NZ525082A - Building member and building system - Google Patents

Abstract

A building member is described to comprise of a joining edge portion such that when a first building member is joined to another building member, a space therebetween is shaped and adaptively formed to at least allow for the passage and/or location of services. The joining edge portion includes a tongue member having a recess therein, the recess being at least adapted to provide a surface for services to pass thereover or be located thereon. Also disclosed is a wall constructed with a plurality of interfitted building members that interfit to provide a space therebetween for location and or passage of services. A method of wall construction, involving building members, battens and cladding comprises the following steps: cutting one plank in two to form one board having a tongue and the other having a groove; placing the tongue on a base support; placing tongue and groove planks on the tongue board to form the wall; and placing the groove board a the penultimate top of the wall.

Description

Patents Form # 5 INTELLECTUAL PROPERTY OFFICE OF N.Z - 1 apr 200*1 received NEW ZEALAND Patents Act 1953 COMPLETE SPECIFICATION AFTER PROVISIONAL # : 525082 DATED : 1 April 2003 TITLE : BUILDING MEMBER AND BUILDING SYSTEM We, FRONTIER SOLID WOOD HOMES LIMITED Address: 8 Whakatau Street, Rotorua, New Zealand Nationality: A New Zealand company 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: PF05.JWP FEE CODE 1050 This invention relates to a jointing system, building member and construction method. The invention is directed particularly, but not solely, toward a building member and construction method for house construction.

BACKGROUND OF THE INVENTION Traditional cavity walls having timber framing with cladding, is the most popular form of building construction. Framing normally consists of 4 x 2 timber nailed together with or without cladding. Fixing of the framing and cladding and intersecting wall sections is either manually or mechanically carried out with nailing and or bolting. Alternatively, walls can be fabricated from spaced solid wooden panels using locking keys between the panels.

Long holes or channels for services are then drilled from top to bottom or from side to side in both the solid wall panels and the cavity framing method. At the base of existing walls there is a need to secure the wall to the floor or base. This is achieved by using brackets or cleats which then need to be covered or concealed by a skirting board which increases building costs.

Drilling the long holes for services is a tedious and long-winded job. Also it is difficult to keep the hole straight and not damage the wall surfacing. The drilling also produces dust and rubbish and slows down production and other building installation work.

Existing solid wall panels also comprise components such as panels and keys which require assembly to put together to make up a finished wall section. Extra componentry and 20 permanent fixings, combine to increase material costs and lengthen construction times which affect the final building cost.

The use of non-readily detachable fixing such as nailing also makes the current form of building construction difficult to modify and alter. Walls cannot be simply removed, replaced, or adjusted. Also the use of nail fastening produces a structural joint dependent on 25 friction within the framing members such that reliability and performance is difficult to predict over time.

It is the object of the present invention to provide an improved building member and construction method which will obviate or minimize the aforementioned problems in a ] 10128NZ_completespec.08jul2005.doc intellectual property office i of n.z. 1 - 8 jul 2005 .received simple yet effective manner and or which will at least provide the public with a useful choice.

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

STATEMENT OF INVENTION Accordingly in a first aspect the invention consists of a building member, the building member comprising a joining edge portion such that when a first building member is joined to another building member, a space therebetween is formed to at least allow for the passage and/or location of services wherein the joining edge portion includes a tongue member, the 10 tongue member being at least adapted to provide a surface for services to pass therethrough or be located thereon.

Preferably the building member is a plank having longitudinal and transverse edges.

Preferably the joining edge is located on at least two longitudinal edges of the plank to thereby form in use an upper joining edge and a lower joining edge.

Preferably the upper joining edge includes a tongue portion and the lower joining edge comprises a groove portion such that the tongue can at least interfit within the groove.

Alternatively the upper joining edge and lower joining edge comprise a grooved portion.

Preferably the tongue portion is formed by a separate member having joining edges being inserted within the grooved portion.

Preferably the separate member is elongate and is sized and shaped to be insertable within the groove leaving a portion protruding from the groove forming a tongue portion.

Preferably the separate member is a hollow member.

Alternatively the separate member is a solid member.

Preferably the separate member is shaped to enable a friction fit with the groove. 25 Preferably the separate member has a recess on at least one joining edge. 110128NZ_completespec.08jul2005.doc intellectual property office of n.z. 1 2 jul 2005 i f RECEIVPr 7 Preferably the tongue is less in volume than the groove, to produce the space therebetween. Preferably the tongue is formed with a recess thereon.

Preferably the space is elongate in shape.

Preferably the plank is a substantially solid wooden member.

Alternatively the plank is a plastics member or blend/combination of materials.

Preferably at least one of the plank longitudinal edges is rounded.

Accordingly in a second aspect the invention consists in a wall constructed with a plurality of interfitting building members or planks as previously disclosed wherein the interfitting planks provide a space therebetween for location and or passage of services or fluid, etc.

Preferably the planks can be in several forms wherein one form is a plank having tongue and groove joining edges, the second and third forms are formed from longitudinally cutting another first form plank in two such that one plank (the second form) has the tongue portion thereon and the other plank (the third form) portion has the groove portion thereon.

Preferably there is a fourth form of plank which is formed by a grooved plank having a 15 tongue formed by a separate member.

Preferably second and third planks form the bottom and top plank members in a wall respectively.

Preferable at least one of the planks longitudinal edges is rounded.

Preferably battens can be affixed to at least one side of the wall with fixing means and the 20 battens can extend from the base of the wall to the top of the wall.

Preferably the fixing means can be impact fasteners, friction fasteners or tension fasteners.

Preferably cladding can be attached to the battens to form a cavity for insulation, and to allow for condensation and weather tightness and/or other services. 110I28NZ_completespec.08jul2005.doc iWtllECTiiML PRCPdflY OFFICE fF Nl - 8 JUL 2005 received Accordingly in a third aspect the invention consists in a method of wall construction, being provided with building members or planks as described wherein the method comprises carrying out the following steps: - forming at least two portions from one plank, to form one board having a tongue and the 5 other board having a groove these being a tongue board and a grooved board; - placing the tongue board on a base support; placing tongue and groove planks in turn on each other, on the tongue board to form the wall; placing the groove board at the penultimate top of the wall.

The method as disclosed wherein after placing the groove board in place, affixing a continuous top plate member.

The method as disclosed wherein after the top plate vertical battens extending from the base support to the top plate are affixed to one side of the planks.

The method as disclosed wherein the cladding is affixed to the battens.

The method as disclosed wherein the tongued plank is affixed to the base support by fixing means.

Accordingly in a fourth aspect the invention consists in a method of wall construction, being provided with building members as described wherein the method comprises carrying out the following steps: Forming base board from grooved plank and placing whereby a groove is facing upwards; Inserting tongue member followed by plank until the desired wall height is achieved.

Affixing battens to at least one surface of the wall during the assembly.

Placing final plank having groove on one edge only, on last tongue. "intfl l-ectual propcfify oft-'iU: OF M.Z 110128NZ completespec.08jul2005.doc | . - 8 jul 2035 RECEIVED DRAWING DESCRIPTION Preferred forms of the invention and modifications thereof will now be described with reference to the accompanying drawings in which: Figure 1 shows a cross sectional view of the building member of the invention.

Figure 2 is a cross sectional view of a bottom part of a wall construction.

Figure 3 is a cross sectional view of a top part of a wall construction.

Figure 4 is side view of a typical wall construction with labelled suggested plank lengths and depths shown Figure 5 is a typical building member material schedule.

Figure 6 is a perspective exploded view of a wall to wall joint.

Figure 7 is a cross section of another building member.

Figure 8 is a cross section of another form of the tongue for the building member of figure 7.

Figure 9 is a perspective view of building member of figure 7 with the tongue of figure 8.

DESCRIPTION OF THE PREFERRED EMBODIMENTS As shown in figure 1 there is a cross-section of a typical building member having a jointing system. The building member in this example can be a solid plank member. For example, the solid plank member can be substantially wooden. Other materials and blends such as 20 metal or plastics are equally possible. The plank 1 in use will have a top portion 2 and a bottom portion 3 and sides 4 and 5. The plank member is preferably substantially a rectangular shape whereby in use, the top portion 2 and bottom portion 3 at least provide joining surfaces. The top portion has a tongue member 6 with shoulder portions 7 and 8 on either side thereof. The lower portion 3 includes a groove 9 with raised shoulder portions 10 25 and 11 thereabout. The top portion 2 and bottom portion 3 define the in use longitudinal edges and ends 14. The rounded shoulders or edges 7, 8 and 10, 11 assist in handling, 110128NZ_completespec.08jul2005.doc —— UlTT'll lijiniMJligl intellectual pruph-isv gf nc* of fiz. - 8 jul 2005 received provide safer more robust durable edge and also improve the design looks of the wall when viewed at a distance.

As shown in figure 1 the tongue member 6 is sized to be less than the groove to form a space therebetween to provide either for services to be able to be located therein or to be able to 5 pass through. The space can be any shape as long as services can accommodated. The space can be formed by the tongue having depth less than the groove. Additionally the tongue has a recess portion 12. Groove 9 is rounded and shaped and sized, such that when one plank is interfitted with another plank, the groove of one plank interfits within the tongue of the other plank, to provide at least one space 13 therebetween (see figure 2 and 3) defined and limited 10 by the recess 12 of tongue 6 and the grooved area of groove 9 of another plank. The space being elongate in shape and extending the length each plank or a specified distance as required. Access to the space 13 can be simply at the ends of each plank or by way of an aperture through the face of the plank.

This space 13 is a defined space is constructed and adapted to provide a suitable conduit for 15 services to be located therethrough. The services can be for example electrical and or plumbing or fluids such as air. Therefore in a wall constructed of several interlocking planks, there will be a plurality of spaces for services anywhere up the wall. Alternatively the space can be sized to be used with anything that is intended to be carried therethrough. The plank is sized from a standardly available rough sawn size to reduce wastage during 20 dressing.

As shown in figures 2 and 3 there are details showing the bottom part of the wall and the top part of a wall respectively. Figure 2 shows the lower portion of the wall having planks 20, 21 and 23. Figure 3 shows the top part having planks 30 and 31. To form the bottom and top planks 23 & 31 of the wall, one can at least cut or have pre-prepared, a standard plank 25 (e.g. plank 1 or 20 or30) whereby two smaller planks are created out of this one standard plank. This is termed as 'ripping' a standard plank. The standard plank is as shown in figure 1 and has a tongue 6 and a groove 9. If such a plank is cut or 'ripped' anywhere between the top surface 2 and the bottom surface 3, two smaller planks or panels are produced. In use, one panel has a tongue member on the top surface and a flat surface on the bottom while the 30 other panel has a groove only on the bottom surface and a flat surface on the top surface. These planks can be termed 'a tongued plank' 23 and 'a grooved plank' 31. 110128NZ_compIetespec.08jul2005.doc intellectual pfigplffly officii of n.z - 8 JUL 2005 There are at least two main types of walls. The first is the internal wall comprising the planks with decorative and or fire rated wall board on at least one face. External walls can also have battens eg 75mm x 50mm on the outer face. These extend in length from the top plate to the bottom plate and are positively fixed to the planks and can be spaced along the 5 wall. In cases of wind, earthquake loading or where extra strength is required, one can place a bracing layer between the battens and any outer cladding. The bracing can be for example, plywood which then means that the battens will be thinner keeping the cladding at a constant spacing from the planks. A cavity is formed between the cladding and planks which can also be used for services, insulation and weather tightness etc. Optionally the battens can be used 10 on the internal walls if necessary.

On the bottom of the wall and more likely at the beginning of the method of constructing each wall section, the tongued plank 23 which can be shorter in width/depth than the grooved plank 31 is initially placed on a predetermined position on the floor, according to the construction layout plans. Normally tongued plank 23 is located on the finished floor 24 to 15 enable the rest of the standard planks 20 and 21 to be slotted on top and into place. Figure 3 being the top part of the wall detail, shows the grooved plank 31 being placed at the top of the very last standard plank member 30 to provide a flat top surface for the location of the top plate and or rafters etc.

Figure 4 shows a typical wall having all the planks labelled according to their length. 20 Therefore a schedule for all the boards or planks required can be tabulated in a list as in figure 5 so that each plank can be automatically and conveniently ordered to size. There is a typical wall unit 40 shown with the rows of planks labelled both in their position from the bottom and their characteristic in terms of board length. In this method of construction each plank/board as drawn has a board number which is characteristic of a board length. Then the 25 quantity of these particular board lengths are listed so that all the boards can be simply ordered and cut. There is very little wastage and construction is simpler which saves both time and money to the potential homeowner.

As shown in figure 6 there is a drawing showing the location of a fastening means 50, which enable one plank to be joined to another plank. A series of planks together can form a wall 30 section. The fastening means can be screws 50 which can be self-drilling or not such that each wall can have at least one screw 50 that fix one wall to an opposing wall. The fastening 110128NZ_completespec.08jul2005.doc fn tlllec t i-jtt^ffujf^^iyylj ff! c c of n.z. - 8 JUL 2005 received means can also be nails or bolts in combination with adhesive, in any selected spacing. These can be countersunk if desired.

Accordingly the method of construction is very simple. The following steps or at least some of the following steps can be used to construct a building.

Step 1 Decide on a layout as selected by the purchaser.

Step 2 Prepare plans with the appropriate schedule of quantities. See figure 5.

Step 3 Materials are ordered from a fabricator or sawmill.

Step 4 Precut materials are delivered to site.

Step 5 The floor is constructed.

Step 6 The one plank member or as many as are required are ripped to provided a grooved plank and a tongued plank. The smaller plank, which will be the tongued plank, is laid out on the floor according to the overall layout of the building with each of the internal and external walls laid out in position.

Step 7 The tongued member is affixed to the floor plate or floor.

Step 8 The plank members for all the walls are then placed on top of the tongued member 23.

Step 9 Each wall is formed either at the same time or at the same point whereby the grooved member 31 is placed on top.

Step 10 The continuous top plate member is then screwed or nailed right around the building 20 to finish off all the walls both externally and internal.

Step 11 The rafters and roof members are placed on.

Other variations of this method are possible for example the cladding can be placed on the external walls as soon as the external walls are in position which may be before the internal walls are placed. However in terms of bracing and strength during construction and during 25 its lifetime the internal walls may also be placed at certain points. Screw fixings 50 can be 110128NZ_completespec.08jul2005.doc inhllectu/l of nz * 8 JUL 2005 I received placed as the walls and or planks, are being constructed upwards thus providing a strong building construction retaining 'framing action' throughout the erection process.

Generally the external walls can be affixed to the intersecting internal walls before the cladding is attached. For external walls, battens eg 75x50 can be affixed to at least one face 5 of the plan wall. These battens extend from the top plate to the bottom plate and can extend further to overlap the concrete foundation to keep the cladding spaced therefrom or the battens may extend just to the bottom edge of the bottom plate on a timber floor on pile foundation.

For internal walls/ceilings battens can be used if required. However decorative and or fire 10 rated wall boards can be affixed when or where required.

In another variation, the plank can be formed from a grooved plank as shown in figure 7. Here there are grooves 51 & 52 formed therein. The tongue can be formed from a separate member 53 which can be hollow or solid as shown in figure 9. Separate member 53 has an interior 54, an exterior surface 55 and recesses 56. In use as shown in figure 8, the separate 15 member is inserted into groove 52 to a certain depth which can be limited by any suitable stopping means, eg. a ledge or by friction or by adhesive or by removable spacers. Figure 9 shows the separate member in place on a typical grooved plank 50. For a wall, the first member can be a plank 50 cut in half with one groove facing upwards. One separate member is then inserted into that groove followed by a grooved plank followed by another 20 separate member and so on and so on. At the top the last plank can be formed as shown in figure 3.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and application of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The 25 disclosures and the descriptions herein are purely illustrative and are not intended to be limiting.

Throughout the description and claims of this specification the word "comprise" and variations of that word, such as "comprises" and "comprising", are not intended to exclude other additives, components, integers or steps. 110128NZ_cornpietespec.08jul2005.doc - 8 jul 2305 received The building member and construction method has the following advantages: 1. Simple installation method. 2. Modest production costs. 3. Little waste material. 4. Easy to alter, construct, adjust and move walls.

. Minimised building costs. 6. No need of skirting boards. 110128NZ_completespec.08jul2005.doc INTELLECTUAL PRQPi^fyoFF OF N.Z - 8 JUL 2005 received

Claims (33)

WHAT WE CLAIM IS:

1. A building member, the member comprising a joining edge portion such that when a first building member is joined to another building member, a space therebetween is shaped and adaptively formed to at least allow for the passage and/or location of 5 services, wherein the joining edge portion includes a tongue member having a recess therein, the recess being at least adapted to provide a surface for services to pass thereover or be located thereon.

2. A building member as claimed in claim 1 wherein the building member is a plank wherein the plank has longitudinal and transverse edges. 10

3. A building member as claimed in claim 2 wherein the joining edge portion is located on at least the two longitudinal edges of the plank to thereby form in use an upper joining edge and a lower joining edge.

4. A building member as claimed in claim 3 wherein the upper joining edge portion includes the tongue portion and the lower joining edge comprises a groove portion such 15 that the tongue of one building member can at least interfit within the groove of another building member.

5. A building member as claimed in claim 4 wherein the upper joining edge and lower joining edge comprise a grooved portion.

6. A building member as claimed in claim 5 wherein the tongue portion is formed by a 20 separate member having joining edges being inserted within the grooved portion.

7. A building member as claimed in claim 6 wherein the separate member is elongate and is sized and shaped to be insertable within the groove leaving a portion protruding from the groove forming the tongue portion.

8. A building member as claimed in claim 7 wherein the separate member is a hollow 25 member.

9. A building member as claimed in claim 8 wherein the separate member is a solid member. 110l28NZ_completespec.08jul2005.doc imlllectual PRGPjiTY OF-FiC; of n.z. - 8 JUL 2305 RECEIVED - 13-

10. A building member as claimed in claim 9 wherein the separate member is shaped to enable a friction fit with the groove leaving a portion protruding to form the tongue.

11. A building member as claimed in claim 10 wherein the separate member has the recess on at least one joining edge. 5

12. A building member as claimed in claim 11 wherein the tongue is less in volume than the groove, to produce the space therebetween.

13. A building member as claimed in claim 12 wherein the space is elongate in shape.

14. A building member as claimed in claim 13 wherein the plank is a substantially solid wooden member. 10

15. A building member as claimed in claim 14 wherein the plank is a plastics member or blend/combination of materials.

16. A building member as claimed in claim 15 wherein at least one of the plank longitudinal edges are rounded.

17. A wall constructed with a plurality of interfitted building members as claimed in any one 15 of claims 1-16 that interfit to provide a space therebetween for location and or passage of services.

18. A wall as claimed in claim 17 wherein the planks can be in several forms wherein one form is a plank having tongue and groove joining edges, the second and third forms are formed from longitudinally cutting another first form plank in two such that one plank 20 (the second form) has the tongue portion thereon and the other plank (the third form) portion has the groove portion thereon.

19. A wall as claimed in claim 18 wherein there is another form of plank which is formed by a grooved plank having a tongue formed by a separate member.

20. A wall as claimed in claim 19 wherein the second and third planks form the bottom and 25 top plank members in a wall respectively. jjffrl l ectuat fropa-tfy 0ffic2 of n.z. 110128NZcompletespec.08juI2005.doc | _ - 8 jul 2005 received - 14-

21. A wall as claimed in claim 20 wherein at least one of the plank longitudinal edges are rounded.

22. A wall as claimed in claim 21 wherein battens can be affixed to at least one side of the wall and can extend from the base of the wall to the top of the wall. 5

23. A wall as claimed in claim 22 wherein the cladding is attached to the battens to form a cavity for insulation, and to allow for condensation and weather tightness and/or other services.

24. A method of wall construction, being provided with building members, as claimed in any one of claims 1-16, battens and cladding wherein the method comprises carrying out 10 the following steps: cutting one plank in two to form one board having a tongue and the other board having a groove; placing the tongue board on a base support; placing tongue and groove planks on the tongue board to form the wall; 15 placing the groove board at the penultimate top of the wall.

25. The method as claimed in claim 24 wherein after placing the groove board in place, affixing a continuous top plate member.

26. The method as claimed in claim 25 wherein after the top plate vertical battens extending from the base support to the top plate are affixed to one side of the planks. 20

27. The method as claimed in claim 26 wherein the cladding is affixed to the battens.

28. The method as claimed in claim 27 wherein the tongued plank is affixed to the base support by fixing means. 110128NZ_completespec.08jul2005.doc - 15 -

29. A method of wall construction, being provided with building members as claimed in any one of claims 1-16 wherein the method comprises carrying out the following steps: forming base board from grooved plank and placing whereby a groove is facing upwards; 5 inserting tongue member followed by plank until the desired wall height is achieved; affixing battens to at least one surface of the wall during the assembly; placing final plank having groove on one edge only, on last tongue.

30. A building member herein described with reference to the accompanying drawings.

31. A wall herein described with reference to the accompanying drawings. 10

32. A method of wall construction as claimed in claim 24 as herein described with reference to the accompanying drawings.

33. A method of wall construction as claimed in claim 29 as herein described with reference to the accompanying drawings. 15 PIPERS Attorneys for FRONTIER SOLID WOOD HOMES LIMITED 110128NZ_completespec.08jul2005.doc itfftllectual profew ufr of HI. - 8 jul 2035