NZ194847A - Building method using slotted planks - Google Patents

Description

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!^S^te..J4.P£C19fi4 | P.O. Jours-si r-Jo: ... .'£^5 NEW ZEALAND PATENTS ACT, 1953 Addition to No. 177 611 No.: Date: COMPLETE SPECIFICATION MODULAR BUILDING SYSTEM I/Wfc? HANS JUERGEN GIESS a German national of 5 Burn Road Rotorua, New Zealand hereby declare the invention for which I / jfjfs pray that a patent may be granted to jne/ists:, and the method by which it is to be performed, to be particularly described in and by the following statement:- n 4 BACKGROUND OF THE INVENTION Many forms of building are known which embody the use of factory prepared lengths of timber or other material pre-cut or otherwise formed which can be over layed or stacked lengthwise (normally in a tongue and groove relationship) in order to provide the walls without there being any need to provide external cladding or interior cladding. Such systems can be extended for use as sarking, floors and the like. For ready use however any such pre-cut system should lend itself to easy on site erection and for this purpose various nail-less types of construction and components therefore have been devised. No satisfactory nail-less system however has yet been devised which enables solid or seemingly solid plank-like members to be used without leading to significant difficulty or expense with regard to provision of aligned holes which define conduits necessary for receiving ties or utilities such as plumbing and electricity.

It is believed therefore if some modular system is devised in connection with a plank-like method of construction that cheaper factory treatment of the plank-like components in a substantially standard way will not o'nly meet specific needs but will allow for on-site assembly flexibility as well as future specific demands. It is therefore an object of the present invention to provide means and methods which will go someway to meeting the abovementioned desiderata. It should be realised of course that any such means and/or methods will have application not only within buildings per se (including toy buildings and like structures) but also in such items as feed bins, tanks, pools, partitions, shelving, boxes, containers, etc. w 194847 BRIEF SUMMARY OF THE INVENTION Accordingly the present invention consists in a building system havi ng a planar structure of a plurality of plank-like components engaged along longitudinal edges, each component having tongue and groove formations along solid edges and a plurality of transverse parallel holes in the plane of the structure passing completely therethrough, at ' least one of said holes, and the corresponding aligned hole of all other components in the planar structure having, in a plane which substantial! includes the axis of said hole, a planar saw cut slot from the hole to the periphery of the component, said slot extending the full axial extent of said hole, each component being further characterized in that at least a majority of said plurality of parallel fully extending transverse holes are spaced with respect to each other along the component in a modular manner, a second structure, whether of a unitary or an assembled structure which substantially abuts the planar structure over the aligned planar saw cut slots, said second structure having a planar slot to a hole or aligned holes which runs or run parallel to that of the first structure and so arranged that the spline member can interconnect the planar structure with said second by use of the substantially mirrored slotted hole arrangements, a spline member interconnecting the planar structure and said second structure by use of the mated slotted holes in a manner substantially as hereinbefore described, and /, ' - ' *' V:' 194847 with said planar structure a dowel or dowels extending through some of the aligned holes and interconnecting the components is such a way as to provide some measure of resistance to racking.

Preferably a tie member passes through the structure along at least one series of aligned holes.

BRIEF DESCRIPTION OF THE DRAWINGS Preferred forms of the present invention will now be described with reference to the accompanying drawings in which; Figure 1A is a view from above of a length of timber in accordance with one preferred form of the present invention showing holes that transversely pass therethrough to lie substantially parallel with the sides of a rectangular sectioned plank-like component which in use, if used for a wall, would have the holes lying in substantially a vertical direction, the holes themselves being mutually spaced apart at a constant predetermined modular distance of for example 50mm, Figure IB is a similar profile to that of figure 1A but showing the appearance from above of a tongue profile of a kind substantially shown in figure 2, Figure 2A is a section view AA of a length of timber but which has a profile shown in Figure IB and which is adapted for a tongue and groove arrangement, the dotted lines denoting the transverse extent of the holes that pass therethrough, Figure 2B is a variant of the profile of Figure 2A and which for convenience does not show the dotted extent of the holes that would pass therethrough, the variant of figure 2B being one where common sized saw mill components are shown laminated to provide a profile 1 substantially as shown in Figure 2A, the use of such lamination being such that each part of the lamination will tend to counteract any warping characteristic of the other, Figure 2C is a similar view to that of Figure 2B but showing a cavity type construction, the cavity either being left empty or being filled with for example a thermal insulating plastics material, for example polyurethene foam, Figure 3 is a sectional view AA of the profile of Figure 1 with the dotted lines again showing the extent of the longitudinally spaced wholly extending transverse holes thereof, Figure 4 shows the nature of the tongue and groove arrangement which results in the use of sections as shown in Figure 2A and showing the nature of the aligned holes which permit the fitting therein of wiring or plumbing or expanded ends of an extruded spline member (provided there is an appropriate cut or slot), a roof, tie member or other metal tie member or a tight fit shear resisting member or members in accordance with the present invention, Figure 5 is a similar view to that of Figure 4 but showing alternative tongue and groove arrangements, suited for exterior walls, the right hand side being the weathering side of the structure, Figure 6 is a similar view to that of Figure 4 but with the additional dotted outlines showing possible extentions intergal or fabricated to the section which would enable particular lengths of timber to be appropriately positioned within a wall structure so that the shoulder or shoulders can provide a bearing support for ♦ floor joists or other beem members, eg ceiling joists or roof rafters, Figure 7A is a further transverse section of a fabricated or laminated construction but which for convenience omits the dotted lines which show the whole extent of the transverse holes thereof, the particular section showing how a plurality of cavities could be defined which could be filled with for example insulating material for the purpose of heat insulation when incorporated in an exterior cladding, Figure 7B is a similar view to that of Figure 7A showing how if desired minimal cavities or no cavities at all need be provided even in such a profile of the composite construction and exterior outline of figure 7A, -t- J 948 47 Figure 8 is a plan view of the kind shown in Figure 1 but showing various types of connections whereby cuts can be made to or arranged for appropriately positioned aligned holes of the overlying lengths of timber (or such other material from which the planklike components may be formed) to provide butt joints of any of the kinds shown or a mitred joint as shown (the mitred joint not being the most preferred as it tends to lose the module of the construction as will hereinafter be discussed), Figure 9A shows sectional view of various overlying lengths of timber or other material showing various means whereby the same can be set one upon the other, with some of the forms showing modifications to a tongue and groove arrangment (for example using substantially horizontal spine members and the like) the preferred form however being those which do not include splines for this purpose as the provision of splines will interfere with?passage of material whether it be shear resisting members, conduits, plumbing or electrical or the like down through any aligned holes, Figure 9B shows how in some forms of the present invention the plank-like components in accordance with * the present invention can not only be composite from a lamination point of view but can also be composite from an abutment engaging point of view (the term "planklike" component as used throughout the present specification and the apended claims therefore including any such composite fabricated or the like component), Figure 10 is a perspective view of one means whereby ends of lengths of timber within a wall structure can be brought into a relationship whereby a tying member can tie to wall structures together by the passing thereof down through the aligned holes in the corner without interfering with the module and leaving free a plurality of aligned holes for the purpose of carrying wiring or plumbing if any and of course shear resisting members in order to minimise deflections under racking or the like loads, Figure 11 shows an alternative to the form in Figure 10 whereby lengths which are unmodified at the end (save for having the cut at the end position so as to preserve the modular inter relationship) can be stacked alternatively to provide an alignment of holes at the corner whereby a tie member can pass down therethrough to not only locate the two walls relative to each other but also if desired tie a roof structure to the foundation from which the tie may originate, Figure 12 is a variation of the arrangement shown in Figure 11 whereby it is possible to have a partitioning wall or the like tied by a member in a simple manner from an exterior wall or vice versa, Figure 13 is an arrangement whereby a tie in the direction shown by the dotted line can provide a located connection between butted wall sections which are substantially in the same plane without it being necessary to provide a spline member as will be hereinafter described, (a spline member or dowel or the like resisting member being viable alternatives to a tie for purposes of horizontal location), Figure 14 shows in a perspective manner the arrangement shown in Figures 11 and 12 with portions of a metal tie extending upwardly out of the stack structure, Figure 15 is a similar view to that of Figure 14 but showing instead spline members holding the three lots of wall structure together, only one of the spline members being shown extended above the upper layer of the structure and the dotted line showing how the modular inter relationship between the aligned hole of wall structures does not vary if in fact the module is preserved by judicious cutting with respect to the openings and the use of a connecting spline members whose expanded end regions are spaced sufficiently to preserve the modual also, Figure 16A is a composite section of one form of post which can be used so that the cuts can be taken 1948 47 into an appropriately positioned longitudinally extending hole thereof if a spline member is to be received therein to tie the same to either a wall structure or the like, any other hole if not being used within the post being suitable for the purpose of carrying conduits, tie members and the like, the section however as shown not being the most desired other than for stiffening purposes where it is not required to maintain the module as it would tend-to result in the loss of the module throughout the building if such a structure is included as part of a wall, Figure 16B is a composite section of a post which is preferred as it enables the preservation of the building module as the spacing of each hole from its nearest neighbours is the same distance as will exist between the holes along the length of the piece of timber, the distance of each hole from the nearest edge of the post being substantially half the modular distance so that the same combines readily with the end of the length of timber which has had the end cut thereof positioned substantially half way between adjacent holes on the length of the timber or the distance from each hole of the length of timber to its transverse edge is approximately half the modular distance so that the same is spaced in the modular manner from a post butted thereagainst or the end cut of a similar length of timber, Figure 17A is a further variant of the four hole module preserving configuration of Figure 16B showing an additional pair of holes located between those pairs for the purpose as will become evident from a consideration of Figure 18 hereinafter, Figure 17B is a variant of configuration as shown in Figure 16A showing how if considered desirable the two component parts of the fabricated structure can be splined together, 194^ Figure 18 shows in dotted outline how the module can be preserved with various configurations using a post of the sections shown in Figure 16B, the various spline members being shown located in appropriate holes, the figure also showing with dotted additional holes how a post of section as shown in Figure 17A does not interefere with the module but can allow if desired the taking off of a wall or the like from the post at a position centrally of the post, Figures 19 to 31 show diagramatically various different kinds of spline connectors all of which are capable of being extruded from a metal or alternatively a plastics material, all of them including a shank and expanded end regions and the majority of them having expanded end regions substantially hollow so as to enable if desired the metal tie of the like to pass down through or if desired utilities to pass therethrough, Figure 32 shows the preferred section of the spline connector in accordance with the present invention which has substantially circular expanded end regions which are open on the non load bearing regions thereof and which have on the shank regions thereof ridges adapted to fit the shank tightly into the cuts, such a configuration therefore by virtue of its substantial conforming to the holes between which it splines and the engagement of the shank ridges with components to be splined providing not only accurate locations and holding together of the components but also some degree of shear or racking resistance for the structure, Figure 33 is a view BB of the section shown in Figure 32, Figure 34 shows in perspective a connecting spline of the kind shown in Figures 32 and 33 received within joints of timber of sections similar to that shown in Figure 3, Figure 35 is a side elevation view of such a butt joint showing the extrusion extending in its connecting mode upwardly and showing two tie members that extend upwardly through the wall structure, one of the tie members being shown passing through the open expanded showing upwardly extending portions of the preferred shear resisting tight fit members, Figure 36A shows the preferred form of tight fit shear resisting member which is preferably a wooden dowel of length such the same projects in a tight fit manner into part only of each length of timber which has the same extending therebetween, (preferably non glued) after its being driven subsequent to the abutment of adjacent lengths of timber into its final position, Figure 36B shows a variant of the configuration as shown in Figure 36A, Figure 37 shows a section of an exterior wall, the exterior face being on the right with a dotted line showing the ceiling level and the portion thereabove being a wall section of a gabled end region showing how the same can have a cladding sheet mounted thereon over a spacer and insulation yet at the same time the overlying lengths of timber can have in the aligned holes the metal ties, spline members and/or shear resisting tight fit members, it being realised of course the different * profiles as previously shown are adapted to being substantially interchangeable to provide some degree of flexibility in design and appearance ofy a structure, Figure 3 8A shows a diagramatical view of a wall structure showing a sill ceiling joist connection and a rafter, sarking and soffit arrangement, the ceiling beam member having a hole or holes thereof splined in the normal manner (shown figuratively by the various dotted outlines) to a preferred single vertical width of a. component of the wall and having the same resting on a sill or the like portion, for example as described with reference to dotted outlines in Figure 6, Figure 38A also showing diagramatically in a third 'angle projection the section of, for example, an appropriate end of the extruded spline connector, said figure also n 1 94^4 rafter member having appropriate recesses for receiving cladding sheets or the like for a soffit and sarking (of course in alternative forms the sarking could be formed using profiles in accordance with the present invention), Figure 38B showing in more detail but without showing the splining of the ceiling joists how a rafter can be splined into a wall (for this purpose a short length spline member preferably of section as shown in Figure 32 is shown in dotted outline), Figure 39A shows diagramatically how a wall structure in accordance with the present invention can tie down and locate a rafter or truss even when a full wall height tie member is not used, the tie member being shown in Figure 39A being for example a length of 3/8" diameter rod with an expanded head at its lower extremity with a coach screw thread which can be anchored down into some horizontal wall component and have the shank thereof pass up through the aligned holes thereof to thus anchor the rafter or truss with an appropriate washer and nut at the upper extremity, Figure 39B is an alternative form which shows for example d full length bolt like screw screwed down into the aligned holes to tie a rafter or truss, Figure 4 0 shows how even with the location of such rafters by for example the'arrangement as shown in Figure 39A those horizontal plank-like components which form part of the present invention can themselves be firmly anchored by fully extending tie rods to the foundation shown diagramatically at either end of the wall, Figure 41 is a view of connected wall structures showing how the same can be spaced in order to provide an insulating space for exterior walls if desired, each of the wall structures however being a structure in accordance with the present invention, Figure 42 shows how wall structures can be arranged in order to provide an alternative to a post structure, said alternatives being useful for ducting large diameter utilities in the vertical direction and providing a support frame for the roof, Figures 43A and 43B show how an exposed end of a wall can if desired be weatherproof or dressed, Figure 44 shows a further variant of the arrangement shown in Figure 43, Figure 45 shows in a similar direction to those shown in Figures 2 to 5 how a lower most length of timber or other material in a wall can be rested on the floor or floor joists and can if desired have a dowelling member passed down into a hole in the floor or alternatively can have a tie passed down thereinto, Figure 46 is a similar view to that of Figure 45 but showing how an extruded or roll formed metal bracket can locate such a lower most length of timber against movement in a direction which is horizontal yet perpendicular to the elongate axis thereof, again showing in dotted outline the position whereby if desired dowels or tie rod like members can be passed down below the supporting level of the floor or floor joist, Figure 47 is a perspective view of a roof structure showing a. plurality of lengths of timber in accordance with the present invention which are joined at or about the apex by a spline member in the normal manner described in regard to walls and showing how with the holes of each length of timber lying substantially horizontal how using tie members and dowel members, (the preferred tight fit shear members) a diaphragm type roof structure can be erected, Figure 48 is a plan view of how a woooden plate or metal channel member can be affixed, for example, by nailing into an existing wall structure e.g. a concrete wall so as to locate the end of a partition wall or the like formed from a plurality of lengths of timber in accordance with the present invention, Figure 49 is a plan view showing how short lengths of timber in accordance with the present invention can 1 be splined together by a variety of mitre or modified joints so as to define a shape suitable for example, below and above a bay window, cylindrical structures, tanks or other curved structures, Figure 50 is a plan view of a corner of a wall showing how the exposed grain of one wall can be protected from the effects of weather using metal or plastic members, the system being an alternative to that shown in figures 43 and 44, the construction of figure 50 showing a nailed or screwed in member over which can be clipped the weathering member, Figure 51 is a side elevation of a wall structure showing how within a wall structure irrespective of whether or not lengths of timber are not provided with tongues and grooves, how shorter lengths can if desired be butt jointed, the dotted lines showing the extent of a spline member which not only substantially weatherproofs the joint but also makes the joint strong, Figure 52 is a diagrammatic elevation view of a floor for example, a concrete floor which has anchored therein any conventional form of concrete socket, for example a concrete anchor member and showing how a tie t rod or the like of the present invention can be screw engaged therein, (obviously a simple washer and nut arrangement being provided at the upper end (not shown)), Figure 53 shows a similar view to that of figures 2 to 5 but showing how at the floor joist level a covering member maintains the appearance of the outer face of the wall below the floor joist level if required, Figure 54 shows diagrammatically a side elevation of composite members that can be preassembled so as to provide an outline for a window, door or the like opening which minimises the amount of flashing needed, the arrangements shown in solid outline being ^those that would be preassembled bearing in mind the reduced section which would probably not be self-supporting, - >r- |T ! 9 4 d Figure 55 includes sectional views of two possible forms of rafter (see figure 38) which are capable of supporting on the shoulders thereof, ceiling linings, soffit lining and the like, Figure 56 is a similar view to that of figures 2 to 5 but showing how a longitudinal recess can provide means whereby a timber or plastic flashing member for weatherproofing or aesthetic purposes can be engaged therefrom for any number of purposes, Figure 57 shows a plan view of a structure showing a multitude of different jointing arrangements but showing how in a majority of instances the modular inter relationship between walls and the like can be maintained, some of the wall structures being of a non plank-like construction so as to show how additions are possible to an existing structure using a building system in accordance with the present invention, Figure 58 shows in a sectional view how one of the holes that extends wholly through the transverse section of a plank-like member in accordance with the present invention could have located therein prior to on site location or at least prior to the abutment a shear I resisting member which upon said abutment need not be inserted first in the plank-like member shown in Figure 58 but need only have the shear resisting member pushed therefrom so as to provide the inter engagement with the previously located length, Figure 59 showing the resulted position in the same terms as shown in Figure 58, and Figure 60 shows diagramatically a wall section which could wholly or in part be formed in a factory or on site if deemed desirable (though unlikely) which could have sections of the plank-like members glued one to another to provide a rigid section of an overall building structure with probably more resistance to deflection than sections of the building simply provided with the measure of racking resistance that results from the use of the shear resistant members, such a - ytr- ( 114247 factory or the like prepared structure possibly finding some use in the provision of short walls or the like which even when assembled can be readily man handled on the site.

The system of the present invention is primarily designed for use in combining building components preferably formed for laying substantially horizontally in an overlying relationship so as to define wall structures. However persons skilled in the art will appreciate the building components in accordance with the present invention could be formed for laying at an angle to the horizontal and yet still embody some of the features of the present invention.

In still other forms of the invention a roof structure could be formed whereby while the longitudinal axis of the lengths of timber are inclined the holes that pass transversely thereto lie substantially horizontally.

Moreover when used for partitions it would still be / possible to provide instances where the holes that pass transversely through the lengths of timber lie substantially horizontally, i.e. with the longitudinal axis of the lengths of timber lying substantially vertical. This may be a'form that is appropriate for, for example, A-frame buildings which have steep inclined walls.

Primarily however the preferred form of the building component is one such as shown in figure 1 where a plurality of holes 1 are provided which pass into and through a transverse section of the elongate building component. Figures 1A and IB show two different profiles. Ideally the building component is formed from timber or other lightweight material and has a section as shown in figure 2A or some equivalent (such as Figures 2B and 2C) which allows an overlying tongue and groove type relationship which offers a weather seal, an aesthetic finish and also some resistance to deflection in a direction perpendicular to the vertical plane of the longitudinal axis thereof. In other forms of the present invention the length of timber or other material from which the building component is formed could be for example as shown in figure 3. With such a simple configuration some means could be necessary if such component was used for a wall exposed to the weather (especially in a residential building) to weather proof between joints e.g. butyl tape, mastic or the like.

Figure 9A shows various other configurations of the cross section that could also find favour. All of the preferred building components however do have one thing in common and that is the positioning of holes 1 (see the dotted lines in figures 2 and 3 which show extent) which are spaced at a modular distance with respect to each other along the length of the timber. The splined profiles of Figure 9A are not preferred where shear resistent members are to be inserted unless of course the spline is fixed and has the holes extending therethrough. In the preferred form of the present invention the centre to centre distance of the modularly spaced holes is 50mm. Obviously however other forms of hole could be provided and the modular spacing could be quite -different. In fact in some forms of the present invention it is envisaged that it may be appropriate to provide modular spacings between groups of holes, however, to » give the greatest possible flexibility and reduce waste preferably the holes 1 are spaced evenly along the length of each building component and each passes completely through the major transverse dimension of the timber. Preferably the cross section of the lengths of timber is approximately 150mm x 50mm.

In the preferred form of the present invention the holes 1 are circular owing to the fact that they are the easiest type of hole to form, thus making it possible to drill the holes by normal drilling.

Figures 4 and 5 show the various tongue and groove engagements that would find favour. Figure 4 shows one that is suitable for internal wall structures and also is suitable for external wall structures. Figure 5 however shows a variation where there is a non-laminated - ±*--n version having a weather face (the right hand side of the drawing) and an inner face. However these variations are not an essential feature. In order to understand the present invention the dotted lines shown in figures 4 and 5 show the manner in which the holes 1 pass down neatly between the tongues and from and to a flat face, thus making drilling from either side relative easy. Moreover by having the holes positioned between two tongues it is possible to ensure the accurate alignment of the holes of the lengths of overlayed timber by simple end adjustment or by simply sliding down a tie (difficult), or spline member. Usually the fitting of each tight fit member resistant to shear provides progressive alignment of the layers.

Figure 6 shows a variant of the type of arrangement shown in figure 4. However the concept shown by figure 6 has application to many other forms of configuration including the simple form shown in figure 3 and the other forms shown in figure 9 . In figure 6 can be seen dotted projecting portions 2 and 3 which would be formed integrally with the length of timber 4 or alternatively could be glued or otherwise fitted thereto preferably at the factory precutting and preparation stage. One or both of the projecting portions 2 and 3 could be provided so as to define shoulders onto which floor joists or other beams or including even the ends of rafters or the like could rest. A person skilled in the art will appreciate how the use of a shoulder of a region 2 or 3 could support a member which is to be spline attached to a hole 1 of the aligned wall structure of which the section 4 forms but part.

Whatever profiles of the kinds herein are used in a building it can be seen that it is possible, for example, for a wall of one profile to butt against a wall (or posted wall) of another without a loss of hole modularity. lb 94 Figure 7A shows a further section (which does not include in dotted, outline the central or substantially central positioning of the holes 1 for ease of explanation) which has on the weather face thereof a lamination (e.g timber, particle board, asbestos-cement sheet, moulded plastic, metal or the like) which defines a i cavity or cavities in order to minimise glue requirements when the same is fabricated (preferably at the factory stage) and also allow inclusion of insulation. Preferably the weathering member 5 includes in the hollowed out regions 6, some insulating material such as polyurethane, polystyrene, phenolic or urea foam. Preferably the material is polyurethane, such a foam making the system readily adaptable without a double wall structure or further attention for use in climates where heat loss or air conditioning is important.

Figure 7B shows an alternative form to that of Figure 7A.' Figure 8 shows in plan various lengths of timber of the kind shown in figure 1 showing the principal of the present invention. In figure 8 can be seen a series of different lengths (very much simplified for ease of explanation) where holes 1 of any particular length of timber are spaced evenly by the modular distance. Some of the holes that are to be connected by a spline connector as will be hereinafter described in more detail have a cut 7 (end cuts) 8 (side cuts) or 9 (mitre cuts) leading thereto adapted to locate firmly the shank of an extruded section which has a shank with at each end an expanded end slidably receivable within a hole 1. It can be seen however that if the connecting spline member is to have the expanded end regions receivable within a hole and the same is to maintain the module of the structure, the expanded ends of such a connector must be slidably receivable into adjacent holes spaced apart by the modular distance if in fact such holes had an appropriate cut passing ! 94B therebetween. As can be seen however from figure 8 difficulties arise from the use of other than butt joints between an end or ends of the length of timber and/or a side face thereof. For instance the mitre joint shown generally as 11, obviously has the holes 12 and 13 that are connected by the aligned cuts 9 spaced apart by the modular distance, i.e. preferably 50mm. However if the section of wall or the like structure 14 is to have the holes 12 thereof relate for example to one of the holes 16, it can be seen that such a relation is out of modular relationship with remainder of structure owing to the module being lost between the holes 12 and 13 that are connected at the mitre corner 11, owing to the angle at which the spline member must necessary be received with respect.to the remainder of the connections-of the arrangement as shown in figure 8. If the effect of the mitred joint 11 is ignored it can be seen how the various side cuts 8 and end cuts 7 inter-relate to enable a series of different types of butt joint, i.e. some in line and others forming a T section, to be arranged in order to maintain the module throughout the building.

Figiire 9A shows several different sections of lengths of timber which could be embodied in a system in accordance with the present invention. Some of these systems are joined by horizontal splines, or the like. Others simply rely upon a modified form of tongue and groove, the inter engagement of a convex and concave (whether stepped or smoothly curved) surface or the like. All of these however do have some application within the scope of the present invention as each embodies one face to which the vertically extending modular holes in use could be parallel.

Figure 10 shows how the most simple form of the present invention can be employed if it is desired to build a structure to hold same together at corners using upstanding ties. With such lapped cuts the holes VO 6 I 94^4-7 1 can be readily aligned so that the whole structure, for example for a shed, barn or the like can be simply held together by vertical ties. Thus the spline members could be used elsewhere for different forms of connection if desired. Obviously the shear resisting members of the present invention which will be described more fully hereinafter could also be used.

Figure 11 shows a different way whereby unmodified ends of a section shown in the top right of the figures contained within figure 9 could be arranged so that a tie member could tie aligned holes 1. Figure 12 shows a different form of overlapping that would be appropriate. Figure 13 shows yet a further simple form.

Figure 14 shows in perspective form and showing metal ties or the like members 10 projecting from the uppermost of the holes from both of the kinds of arrangements shown in figures 11 and 12. Figure 15 shows in perspective a spline connecting member in accordance with the present invention projecting from a structure formed in accordance with the present invention, said member having a shank and expanded end regions, each of with is receivable within aligned holes. As » can be seen from the perspective view of figure 15 a similar member to that designated 17 would protrude from the corner. The dotted line of figure 15 suggests how the modular relationship between holes of associated walls is lost if in fact the distance between the expanded ends is not such as to preserve the module.

Figure 16A shows the cross section of one post section. The distance between each hole and the nearest face would preferably be half the modular distance if in fact such posts are to be used with lengths of timber which have the cuts to be associated therewith effected by extending from a hole to the abutment face at the same distance or vice versa. If such an arrangement is not used then obviously careful matching of connecting members would otherwise be necessary. It is anticipated IW47 however that the length of timber whether they be provided with tongues and grooves or not be double sided in the sense that each side bears a similar relationship to the holes that pass substantially parallel therebetween. In the most preferred form of the present invention both sides are parallel to the holes that pass therethrough and if the modular distances i.e. the space in between the holes is considered as X then obviously it is desirable that end cuts be at a distance which will mate with the hole to side face distance so as to be engaged with spline member which has the expanded ends thereof spaced apart by a distance of substantially X. Such a spline joint in the preferred form of the present invention need not be a tight fit save for aesthetic reasons. Having regard to the fact that structural strength derives primarily from the combination of tongue and groove relationship between planks and boards if there is such a tongue and groove relationship the fitting of the dowels (and/or the spline members in a low load situation) as the structure is being erected, and the provision of tie rods, thus making each wall more unitary in characteristic.

In the preferred form of the present invention the holes would be regularly spaced along a length of timber in order to save wastage and also to enable on site cutting, -«r i 1 slotting-etc. Of course the timber would be double sided again to save wastage and difficulties in fabrication. The post according to the arrangement as shown in figure 16B is preferred over that of figure 16A where the module must be carried through. With such an arrangement preferably each hole is again the same half modular distance from each near face, i.e. each of the two nearest faces. Figures 17A and 17B show additional forms. That of Figure 17A is a splined version of that of Figure 16A while that of 17B has six holes to enable (see Figure 18) the posted connection of right angled walls. With such arrangements any of the configurations as shown in figure 18 can be used. A person skilled in the art will appreciate the modular inter-relationship between the various types of members determinable therefrom.

Figures 19 to 31 show diagramatically various sections of extrudable members that are capable of being used as spline connector members in accordance with the present invention. Each has a shank and expanded ends at each end thereof. Obviously some of the members as shown are composite members. Others are more complicated in that dependent from the shank thereof are other regions all of which would have some application. Obviously however care should be taken to maintain the module when used. A majority of the sections it will be noted include open expanded ends.

This is for ease of extrusion, the saving of material and takes into account the only fully stressed region of the expanded ends is that portion thereof which will be most closely adjacent to the connecting region with the shank.

The preferred section is that shown in figure 32 and which is shown sideways by figure 33 in the direction BB denoted on figure 32. Shown by the broken line in figure 32 is the axis of symmetry with the shank 18 and the expanded ends 19 bearing an identical mirror like relationship thereto. Shown in figure 32 and 33 are - Xc-1'5' J.948 ridges 21 adapted to ensure a tight yet axially slidable non rattling fit in the aligned cuts of the members to be connected. Also shown is the open region (preferably outwardly) of each expanded end 19. It can be seen that utilities, tie rods or the like could easily be slid upwardly through the open sectioned expanded ends. As can be seen it is desirable to have an expanded end that locates reprocibly in the modular holes as it is desired to be able to slide fit one expanded end into a . length of timber or aligned lengths of timber and for the shank to be correctly indexed so that the same can have a normally cut piece of timber that is to be associated therewith readily engaged with the other expanded end 19 without the need for wrestling with the inclination or position of the extruded spline connecting member.

The shape of the expanded ends and the ridges 21 provide a good measure of rigidity to a structure as . well as good component location.

Preferably the spline connector in accordance with the present invention is formed from aluminium. Other forms can be formed from other materials e.g. that of figure 22 .would be spot welded galvanised steel. Other materials include plastics material.

Figure 34 shows in perspective a length of timber 33 that has had shank region-of a spline connector as shown in figures 32 and 33 fitted there into. The shank of course lies reproducibly within the cut 22 of the length of timber 23. Obviously also as can be seen the connector 25 passes down into lowermost layers. In use of course that spline member would continue upwardly to locate any further layers of timber to be placed on the structure shown in figure 34.

Figure 35 shows the side elevation of a wall structure (reference 23 being used to denote the type of length of timber as shown in 34) having the spline connector extending upwardly. Such a structure shows metal ties, preferably steel, 24 that can extend up _ _2r-z-f 1.94.8 through al-igned holes of the wall structure or through the foundation to the wall structure and the roof as well as tie the components of the wall together.

One aspect of the present invention that is of and the possibility of preassembly and figure 36A shows a preferred shear resisting member which is capable of a tight fit relationship with a hole of each length of timber. Preferably these members are formed from wood though some other material such as plastic, (see for example Figure 36B for a suitable profile) aluminium or the like can be used. With a wooden dowel of short length (preferable of Figure 36A configuration) it is possible to lay each length of timber 2 3 and locate the same as required with ties, spline members 25 or the like and to drive members 26 as required so that they span between adjacent planks, lengths of timber or the like 23 through the aligned holes thereon. Preferably the shear resisting members are not of such a length, such that the same in use span more than about the full vertical transverse section of a length of timber 23. It is envisaged in use that an appropriate number of members 2 6 would be hammered in, pressed -in or otherwise located in the structure being erected to provide the required resistance to racking.

Of course the posts as shown in figures 16A, 16B, 17A and 17B cannot be prepared simply by drilling owing to their great length and for this purpose ideally the same are formed as composite members in a technique defining conduits as has been use for example in hollow mast construction.

Figure 37 shows with the horizontal dotted line 28 a ceiling level and shows how an alignment of holes 1 can persist thereabove especially at gables ends and how an internal board can be made to fit an exterior board if required. A packing member or the like 29 an expanded end of a spline connector 25. Such ties tie considerably importance is the resistance to racking 114.1 could be provided to locate a gable cladding face 30, under which can be positioned some appropriate insulating material or the like 31 if deemed necessary. Shown in figure 37 too also is a cladding material which is preferably factory attached to basic timber component 32. The cladding 33 can be of any appropriate material but is preferably formed from a factory treated timber.

Figure 38 shows in detail a sill ceiling joist connection and a rafter sarking detail. The alignment of the holes of the wall structure are not shown nor is the preferred tongue and groove arrangement. Persons skilled in the art will appreciate however how the same • relates to, for example the sill arrangement shown diagramatically in dotted outline in figure 6 of the drawing.

In figure 38A can be seen a ceiling beam which is shown spline fitted to an exterior wall, the spline having been shown diagramatically. The figure also shows in third angled projection a sectioned view of the rafter. The soffit lining and sarking is shown in a solid band for ease of explanation and shown skeletally thereabove is a layer of insulation and roofing battens that would bear any conventional cladding. The actual ceiling beams shown, which could if desired be splined to internal walls (shown in Figure 38A diagramatically). could themesleves be clad by ceiling linings and left exposed together with the sills for aesthetic purposes.

Figure 38B shows a similar view to that of Figure 38A but shows how a spline (in dotted outline) could be used to spline a rafter into the wall ideally (not shown) down into the floor joist. For this purpose therefore it is envisaged that a spline of approximately twice a plank height would be used so that the same member splines not only the rafter to the wall but also the joist to the wall thus also providing some degree of inter engagement between the joists and the rafter. For the purpose of splining the rafter a hole at an angle other than strictly transverse would be necessary. • 0 1945 Figure 39A shows how a rafter can be tied down into a wall structure where a full length tie member from foundation to rafter is not used. In this form of tying a metal member with an enlarged lower end would be provided with an appropriate coach screw thread which allows the same to be screwed down into one of the uppermost plank-like members and have the upstanding shank thereof passed through subsequently positioned plank-like members (if any) and eventually passed through the rafter and receive a washer and nut thereon. An alternative form to that shown in Figure 39A is that shown in Figure 39B where a straight threaded member could be screwed down through the rafter into one or a plurality (2 as shown) elongate members that form part of the wall structure.

Figure 40 shows how a fixing system as shown in Figures 39A and 39B can if desired be used in conjunction with a full length tie, the dotted arrows denoting a full length tie as an alternative to the forms of tie shown in solid outline in the wall structure of figure 40, showing for example how a limited tie of the kind shown in figure 39A is appropriate above for example a window.

Figure 41 shows a plan view showing how wall structures can be connected by connectors to define an insulating space 34 if the same is deemed necessary.

Where such a structure is for external walls inner sections of timber could be employed having a different . section to that of the weathering wall. A person skilled in the art will appreciate the potential of this system and the fact that with the modular spacing of the holes incremental adjustments of wall thickness can, if desired, be readily achieved.

Figure 42 shows how it is possible to create a composite post structure formed wholly of horizontally positioned axial lengths of timber or the equivalent that are spline connected to each other to thereby provide a space 35 capable of hiding utilities such as il 9 4-8 wiring, piping, heating ducts and the like. Such a structure tends to be more time consuming in the erection than the use of a post as shown in figure 17 but would find certain applications. Nevertheless figure 42 does show how the module is maintained between four walls if the concept shown simplistically there is extrapolated in scale.

Figures 4 3A and 44 show simply various types of weather cladding in a plan view of external corners :of a building. Such forms are not preferably necessary but could be employed.

Figures 43A could be used internally. Figure 43B shows the use of such a capping profile as by way of an example a door jamb and as means to tie together a short length of wall.

Figure 4 5 shows as also does figure 46 how a lower most plank or board of a wall structure can be supported by the central tongue region on the surface either in absence of or presence of a metal or the like channel that is affixed to the supporting surface. Moreover in order to firmly anchor the same a tie rod could be passed down some of the holes from at least the ceiling level and «also in order to maintain recovery and racking resistance preferably at least one or more tight fit shear members would be passed down into an appropriate hole in the floor.

Figure 47 shows how planks or boards in accordance with the present invention can also be used to form a structural roof i.e. the longitudinal axes are inclined so that they provide a mateable right angle joint which can receive a spline member at or about the apex or alternatively provide some form of mitre joint at the apex. Obviously with the provision of tie rods along holes of the structure and also the provision of tight fit shear members between adjacent planks throughout the structure an overall strong structure will be provided. In this form of the invention therefore - jsfiS 1943 preferably, the holes are indexed to lie substantially horizontal. Persons skilled in the art on the basis of the foregoing will envisage how the modular arrangement of the hole in this way need not necessarily be but can be arranged to bear some modular relationship to structures below the same.

Figure 48 shows how a wall of the kind previously described can be fitted end wise up against an existing for example concrete wall by virtue of a channel of wood, plastic or metal being fixed by appropriate fixing means for example masonry nails into the structure.

Figure 4 9 shows how spline members in accordance with the present invention can be used to hold together modified mitre joints so as to define for example a bay window structure or other cylindrical or curved structures. Such a structure would also have application in buildings of unusual configuration. Again however difficulties will be encountered in relating portions of such structure to other walls or structures of the building. Persons skilled in the art however having regard to the foregoing will envisage how that can be arranged. - Figure 50 shows a plan view of a external corner of a building having over the end grain thereof affixed a clip member over which a weatherproof capping of plastic or metal material can be clip fitted. A provision of this two part weather protection on a corner enables the clip member to be affixed by screws or nails and have such unslightly nails or screws covered in an aesthetic yet weatherproof manner.

Figure 51 shows how the instance illustrated in figure 28 is not necessarily the only instance in a building where a length of spline member substantially only the length of the major transverse distance of a plank would be used. In figure 51 is shown a wall where a butt joint owing to a need to join lengths of - timber can aesthetically and strongly be mated. This is especially important in instances where some form of - ^ I CI4 S weatherproofing should be provided.

Figure 52 shows a side elevation as previously mentioned of a ground anchoring socket which includes a screw thread into which for example the lower most end of a tie bolt can be screwed after having been passed down through aligned holes of a wall structure. Obviously the upper end thereof would have a washer and nut fitted thereto.

Figure 53 shows capping planks or the like which overlie the end plank of a floor joist yet maintain a constant appearance for the facade of the outer wall down below the floor joist level.

Figure 54 envisages the coupling together at a factory stage of sections for example as shown in solid outline which can be fabricated on site in order to provide window openings into which window frames which require only a minimum of flashings can be received. The lintel arrangement or the lintel receiving arrangement shown obv5iously would result in a plank or board being delivered on site which would be too flimsy to withstand breakage and for this reason such a plank having a reduced section would necessarily have to be coupled with a plank of normal strength for example by tight fit shear members and possibly some glue, if the tight fit shear members are not sufficient. Ideally however no glue would be used.

Figure 55 should be considered in conjunction with figure 38 as the same shows possible profiles of rafter members which are provided with shoulders capable of supporting ceiling linings or the like.

Figure 56 shows a bottom portion of the profile of the preferred boards showing therein a longitudinal groove capable of receiving a portion at least of a flashing member. Such a flashing member could be a portion of for example skirting, formed from plastics materials, or a metal or could be a portion of a weather-proofing flashing. For example, modifications based on - - 1948.4*7 the concept shown in figure 56 could have application to window frames etc.

Figure 58 and 59 show how if desired shear resisting members such as the preferred dowel can be inserted as required in various holes of the plank-like members prior to their being located on top or alongside as the case may be a prior located elongate component and how the same can be driven into its engagement as shown in figure 59 is even envisaged that the planks can be factory prepared with the requiste number of dowel members appropriately positioned for a precut building kit or assembly of components.

For a lower most wall structure the dowel member would be driven down into a floor joist or some foundation dependant member even if it is only a floor and subsequently abutted plank-like members would have their dowel driven down into the abuting plank-like member.

Figure 60 shows diagramatically how for example it may be appropriate in a structure to pre-form certain portions of a structure to minimise assembly time on site. This would be especially so where short lengths of wall are used. This therefore lends itself to the » possibility of the structural wall components being glued one to another to thus enhance the rigidity of any structure that may otherwise rely for its racking resistance on the dowel and the spline connections etc. The instance as shown in Figure 60 shows how by way of example a section of a length of wall could if desired, have various portions thereof glued as they are being assembled on site so as to provide a strong point in the structure which otherwise is simply assembled in the nailless fashion in accordance with the preferred form of the present invention.

From the foregoing then it can be seen that the present invention in its most preferred form embodies several important features. ~ jacy' 1. Standard modular distances between holes which are spaced preferably continuously along the length of each length of timber that is to form part of a wall structure. Ideally the lengths are precut prior to being delivered on site to ensure speed of on site assembly and neatness of jointing. Such joints do not require tightness as such tightness is only a visual and non-structural requirement. Moreover the factory cutting could include predetermined cuts for spline connector members in accordance with the . present invention. 2. Such building components can be erected speedily as they can be readily indexed into position on site. 3. The shear resisting members (also the spline members) can be used in order to resist racking deflections and assist in factory preassembly of the structure with the number of shear resisting members that are used being determined on the likely racking loads to be experienced and the deflections which are to be allowed and 4. the utilities can be placed virtually at will at any portion along a wall structure owing to the communications possible down the preferably otherwise solid structure owing to the aligned modular holes.

A person skilled in the art will appreciate that. very little strength of a structure is lost owing to the number of holes as the same are all preferably passed down the centre of each length of timber and of course the centre of a length of timber is not that section which is placed under compressive or tensile stress in most stressing conditions.

Aspects of the racking resistence should now be considered. - 1 94$47 The spline members of the present invention as previously stated hold the structure together and also provide some measure of racking resistance. Obviously . the provision of ceiling rafters and the like will square up the structure after it has been initially erected. Also as it is being erected the tight fit shear members will be fitted thereby making each wall structure reasonably rigid on its own. The need however for the tight fit shear members is in order to ensure that the structure is correctly indexed as it is being erected and also to ensure that it meets required building codes concerning recovery after deflection, a resistance to excessive deflection and the like. Owing to the clearance of the holes that is needed in order to easily slide the planks down onto the spline members a certain amount of plank movement would occur under load if it were not for the tight fit shear members.

Such movement forms a considerable proportion of the total deflection of a wall structure or building which includes such a wall structure when added to the initial small load deformation of the timber where the contact between it and the extrusion takes place. The problem of this excessive deflection and recovery has been solved by the use of dowels between adjacent boards thus almost relegating the spline member to the position of being a connector only. i.e. it holds wall structures or the components thereof together. The dowels are sized to give a small interferrence fit while remaining easy to drive. They are equal in length preferably to the depth of each individual board and once placed accurately in the bottom board and floor are driven into contact in the subsequent boards making accurate placing easy. Dowels used in the structure were 18mm in diameter. Some initial shear tests were carried out using solid aluminium dowels which gave marginally better performance. Of course aluminium tends to be more expensive and does not have the recovery that wood 4^ has Tests have been conducted on a test panel of different heights and different lengths. Dowels were spaced at different spacings and different numbers of dowel were used for different lengths and sizes of panel. Moreover tie rods were varied throughout and the overall structure was tested under impact loads, repeated deflections, usual destructive deflections etc. Tests showed that racking load when plotted against the number of dowels per unit length of panel indicates that the racking load is directly proportional to the number of dowels plus a constant in each case with the effect of the surcharge varying the constant the lines remaining essentially parallel. Aberrations were located however over short lengths from which it would not have been possible in the absence of full tests being conducted to presume that a rule of thumb could be arrived at whereby a person on site seeing the length of wall involved could apply a simple building code concerning the number of dowels required thereto. The test showed that for panel widths greater than for example 1500mm other factors such as bending deformation and rotation have little effect while for the short panels they are quite marked resulting in the aberrations i.e. a curved rather than a straight line. From the test however it became plain that when the number of dowels is varied without shortening the panel or otherwise altering its structure a reasonably straight line variation in racking loads occurs. This is reasonably true even for shorter panels.

The test of structures built in accordance with the present invention showed that under the strict requirements of New Zealand building codes panels even after all cycles to + and - what would normally be considered a destructive deformation of a conventional stud and dwang structure the panels still retained 90% of their original strength and resistance to deflections 1 * ^L' •% 1 74^ although residual deflections were understandably greater than prior to such cycled heavy deformations but still within the maximum permissible. Still however after the test the structure was shown to exhibit 60% more resistance to racking than a newly built conventional wall.

For wind loads especially high wind loads such as those that would have been experienced for example, in the Darwin cyclone, a building in accordance with the present invention could readily be erected so as to be capable of withstanding expected wind loadings. Obviously the exterior walls need not have the high racking resistance of the interior walls if there are interior walls that will bear wind loads. Impact tests on the structure which simulate the effect of flying debris etc, in a cyclone showed virtually a total resistance thereto at normal test levels.

From the foregoing then it can be seen that the present invention provides a structure which can be selectively strengthened against racking load using the fact that the racking load resistance will be proportional to the number of dowels chosen, thereby enabling the erection of a resilient strong structure than can simply be erected from factory prepared timber, precut or otherwise.

Obviously the means and methods of the present invention are applicable to toy structures and building structures of human proportions - hence building as used hereinthroughout includes within its ambit toy building etc as well as, where the context allows, any commercial structures for containment of goods, cylindrical and curved structures etc.

Claims (3)

WHAT I CLAIM IS:

1. A building system having a planar structure of a plurality of plank-like components engaged along longitudinal edges, each component having tongue and groove formations along said edges and a plurality of transverse parallel holes in the plane of the structure passing completely therethrough, at least one of said holes, and the corresponding aligned hole of all other components in the planar structure having, in a plane which substantially includes the axis of said hole, a planar saw cut slot from the hole to a periphery of the component, said slot extending the full axial extent of said hole, each component being further characterized in that at least a majority of said plurality of parallel fully extending transverse holes are spaced with respect to each other along the component in a modular manner, a second structure, which can be a unitary or an assembled structure which substantially abuts the planar structure in the region of the aligned planar saw cut slots, said second structure having a planar slot extending from a periphery thereof to a hole or aligned holes which runs or run parallel to the holes of the first structure and so arranged that a spline member can interconnect the planar structure with said second structure by use of the substantially mirrored slotted holes, a spline member interconnecting the planar structure and said second structure by use of the mirrored slotted holes in a manner substantially as hereinbefore described, and within said planar structure a dowel or dowels extending through some of the aligned holes and interconnecting the components in such a way as to provide some measure of resistance to racking.

2. A building system as in claim 1 wherein a tie member passes completely through the planar structure along at least one series of aligned holes. r<V *£ 36 - 1 10 SEP 1984 lf48W

3. A building system as claimed in claim 1 or claim 2 substantially as hereinbefore described with reference to any of the accompanying drawings. By his/'tihtfr authorised Agents. A. J. PABK & SON, PER jLm -b-n