NZ264207A - Building wall construction, boards make up each panel with intersection between panels connected by connector plates placed in panel recesses connected to rods - Google Patents

Description

NEW ZEALAND PATENTS ACT, 1953 No: 264207 Date: 9 August 1994 COMPLETE SPECIFICATION KIT SET BUILDING SYSTEM We, POST & BEAM NEW ZEALAND LIMITED, a company duly incorporated under the laws of New Zealand of 45 Herbert Road, Hamilton, New Zealand, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: This invention relates to building systems and more particularly but not solely to solid timber building systems in the form of kit sets.

It is known that the construction of a solid timber building may be accomplished with the aid of a partly pre-built and packaged kit set. In this way much of the preparation and planning of the building's construction may be carried out at the builder's premises simplifying the task of the builder on site.

Many prior art building systems in which part of the construction process is carried out away from the building site still require a large investment of time in the assembly of the kit set components on site. Also many kit sets do not take into account the positioning of windows or doors or if these are taken into account in the construction of the kit set, alignment of the various components making up the door or window may cause difficulties. Because the building systems have previously consisted of individual boards which may be connected together by an adhesive and/or interlocking joints or the like, the strength of the overall construction has been insufficient to preclude the necessity to provide joists or beams.

Typically, "kit set" homes constructed from wooden materials are known to expand and contract excessively because of the lack of rigidity in the completed structure. These movements give rise to creaking as adjacent boards move against each other and may distort or skew the structure. Creaking and squeaking may also arise from the differential expansion and contraction of adjacent timbers due to the difference in effect of temperature changes on boards of different densities. Also, many available kit set buildings are designed for erection by a skilled builder and additions or extra add ons are not easily incorporated into the completed house at a later date.

It is therefore an object of the present invention to provide a solid wood building system which goes some way towards overcoming the above disadvantages or which at least provides the public with a useful choice.

Accordingly, in one aspect the invention consists in a kit set for the construction of walls of intended building comprising: a plurality of panels, a preferred number of boards being connected edge to edge to 264207 form said panels, each said wall in said intended building in use being made up of a number of said panels, vertically arrayed edge to edge, with horizontally adjacent said walls joined to each other at intersections, and a plurality of wall connectors for connecting intersecting walls at said intersections, for each intended said connector connected intersection between a first said wall and a second said wall there being at least one said wall connector having a main portion for location between vertically adjacent panels of said first wall at said intersection, and a protruding portion, said protruding portion for extending externally of said first wall, for securing the abutting end of said second wall of said intersection, and intended said vertically adjacent panels of said first wall, between which said connector main portion is to be located in use, having abutting edges formed, at the location of said intended intersection, to cooperate to provide a recess there between when abutting, said recess adapted to accommodate said connector main portion therein and to allow said connector protruding portion to protrude therefrom.

In a further aspect the invention consists in a method of constructing the walls of a kit set building, said kit set building comprising a plurality of panels and a plurality of panel connection means, said panels precut so as, in combination, to form the walls of a building, wherein said method comprises the steps of: i) preparing a base for said building, ii) standing a first level of said panels in positions corresponding to the required walls of said building, iii) standing a further level of panels atop said first level of said panels, iv) at each intersection of horizontally adjacent panels, applying a said panel connection means on the top edge of said panels, said panel connection means having a portion on the top edge of one of said horizontally adjacent panels and a portion on the top edge of the other of said panels, and v) repeating steps (iii) and (iv) as desired to increase the height of said walls to a desired height.

In a still further aspect the invention consists in a wall of a building constructed from kit set as set forth in the above paragraph.

In a still further aspect the invention consists in a wall of a building constructed using the method as set forth in the above paragraph.

In a still further aspect the invention consists, in a building including a wall as set forth in either of the above paragraphs.

Figure 1 is a cross-sectional side elevation of one wall of a building according to the present invention, Figure 2 is a cross-sectional side elevation of wall panels making up a wall of Figure 1, Figure 3 is a cross-sectional front elevation of the wall panels of Figure 9, Figure 4 is a front plan isometric view of two corner intersecting walls of a preferred embodiment of the present invention, Figure 5 is a front plan isometric view of an internal wall connection of a preferred embodiment of the present invention, Figure 6 is a front plan isometric view of two longitudinally intersecting walls of a preferred embodiment of the present invention, Figure 7 is a plan view in cross-section of a wall, end cap and supporting post of a preferred embodiment of the present invention, Figure 8 is front plan isometric view of two comer intersecting walls of an alternative embodiment of the present invention, Figure 9 is a front plan isometric view of an internal wall connection of an alternative embodiment of the present invention, Figure 10 is a front plan isometric view of two longitudinally intersecting walls of an alternative embodiment of the present invention, and Figure 11 is a plan view in cross-section of two partially constructed longitudinally intersecting walls according to a third embodiment of the present invention, and Figure 12 is an end view in cross-section through AA of the two partially constructed longitudinally intersecting walls of Figure 11. 2p 4207 The present invention provides a method constructing a building from a kit set. The method includes the construction of walls from interconnected boards and the use of connectors at each level of construction to join intersecting boards. The connectors are preferably hidden from view and provide significant strength and stiffness to the overall construction. It is also useful but not necessary to have tie rods passing through the walls to provide strength, decrease expansion and contraction and secure the walls firmly to the base of the building. The tie rods are passed through holes in the interconnected boards and the connectors ensure that each hole is aligned. It is also described that for matters of convenience and to provide particular benefits, several boards should be adjoined prior to assembly of the kit set, to form panels which may be more easily handled and may provide benefits in terms of accuracy and speed of assembly.

With reference to the preferred embodiment of the present invention shown in Figure 1, a concrete base 15 for a building is shown. The shape of the base in plan view is predetermined in association with the proposed wall lay out. In the preferred form of the invention the positioning of the walls determines where sockets 14A are to be formed in the base 15. The sockets 14A may be formed by, for example, inserting metal sockets in the freshly poured concrete base around the perimeter of the base and along the lines of proposed walls. Alternatively the sockets may be formed by drilling into the hardened concrete base and inserting metal sockets into the holes formed therein. The purpose of the sockets 14A is described below.

With reference to the drawings, in particular to Figures 1,2 and 3, panels 1,2 and 3 can be seen to be made up of a number of individual planks or boards 4. The embodiment shown uses for example two planks of preferably 145 mm overall width, joined to form each panel. With particular reference to Figures 9 and 10 it can be seen that each board 4 has a tongue 11 at one edge thereof and a groove 10 formed in another edge thereof. The tongue of one board in the panel is firmly interlocked with the groove of the other board of the panel. This results in the construction of panels 1, 2 and 3 having a tongue at one edge thereof and a groove at the opposite edge thereof. Preferably the boards of each panel are further secured by the gluing of the joint 264.207 between the boards.

With reference to Figures 1,2 and 3, the tongue of the board in panel 1 which is adjacent the board in panel 2 (which has a groove) are then firmly interlocked. It is envisaged that joints, between panels may also be glued for added strength. Other shapes of tongues and grooves may also be used, for example, a half round shaped tongue may fit into a half round shaped groove. It is anticipated that improvements in expansion and contraction performance may be achieved with this half round shaped interconnection.

In addition to the previously described tongue and groove joint connecting adjacent panels to form a wall as previously described, the boards and therefore the panels may also be provided with predrilled wall holes 12 and 13 which may be, for example, 16mm diameter holes at 500mm centres. The wall holes 12 and 13 are aligned and form a passage for wall reinforcing means, for example tie rods 14 (which may be seen in Figure 1), which are for example 10mm diameter galvanised rods secured at their lower ends in preformed sockets in the concrete base 15. The tie rods 14 are secured at their upper ends by securing means, for example, nuts 16 above the sarking 17 of the building.

The interior of the walls can be provided with skirting 18 along the intersection of the saiking 17 and the wall as well as skirting 19 along the intersection of the wall with the floor. The skirting 18 and 19 may be nailed or otherwise attached to the wall. The bottom board in the wall is fitted with an aluminium angle extrusion 5 to be recessed flush with the side and bottom surfaces of the panel. The extrusion 5 has predrilled holes which align with the sockets in the concrete base 15 so that tie rods may be passed through holes 12 and 13 in the panels, through holes in extrusion 5 and be secured in the sockets in concrete base 15. The dimensions of aluminium angle extrusion 5 may be for example 40mm by 25mm by 3mm by the length of the wall. Extrusion 5 may be attached to the bottom board in the wall by nails or screws or the like.

To form a building it is necessary to join the preformed walls together in various configurations. The following description details the interconnection of walls with 264207 reference to Figures 4, 5 and 6.

The present invention provides for the connection of intersecting walls using panel connection means, for example connectors 20,21 and 33, which are to be applied to the walls as the construction is carried out so that even while under construction the building has considerable strength. The connectors sit in recesses on top of intersecting walls and are covered by the next level of panels which are applied above.

Figures 4,5 and 6 show the preferred construction for joining adjacent walls, using internal brackets 20 or 21. The right angle (Figure 4) or T-junction (Figure 5) wall joint is prepared by firstly cutting a recess into the side of the receiving panel 22, to tightly accommodate the end 23 of the intersecting panel 24. Next, recesses 25 and 26 are formed in the top surfaces of the tongues 27 and 28 of panels 22 and 24 to receive the right angle bracket 20 (Figure 4) or T bracket 21 (Figure 5) such that the bracket, when in place, will lie flush with the outer surface of the tongue. During construction the bracket 20 should be secured to the panels 22 and 24, preferably by screws through holes provided in the brackets. Once the bracket 20 is in place, flush with the top surface of the tongue, further panels (not shown) may be added to increase the height of the walls. It is preferable that this joining procedure is carried out at each level of construction (that is, between each connected panel in a wall).

It is further advantageous that the brackets 20 and 21 have joint reinforcing holes 39 and that walls 24 and 22 have corresponding joint holes (41) to admi t the passage of joint reinforcing means, for example short rods 40. The short rods 40 may for example be 120 mm long and the joint reinforcing holes 39 may each for example be 60 mm long, with joint holes 39 provided both on the upper surface of one panel and in a corresponding position on the lower surface of the vertically adjacent panel. The use of wall reinforcing means passing through holes in the brackets 20 and 21 provide several advantages. One of these advantages is that the construction of the walls and the wall intersections helps to ensure correct alignment of the wall holes in the panels so that the tie rods may pass easily through during construction. A further advantage is that once in place the rods, along with the vertical entrapment of the brackets inside the 264207 recess in the top edges of the panels serve to further secure the brackets, and walls, in their correct positions. Alternatively, in one form of the invention (shown in Figures 8, 9 and 10) the wall reinforcing means are for example tie rods 14 (which can be seen in Figure 1), and run the full height of the wall through wall reinforcing holes 12.

With reference now to Figure 6, a preferred construction is shown for joining two panels to form one continuing straight panel. Similar to the method described above, the panels 22 and 29 are provided with recesses 30, 31 in the surface of the tongues 27, 32 of the panels, to accommodate the straight connector 33. It is possible to provide fascia 34 for cosmetic purposes. As above, the connector 33 is preferably screwed to said panels, and is preferably provided with holes for the passage of wall reinforcing means.

Referring to Figures 11 and 12, a further alternative butt joint construction for longitudinally intersecting walls is shown. Wall panels 45 and 46 abut at a post 47. The post 47 has rectangular recesses 48 and 49 formed along opposing vertical sides, to receive butting ends 50 and 51 of wall panels 45 and 46. The post 47 also preferably includes vertical hole 52 to receive tie rod 53 which may be anchored in the concrete floor slab of the building construction. The post 47 also includes horizontal hole 54 extending between rectangular recesses 48 and 49, to allow a straight connector 55 to pass therethrough. The straight connector 55 which is preferably constructed from galvanised steel is connected by fastening means to the top edge of wall panel 45. The fastening means for example may comprise crosshead screws 56 and 57, or could alternatively be for example nails. Likewise the other end of straight connector 55 is secured to the top edge of wall panel 46, for example by crosshead screws 58 and 59. The connector 55, as in the constructions of Figures 4 to 6 and 8 to 10, resides in a shallow recess formed in the tongue portion of the wall panel.

With reference to Figure 7, an end post 35 is shown for covering internal wall ends and also for providing some structural support. Preferably these end posts are screwed to the wall 37. Similarly, end posts or caps may be used to protect and enhance the appearance of other exposed ends, such as that of receiving wall 22 (Figure 4) in a comer joint. Figure 7 also depicts the provision of supporting posts 36 '649fl7 which may be joined to either external or internal walls. Preferably the supporting posts 36 are provided with a tongue to fit a corresponding groove formed in the wall 37. The post 36 is preferably screwed or otherwise secured to the wall 37.

Once the floor has been laid, a 90° square template is incorporated into the structure. The template comprises, for example, a pre-cut 40mm by 25mm by 3mm aluminium template. The template provides a guarantee to the customer that the building is level and square as the present invention can not be erected unless the template is placed correctly.

In use, much of the construction of a building is carried out away from the construction site (for example by connecting the planks to make panels) leaving the fitting together of the panels and connection of adjacent walls to be carried out on site. The walls may be mocked-up in a workshop so that sections may be removed for doors, windows or the like then the panels disconnected for transportation and final construction on site. This allows for much more accurate alignment on site and increases the speed at which the building may be completed. It should also be noted that the sarking and flooring may be constructed from the same technique as has previously been described with reference to the walls.

As the present invention comprises interlocked wooden planks, it has a built in natural insulation and as a result only the ceilings require further insulation. The exterior may be clad in any appropriate product, for example brick or cedar, and the internal walls may also be lined, for example in plasterboard. The finished building should not suffer from excessive expansion or contraction as has been the case with previous kit set type houses because each wall is braced by tie rods and is effectively pre-stressed. Also the gluing of pairs of boards into panels has been found to reduce the creaking and squeaking associated with buildings formed with unfixed tongue and groove connected boards. This creaking and squeaking is indicative of differential contraction and expansion that occurs when boards of different densities (a result of varying ages and log cuts) are subjected to daily cycle temperature changes and the like. The gluing of boards in pairs in a randomly chosen fashion reduces ihft *nean density differential between adjacent panels and therefore the differential expansion 26420 and contraction, reducing the creaking and settling normally associated with tongue and groove construction. The present invention, having walls strongly connected at every level of construction (that is, between each vertically adjacent plank), reducing the flexing and bending of joints and the tie rods securing the panels in a vertical direction, reduces the need for ground floor and first floor joists because the walls become beams which are bolted from the roof to the underside of the floors below. It is expected that because of the simplicity of the present invention, the product may be sold as a kit set home directly to a person semi-skilled in the art of building to be constructed by them. 264207

Claims (26)

WHAT WE CLAIM IS:

1. A kit set for the construction of walls of intended building comprising: a plurality of panels, a preferred number of boards being connected edge to edge to form said panels, each said wall in said intended building in use being made up of a number of said panels, vertically arrayed edge to edge, with horizontally adjacent said walls joined to each other at intersections, and a plurality of wall connectors for connecting intersecting walls at said intersections, for each intended said connector connected intersection between a first said wall and a second said wall there being at least one said wall connector having a main portion for location between vertically adjacent panels of said first wall at said intersection, and a protruding portion, said protruding portion for extending externally of said first wall, for securing the abutting end of said second wall of said intersection, and intended said vertically adjacent panels of said first wall, between which said connector main portion is to be located in use, having abutting edges formed, at the location of said intended intersection, to cooperate to provide a recess there between when abutting, said recess adapted to accommodate said connector main portion therein and to allow said connector protruding portion to protrude therefrom.

2. A kit set according to claim 1 wherein said protruding portion of said wall connector is for location between vertically adjacent panels of said second wall, and intended said vertically adjacent panels of said second wall between which said connector protruding portion is to be located in use having abutting edges formed, at the location of said intended intersection, to cooperate to provide a recess therebetween when abutting, said recess adapted to accommodate said connector protruding portion therein.

3. A kit set according to claim 2 wherein each said wall connector comprises a flat plate having a plurality of arms thereof meeting at an intersection, a said arm intended for connection to esch wall of an intersection of walls, and each said accommodating recess between vertically adjacent panels when in use, comprising a horizontal slot, with 264207 - 12- each of said connector arms intended to be disposed within a said horizontal slot.

4. A kit set according to claim 3 wherein adjacent boards in said panels are connected by gluing.

5. A kit set according to claim 3 or claim 4 wherein each said board has an interconnection means formed on one edge thereof and a complementary interconnection means formed on another edge thereof to facilitate the connection of boards within panels and adjacent panels.

6. A kit set according to any one of claims 3 to 5 wherein said plurality of wall connectors include "L" shaped connectors having a pair of arms meeting at their ends to form a right angle intended for use where two intersecting walls meet to from a corner, with one said arm located between the abutting edges of vertically adjacent said panels of a said first wall along the line thereof, and the other said arm protruding from the side of said first wall and into the end of a said second wall.

7. A kit set according to any one of claims 3 to 6 wherein said plurality of connectors include "T" shaped connectors having a pair of arms with the middle of a first said arm being intersected by an end of the second said arm to form a right angle intended for use where two intersecting walls form a "T"-junction, with said first arm located between the abutting edges of vertically adjacent said panels of a said first wall along the line thereof, and said second arm protruding from the side of said first wall_and into the end of said second wall.

8. A kit set according to any one of claims 3 to 7 wherein said plurality of connectors include a straight connector having a pair of colinear arms meeting at their end and intended for use where two walls abut in a straight line, with one arm located between the abutting edges of vertically adjacent said panels of a said first wall along the line thereof, and the other arm protruding from the end of said first wall and into the end of said second wall.

9. A kit set according to any one of claims 3 to 8 wherein the top most board in each said panel includes one or more precut recesses in its top edge, said recesses being adapted to accommodate wall connector portions of wall connectors intended to connect said panel to horizontally adjacent panels of horizontally adjacent walls in use. 264207 - 13-

10. A kit set according to any one of claims 3 to 9 wherein said kit set further includes a plurality of sockets for positioning along lines representing the base of the walls of said building when constructed and a plurality of tie rods, said tie rods securable in said sockets and said panels having holes formed from edge to edge there through, through which said tie rods are passed, in use, and each said arm of each said connector includes a hole there through intended to accommodate said tie rod and to be located in substantial registration with a said vertical hole passing through said panels.

11. A method of constructing the walls of a kit set building, said kit set building comprising a plurality of panels and a plurality of panel connection means, said panels precut so as, in combination, to form the walls of a building, wherein said method comprises the steps of: i) preparing a base for said building, ii) standing a first level of said panels in positions corresponding to the required walls of said building, iii) standing a further level of panels atop said first level of said panels, iv) at each intersection of horizontally adjacent panels, applying a said panel connection means on the top edge of said panels, said panel connection means having a portion on the top edge of one of said horizontally adjacent panels and a portion on the top edge of the other of said panels, and v) repeating steps (iii) and (iv) as desired to increase the height of said walls to a desired height.

12. A method as claimed in claim 11 wherein each said panel is made up from a number of boards, the boards of each panel connected along their edges to form said panel.

13. A method as claimed in either claim 11 or claim 12 wherein the connection between adjacent boards in said panel is further secured by gluing.

14. A method as claimed in any one of claims 11 to 13 wherein each said board has interconnection means formed on one edge thereof and complementary interconnection means formed on another edge thereof and step (iii) of said method includes the further step of interconnecting said interconnecting means of one board to said complementary -14- 264207 interconnecting means of a vertically adjacent board.

15. A method as claimed in any one of claims 11 to 14 wherein step (iv) includes at each corner intersection of two boards applying an "L" shaped connector on the top edges of said boards.

16. A method as claimed in any one of claims 11 to 15 wherein step (iv) includes at each "T" junction of two boards applying a "T" shaped connector on the top edges of said boards.

17. A method as claimed in any one of claims 11 to 16 wherein step (iv) includes at each straight line abutment of two boards applying a straight connector on the top edges of said boards.

18. A method as claimed in any one of claims 11 to 17 wherein step (iv) includes positioning said connector in recesses in the top edges of said intersecting boards.

19. A method as claimed in any one of claims 11 to 18 wherein said kit set includes a plurality of sockets and a plurality of tie rods and each said board has holes formed therein from edge to edge and step (i) of said method further includes positioning said sockets in said base along lines defining the foot of the walls of said building and said method includes the further step of passing tie rods through aligned holes in said boards m the erected walls and securing said tie rods in said sockets at their lower ends and to the top of said wall at their upper ends.

20. A method as claimed in any one of claims 11 to 19 wherein step (iv) includes that one or more straight line abutments between two boards, interposing a post between said boards, said post having a horizontal hole therethrough at the level of the top edge of said boards, and applying a straight connector to the top edges of said boards, said connector passing through said hole.

21. A kit set for the construction of walls of a building substantially as herein described with reference to and as illustrated by the accompanying drawings.

22. A method of constructing the walls of a kit set building substantially as herein described with reference to and as illustrated by the accompanying drawings.

23. A wall of a building constructed from the kit set of any one of claims 1 to 10.

24. A wall of a building constructed using the method of any one of claims 11 to 20. -15-

25. A building including a wall as claimed in claim 23.

26. A building including a wall as claimed in claim 24. «■> of claims 264207 f~"~N.Z. WliNTOFRGF~] -3 OEC 1997 figCEfVED