GB2104612A - Frame joints - Google Patents

Abstract

Laminated structural members comprise a plurality of elements A, A', B, extending longitudinally in edge to edge engagement, the ends of at least one element A, A' extending beyond that of the associated element(s), thereby to form an interlocking means for the production of stable frame elements for the production of houses and like buildings. The laminated structural members can be comparatively large, but formed from a plurality of smaller elements of standard size; one or more of said elements extending so as to form mortices of varying dimensions. <IMAGE>

Description

SPECIFICATION Constructed post and beam The present invention relates to a constructed post and beam of the type generally used in building construction.

Timber framed housing is currently enjoying a revival due to the speed with which such buildings can be erected. One of the reasons for this is that structural elements forming the timber frame construction can be machined to appropriate sizes in a workshop; merely being assembled in the correct sequence by a carpenter on site.

In the production of structural members, particularly for the building industry, large sizes must be cut from single pieces of grown timber.

Although this produces satisfactory structural elements, it produces a greater degree of waste than occurs when smaller elements are cut from the same course, or are obtained from trees of a smaller diameter which are far more readily available.

Lamination of a plurality of smaller elongate elements to form a single laminated structural member has been known for some time, for specialist purposes, but it is not generally adopted in the building industry because of the extra costs involved in lamination which exceed the benefits achieved.

In the construction of structurally stable frames it is generally necessary to mortise the ends of the elements used, but this step is often in practice ignored because the time and skill involved in producing a tight mortise joint does not warrant the cost involved.

The Applicants seek to alleviate these problems, therefore, by providing a system whereby more readily available structural elements can be utilized in smaller sizes to form a laminated beam of a predetermined strength; the lengths of some of the structural elements exceeding the lengths of others, thereby to form interlocking means on said laminated structural member for interlocking with an adjacent structural member.

It will be appreciated that by use of this system, not only can structural elements be made from more readily available timber sources, but also the problem of providing readily utiiizable mortises is overcome.

According, therefore, to one aspect of the present invention there is provided a laminated structural member comprising a plurality of elements extending longitudinally in edge to edge engagement the ends of at least one thereof extending beyond that of its associated elements, thereby to form an interlocking means.

In another aspect a plurality of laminated structural members are assembled into a kit to form a structurally stable frame, each of said laminated structural members comprising interlocking means adapted to interlock with other laminated structural members according to a predetermined sequence thereby to form the said frame. The invention therefore extends to structurally stable frames comprising laminated structural members as just described.

In a preferred embodiment the laminated structural members are formed with a rebate along at least one edge thereof, said rebate being adapted to accommodate an insulative panel adapted in use to form the wall of a building.

In another aspect of the invention, there is provided a method of constructing an interlocking frame which comprises providing a plurality of laminated structural members, each of said members being formed of a plurality of elements extending longitudinally in edge to edge engagement, the ends of at least one of said longitudinally extending elements extending beyond that of its associated elements thereby to form interlocking means, assembling said laminated structural members in a predetermined sequence with their ends correctly interlocking, and causing said interlocked ends to adhere together as by adhesive or nailing.

In another aspect of the invention, there is provided a method for the production of laminated structural members as defined which comprises selecting a plurality of elongate elements of a predetermined length, presenting them to a lamination station, applying an adhesive to those surfaces of the elongate elements which are to be laminated, and applying pressure and/or heat to said so formed laminated structural member to cause continuous lamination of the same.

In another aspect of the invention, there is provided a construction system for laminated structural members as hereinbefore set forth which comprises selecting a base width for said elongate elements, selecting a plurality of between three and eight depths, varying between 1 and 5 times the base width, laminating together a sufficiency of said elements to achieve a desired strength, while simultaneously selecting the lengths of the elongate elements such that interlocking means are provided at at least one end of said structural member.

It will be appreciated that whereas the present invention is directed mainly to elongate elements of wood, in suitable circumstances, some or all of the structural elements can be replaced by suitably shaped elongate elements of plastics material, or even metal.

Lamination methods are well known in the art per se, and the elongate elements of the present invention may be laminated by any method currently available.

One aspect of the present invention will now be described by way of illustration only with reference to the production of a timber framed building according to the accompanying drawings, wherein: Figure 1 shows an elevation of a three-way post to wall-plate joint, Figure 1 A shows a side view of the joint of Figure 1, Figure 2 shows an elevation of a two-way post to wall-plate joint, Figure 2A shows a side view in part section of Figure 2, Figure 3 is an elevation of a five-way post and beam joint according to the present invention, Figure 3A is a horizontal side view in part section of the joint of Figure 3, and Figure 3B is a view similar to that of 3A but viewed from a point displaced by 900.

Figure 4 shows an elevation of a three-way post and beam joint, according to the invention, Figure 4A shows a horizontal side view of the joint of Figure 4 in part section from the left hand side, Figure 4B shows a horizontal view of the joint of Figure 4 in part section from the right hand side, Figure 5 shows an elevation of a five-way post and beam joint, Figure 5A shows a horizontal view of the joint of Figure 5 from the right hand side in part section, Figure 5B shows a horizontal view of the joint of Figure 5 displaced 900 anticlockwise from the view of Figure 5A.

Figure 6 shows an elevation of a six-way post and beam joint in accord with the present invention, Figure 7 shows an elevation of a four-way post and beam joint according to the invention, Figure 7A shows a horizontal view of the joint of Figure 7 displaced by about 450 clockwise, Figure 8 shows an elevation of a four-way post and beam joint according to the present invention, Figure 9 shows a structural frame for a house with the foundations and roof trusses omitted for clarity, wherein the joints of Figures 1 to 8 may be utilized in the position shown.

In the description which follows the reference letters are peculiar to each figure, and do not designate structural elements of similar sizes.

Figure 10 illustrates a vertical section of one side of the structure of Figure 9: and Figure 11 illustrates a further exploded view of a typical space frame joint.

Figure 1 shows a soft wood three-way post to wall-plate joint. The wall plate is formed of a 50 x 1 50 plate B having disposed intermediate its longer upper side a 50 x 75 mm element A, wherein said element B extends beyond the element A, as shown particularly in Figure 1 A. The interlocking post as shown in Figure 1 is formed of four elements, two 50 x 50 mm elements E extending upwardly on a plane coincident with that of the plates A, said elements E being laminated along their one edges with a 50 x 100 mm element C disposed perpendicular to a 50 x 1 50 mm element D.The inner ends of elements C and D are rebated to accommodate the ends of elements A and A' as shown in Figure 1 A such that the end of the element D is disposed about both end portions of the element A' while a corresponding rebate in the element C accommodates the end of the element A, the arrangement being such that the element A' as shown in Figure 1 protrudes into the space formed between the lower ends of the elements C and D.

In use the wall plate B is secured to a foundation plinth and trued to form a perfect right angle.

Consequentially the elements A because they are affixed to the wall plate B also form a perfect right angle and are perfectly aligned for interlocking with the beam formed by elements C, D and E. In operation, the post formed by elements C, D and E is positioned as shown in Figure 1 and is secured by nailing and, if desirable by the application of a suitable adhesive. It will be appreciated that joints of this type are considerably stronger than the traditional butt joint and nail usually utilized in such situations.

Figure 2 shows an elevation of a two-way post and wall-plate joint, such as for example, utilized in F2 of Figure 9. In this example a wall-plate D is made of 50 x 1 50 mm softwood and has an element C formed of 50 x 75 mm softwood disposed along a central upper surface thereof.

This is best shown in Figure 2A. The wall plate C is positioned on a suitable foundation plinth as described in Figure 1 and a post formed of elements A, B and A' and is disposed thereover at a suitable position. The post A, B, A' is formed of two elements A formed of 50 x 50 mm softwood disposed along a centre line of a 50 x 1 50 mm softwood plate B. The beam A, B, A' is located on the wall plate C, D by means of nailing and/or application of adhesive, and it will be appreciated that in contradistinction from the usual joint this arrangement provides at least five contact surfaces disposed perpendicular to each other.

Figure 3 shows an elevation of a five-way post and beam joint in accordance with the invention, such as for example may be used in joint F3 of Figure 9. In such a construction as shown in Figure 3 the posts and the beams are all load bearing. Thus, the post and beam construction as shown in Figure 3 is formed of five elements as follows: A right hand horizontal beam A, A, A, a left hand horizontal beam G, F, E, mated with its counterpart G1, Fi, El on a horizontal longitudinal axis, a lower post H, J, K, L, and an upper post B, C, D on a vertical axis coincident with that of the lower vertical post.

The beam A, A, A is formed of three 50 x 1 50 mm softwood elements laminated at their adjacent interfaces. The remote ends of the beam A, A, A interfit into the abutting horizontal beams G, E, F which are laminated together as shown in Figure 3. All elements of this horizontal beam are formed of softwood and are sized as follows: G: 50 x 50 mm.

F: 50 x 150 mm.

E: 50 x 225 mm.

This beam therefore is provided with a central element E having an element F disposed adjacent its longitudinal centre line and laminated thereto.

Element G is laminated to the lower, inner longitudinal edge of the inner element F so as to provide a seat in part for the elements A, A, A. The lower post H, J, K, L is of softwood and is formed of a central 50 x 1 50 mm element J to which is laminated the 50 x 50 mm elements H, K and L.

The elements L are comparatively short and act to provide a support for the underside of the inner element F of the longitudinally extending beams.

The elements L are therefore laminated to the top end of the element K and to the upper end of the element J. Similarly, the elements H are comparatively short acting to provide a further support for the underside of the central element E of the longitudinal beam. The element H is laminated to the edge of the central element J.

The upper post B, C, B is formed of two softwood elements at 50 x 50 mm and a central element C formed in 50 x 1 50 mm softwood. The elements B are laminated to the centre line of the planar face of element C, and extend in length downwardly relative to the element C such as to provide a firm seating on the element F when the element C seats upon the element E.

As is best shown in Figure 3B the vertical post H, J, K seats into the rebate in the underside of the horizontally extending beams F and E while the posts B, C, B is located coaxially above. The elements A, A, A locate into the joint as shown in the dotted lines of Figure 3B such that when secured the joint has great strength by virtue of the interlocked mortise arrangement.

Figure 4 shows an elevation of a three-way post and beam joint in accord with the invention such as may be used at position F4 in Figure 9.

Beam D, E, F is formed of 50 x 1 50 mm softwood, each of said elements being laminated to the other to provide a beam 150 x 1 50 mm. The elements D and F extend by 50 mm beyond the end of the element E thereby providing a mortise joint accordingly. A similar beam of identical size is formed by elements A, B and C but wherein element B extends beyond the elements A and C by 1 50 mm thereby abutting onto the ends of the elements D and F while the end of the elements C butts up against the end of element D. This forms a square aperture as between the two. The post G, H and J is formed of softwood elements G, being 50 x 50 mm, H being 50 x 100 mm and J being 50 x 1 50 mm. The end of the element H is formed with a 50 mm square peg for positioning in the aperture referred to.Similarly, a similar 50 mm peg is formed at the top end of the element J to interlock between the ends of elements A and B.

Although this arrangement is shown with pegs, being cut from the end of larger elements, of course, the element J could be formed of 50 x 50 mm laminated elements, while one of which was longer than the other two.

In use the pegs disposed on elements H and J are located as shown in Figure 4 and the beams A, B, C and D, E, F are brought together to form a right angle about the post. The interlocking means is then secured by nailing and/or adhesive as desired leaving a joint of the requisite strength.

Figure 5 shows an elevational view of a fiveway post and beam joint such as may be used at position F5 in Figure 9. The arrangement of Figure 5 is identical to that of Figure 3 but being a view taken 1 800 about a vertical axis thereof. It differs only in that the element D of the horizontal beam A, B, C is provided along the lower free edges of elements A and C thereof. The elements D are laminated to the beam as described and provide a support for a floor panel or similar.

Figure 6 shows an elevation of a six-way post and beam joint, such as, for example, used in F6 of Figure 9. The arrangement of Figure 6 is identical with that of Figure 5 with the exception that a further 1 50 x 1 50 mm composite beam is composed of three structural elements laminated together. In both cases this beam is provided, adjacent its lower free edges, when laminated with 50 x 50 mm element laminated thereto.

A pinion P is provided as shown in Figure 3B to further locate the upper vertical post as located thereon in Figure 6.

Figure 7 shows an elevation of a four-way post and beam joint in accord with the present invention such as, for example, may be utilized in the joint F7 in Figure 9.

Figure 7 provides the top end of a post G, H, J and K. G, H and J being formed of 50 x 50 softwood and K being formed of 50 x 1 50 mm softwood. The upper end of the element K is provided with a 50 x 50 peg having a length of 1 50 mm. This post is adapted to support a pair of co-axial horizontally extending beams A, B, C wherein the elements A, B, C are each 50 x 1 50 mm softwood and laminated together to form a 150 x 150 mm laminated beam. The ends A extend 25 mm beyond the ends B and C thereby to provide a space for the accommodation of the peg upstanding from the post K. A further horizontal beam D, E, F has a similar cross-section to that of the beams A, B, C with the exception that the central member E extends 50 mm beyond the ends of the elements D and F.This end portion of the element E thereby abuts the central peg of the post K while fitting between the elements C of the two coaxial beams A, B, C. Thus, when conjoined adhesively and nailed suitably this joint provides an excellent mortise joint; the beams being formed of softwood of readily available sizes.

Figure 8 shows an elevation of a four-way post and beam joint such as for example may be utilized at position F8 in Figure 9. The posts have a construction such as shown in Figure 1, while the beams are formed of the central element formed of 50 x 225 mm softwood to which has been laminated on each longer side a 50 x 1 50 mm softwood element. Again this element may be adhesively conjoined and nailed as necessary.

In Figure 9 the main frame of the house is shown, the post and beams as shown in each of Figures 1 to 8 were made up in a workshop according to a predetermined plan. Each of the post and beams is terminated in an interlocking arrangement as shown. The wall plates as shown in Figure 1 were affixed to a prepared foundation plinth and trued up to ensure that they formed a true right angle. The frame as shown was then erected by positioning the posts and beams with the correct joints substantially as shown. By use of this method of constructing post and beam assemblies the structural frame of the house can be assembled very quickly on site thereby enabling the roof to be positioned thereon as early as possible.It will be appreciated with reference particularly to, and for example, to Figure 1 , the elements A and E form with the wall-plate B and the post portion C a suitable rebate for positioning an insulative wall panel therein. With the structural post and beam assembly as shown in Figure 9 erected it can be positioned in the intervening spaces with a minimum of preparation thereby rapidly forming the necessary walls.

In Figure 10 a plywood panel 4 is fixed with nails to a sole plate 2 and to a beam 4. Insulation material 7 may be added between panel 4 and internal panel 8. Flooring panel 5 is nailed into the recesses of adjacent beams 3. It will be noted that the beams 3 are a composite of several pieces of timber which have been pre-sawn to various specific lengths and then bonded by gluing or by other fastening techniques.

The timber cutting and gluing to form the composite beam 3 may be conveniently carried out prior to delivery to the site of the space frame assembly.

Illustrated in position 3A is a beam made from five pieces of timber, each of the order of 5 cm square. Alternatively, in position B a composite beam is illustrated made of three pieces of timber one 15 cm x 5 cm and two pieces 5 cm square each. Posts 2 may, for convenience, be of a similar cross section. The length of each beam 3 and post 2 is typically 2 to 3 metres.

Referring now to Figure 11 there is shown an exploded view of a typical joint in the space frame shown in Figure 9 wherein one post 2 meets three beams 3. It will be noted that good load-bearing wood on wood contact surfaces have been achieved by single cuts in several of the smaller timbers before these are bonded to form the composite beams and post illustrated. The detailed overlap design of the joint can be varied in several ways without altering the principle of the jointing technique.

Similarly, for other joint configurations, for example two beams meeting two posts at a corner, or four beams meeting two central posts the same principle of simple cuts may be used.

However, the actual lengths of the smaller timbers is adjusted by the requisite number of centimeters to make the specific joint arrangement selected. In this Figure there is illustrated simple square cuts in the small timbers but other more complex cuts will also be possible. Furthermore, angled cuts will be convenient when using the principle of the invention to achieve different geometry for all or part of the space frame. For example, triangular, trapezoidal or pentagon floor or wall panel shapes can be achieved when required for architectural reasons.

The cross-section of the beams and post illustrated in Figures 10 and 11 is in a convenient form especially since it facilitates the insertion of panels into the space frame on site so variations can be made in the section dimensions and in the shape and the number of smaller timber members used to make up a composite beam or post.

Forming of the composite beams or posts from several smaller timber sections achieves the desired beam section in an economic manner and also by alternating the grain direction any warping tendencies can be minimised.

It will be appreciated that in addition to the invention features hereinbefore set forth the invention also extends to each and every interlocking joint, substantially as shown in Figures 1 to 8 of the drawings.

In use, when the system was applied to the construction of a three bedroom house, it was found that working from a prepared foundation plinth, less than four man days were required to erect the structural frame as shown in Figure 9, to position the roof trusses, and provide a waterproof covering thereover.

The arrangement of the invention provides, therefore, a facile means of providing structural elements for post and beam constructions utilizing hitherto unusable wood sections, while using them to form the necessary mortise interlocks for a sound construction.

Claims (30)

1. A laminated structural member comprising a plurality of elements extending longitudinally in edge to edge engagement, the ends of at least one thereof extending beyond that of its associated elements, thereby to form an interlocking means.

2. A member as claimed in claim 1 wherein all said elements are wooden elements.

3. A member as claimed in claim 1 or claim 2 wherein at least one of said elements has a base width, and at least one other element has a width which is a multiple of said base width.

4. A member as claimed in any preceding claim wherein at least two ends of said elements extend beyond that associated elements thereby to form a mortise.

5. A member as claimed in claim 4 wherein the at least two ends extend by different amounts relative to each other and the associated elements.

6. A member as claimed in claim 4 or claim 5 wherein the at least two ends extend by an amount which is equivalent to the base width or a multiple thereof.

7. A structural member substantially as hereinbefore set forth.

8. A structural member substantially as hereinbefore set forth with reference to and as illustrated in Figures 1 to 9 of the accompanying drawings.

9. An assembly of a plurality of laminated structural members as claimed in any one of claims 1 to 8 as a kit of parts to form a structural stable frame.

1 0. An assembly as claimed in claim 9 wherein each of said laminated structural members comprises an interlocking means adapted to interlock with other laminated structural members according to a predetermined sequence thereby to form a stable frame.

11. An assembly as claimed in claim 9 and substantially as hereinbefore set forth.

12. An assembly as claimed in claim 9 and substantially as hereinbefore set forth with reference to and as illustrated in Figures 1 to 9 of the accompanying drawings.

13. A structurally stable frame formed from an assembly as claimed in any one of claims 9 to 12.

14. A frame as claimed in claim 13 wherein at least some of the laminated structural members are formed with a rebate along at least one edge thereof, said rebate being adapted to accommodate an edge of an insulative or weather resistant panel adapted in use to form a wall of a building.

1 5. A method for the production of laminated structural members as claimed in claims 1 to 8 which comprises selecting a plurality of elongate elements of a predetermined length, presenting them to a lamination station, applying an adhesive to those surfaces of the elements which are to be laminated, and applying pressure and/or heat to said so formed laminated structural members to cause continuous engagement of the same.

16. A method as claimed in claim 1 5 wherein each elongate element is sized as, or as a multiple of, a base width.

17. A method as claimed in claim 1 6 wherein said multiple is a whole number or fraction from 1 to 5.

18. A method according to claim 1 5 and substantially as hereinbefore set forth.

1 9. A method of constructing an interlocking stable frame which comprises providing a plurality of laminated structural members as claimed in any one of claims 1 to 9, assembly said laminated structural members in a predetermined sequence with their ends correctly interlocking, and causing said interlocked ends to adhere together as by adhesion, and/or nailing.

20. A method according to claim 1 9 and substantially as hereinbefore set forth.

21.The joint of Figures 1 and 1 A.

22. The joint of Figures 2 and 2A.

23. The joint of Figures 3, 3A and 3B.

24. The joint of Figures 4, 4A and 4B.

25. The joint of Figures 5, 5A and 5B.

26. The joint of Figure 6.

27. The joint of Figures 7 and 7A.

28. The joint of Figure 8.

29. The individual joints of Figure 10.

30. The individual joints of Figure 11.