wall unit according to any one of claims 1 to 13 wherein both of said posts have another face with formations thereon, said one of said posts having flanks that converge toward said other face of said one post and the other of said posts having flanks that converge away from said other face of the other of said posts.

15. A method of assembling a wall section of a building comprising the steps of forming a wall unit from a pair of posts that are spaced apart and each of which has an abutment face directed toward the other of said posts, locating at least one log to extend between each said abutment face, securing said log to said posts to form a self-contained wall unit, providing a tapered formation on another face different to said abutment face of at least one of said posts, said formation having a pair of laterally spaced convergent flanks whose lateral spacing varies along the longitudinal axis of said one of said posts, said formation facilitating connection to an exposed face of an adjacent portion of said wall section having a complementary formation formed on said exposed face thereof, positioning said wall unit with said other face directed to said exposed face and said formations offset along a longitudinal axis of said posts and connecting said unit to said portion by moving said one of said posts relative to said exposed face to engage said formations and move said other face and said exposed face toward one another as said formations engage.

16. A method according to claim 15 wherein a seal is placed between said other face and said one face.

17. A wall section of a building having a pair of self-contained wall units connected to one another, each of said wall units comprising a pair of posts each having a longitudinal axis, said posts being spaced apart and each having an abutment face directed toward the other of said posts, at least one log extending between each of said abutment faces and being secured thereto to form with said posts said self-contained wall unit, at least one of said posts of each of said wall units having another face different to said abutment face and configured to abut another face of an adjacent post of the other of said pair of wall units, said other face of each said posts having a formation thereon extending along said longitudinal axis to facilitate connection of said wall units, each of said formations including a pair of laterally spaced convergent flanks, the lateral spacing between said flanks varying progressively along said longitudinal axis to provide a tapered formation of progressively reducing width, said formation of one of said wall units being complimentary to said formation of the other wall unit to permit said formations to nest one within the other and to connect said wall units.

18. A wall section according to claim 17 wherein a seal is located between said other faces.

19. A wall section according to claim 18 wherein a further seal is located on either side of said formation.

20. A wall section according to claim 17 wherein a tongue is formed on one of said other faces parallel to said longitudinal axis and a groove is formed on the other of said other faces to receive said tongue.

21. A wall section according to claim 17 wherein said flanks on said formation on said one of said posts converge toward said other face of said one of said posts.

22. A wall unit according to claim 21 wherein said flanks are planar.

23. A wall section according to any one of claims 17 to 22 wherein one of said formations is located in a recess formed in a respective one of said other faces.

24. A wall section according to any one of claims 17 to 23 wherein said formations are formed as a tapering dovetail with a tail on one of said wall units and pins on the other of said wall units.

25. A wall section according to claim 24 wherein said tails and said pins are formed as separate components secured to respective ones of said posts.