CA2236222C - Building element and method for manufacturing a building element - Google Patents

Abstract

The invention relates to a method of manufacturing building elements in the form of logs, preferably timber logs, provided with jointing recesses which define a joint centre pin. According to the method, the logs are cut into modules optionally in different total lengths, and each module is then centred in relation to a selectable longitudinally extending centering line. The centering line is chosen so that it will form a longitudinal centre line for the joint centre pin in the finished building element. The module is then worked on two mutually opposing sides in its longitudinal direction, such as to provide abutment surfaces. These abutment surfaces coact with corresponding abutment surfaces of nearest adjacent modules. The invention also relates to a building element manufactured in accordance with the method, and to a building constructed by joining together these building elements.

Description

Building element and method for manufacturing a building element The present invention relates to a method of manufacturing a building element, and also to a building element suitable for manufacture a.n accordance with the method. The invention also relates to a building constructed from said building elements.
The building element is preferably a log, particularly a timber log, which is provided with jointing recesses or apertures by means of which such building elements can be joined together.
In the older construction of log cabins, the logs were hammered-in manually so as to obtain tight corner joints. Because of the varying dimensions of the logs, it is necessary to adapt each log individually to match adjacent logs. This task is very time-consuming and requires a great deal of skill and cannot therefore be accomplished by the general public, but must be assigned to a few specialists in the art.
"Log cabins" are today manufactured industrially in accordance with modern methods. These prefabricated log cabins, or timber houses, are bought in the form of a finished construction set which leaves the purchaser very few possibilities of influencing the general layout of the building and its general appearance, etc.
The actual character of a log cabin or timber house, by which is meant a cabin built of logs that are "dove-tailed" at the corners, will disappear to a very large extent as a result of '30 working the logs industrially in different ways. Accordingly, the object of the present invention is to provide building elements in the form of timber logs which are suited for use in the construction of log cabins piece-wise. The logs can be joined together in different ways, so as to enable the builder to influence the general layout of the building himself/herself. The logs shall also be inexpensive and the jointing recesses prepared so as to enable the logs to be joined easily but nevertheless tightly while retaining a log cabin character. The resultant building shall also have the character of a log cabin built from round timber. Finally, it shall be possible to produce the building elements industrially in a rational fashion.
This object is achieved in accordance with the present invention by virtue of a method in which logs, preferably timber logs, are cut into modules, which may have different total lengths, and by then centering each module in relation to a longitudinal, selectable centering line chosen so that each line will form a longitudinally extending centre line of the joint centre pin in the final building element.
The object of the invention is also achieved with a building element which is particularly suitable for use in the aforesaid construction method, wherein for the purpose of forming a joint centre pin in which said pin is centred around a selected longitudinally centering line of the log, said log is provided around its periphery with four jointing recesses which are mutually offset through an angle of 90° along the periphery, wherein the log has a predetermined thickness D which a.s obtained by working two mutually opposing sides of the log in its longitu-dinal direction, thereby forming two shape-bound abutment sides for abutment with corresponding sides of the nearest adjacent logs.
Finally, the invention also pertains to a building constructed of ' said building elements.
Other characteristic features and embodiments of the invention will be evident from the depending Claims.

The invention provides several advantages in addition to achiev-ing the aforesaid obj ect . For instance, the logs may have varying wood dimensions, therewith placing less stringent demands on the choice of wood. The log jointing recesses are mutually identical on all logs, therewith enhancing flexibility. For instance, logs according to the preferred embodiment can be turned upside-down.
The inventive building elements also provide tight corner joints, although sealing strips may be placed over the joints if so desired. The invention also affords the advantage that, if so desired, both -the outside and the inside of the resultant building may be given the appearance of timber logs, so that the cabin, or house, will have all the characteristics of a "log cabin".
The invention will now be described in more detail with reference to the accompanying drawings, in which Fig_ 1 is a schematic illustration of a building element accord ing to a first embodiment of the invention, in the form of a log provided with two jointing recesses;
Fig. 2 is a schematic illustration of a second embodiment of a building element in the form of a log having three jointing recesses;
Fig. 3 is a view from above of two joint-forming logs cross-laid at an angle A;
Fig. 4 illustrates two cross-laid logs corresponding to Fig. 3 '30 but according to another embodiment in which angle A is equal to 90°;
Fig. 5 is a side view of a log according to Fig. 4 and illus-trates the joint-forming recesses more clearly;

Fig. 6 illustrates the log in Fig. 5 from above; , Fig. 7 is a sectional view of the log shown in Fig. 5 taken , through the line VII-VII; and Fig. 8 is a sectional view of another log embodiment in which the abutment surfaces have a drop nose configuration.
In practicing the inventive method, logs are cut into modules 1, IO 4, 10, 40, which may have different total lengths. Each module is then centred along a predetermined, longitudinally extending centering line a, b chosen so that said line will become the geometrical, longitudinally extending centre line of the centre pins 13, 15 of the jointing recesses 2, 3, 5, 6, 7, 12, 14 of the final building element subsequent to working the sides of the log to provide these jointing recesses. Subsequent to centering each module, two longitudinally extending sides 16, 18, 46, 48 of said module are worked to provide shape-bound abutment surfaces, e.g.
a drop-nose ? shape (Fig. 8) for instance, either by double sash sawing or in some other suitable way. The module, or log, therewith obtains a thickness D (i.e. a height in a horizontal position) between the worked sides that is predetermined by virtue of the fact that the height or thickness of the centre pin 13, 15 for the future joint is determined as D/2. The jointing recesses 20, 22, 30, 32 are then produced so as to form a centre pin 13, 15 for each joint. The jointing recesses may optionally be provided prior to working the sides of respective modules.
Fig. 1 illustrates a first embodiment of an inventive building element in the form of a timber log 1 which has been cut to ' provide a module that includes two jointing recesses 2, 3 at respective positions along the module, normally in the vicinity ' of its ends. The module is cut to a length such that the distance between the two jointing recesses has a predetermined length 1.

1 is equal to L in the illustrated case. Fig. 2 illustrates a second embodiment of an inventive building element in the form of a module 4 that has been cut so as to include three jointing recesses 5, 6, 7.

The inventive building element will be described hereinafter mainly with reference to Figs. 5, 6 and 7 which illustrate the special case from Fig. 4 in which A=90°, although the following description is also valid in respective of other values of the angle A, as shown in Fig. 3, for instance. The described building element may be any one of the modules illustrated in Fig. 1 or Fig. 2, or may be some other module.
Fig. 5 is a side view of a module 10 provided with jointing recesses 12, 14 close to respective ends of the module. The module has been double sash sawn on two mutually opposing sides so as to provide flat abutment surfaces 16, 18; see also Fig. 6.
When the log modules are j oined together horizontally, one on the other, the respective module abutment surfaces will be in mutual abutment. Because the modules are double sash sawn, each module will have a constant vertical height D. This height may be varied depending on the thickness of the modules, or logs, available, although it is the intention that a large number of modules will have mutually the same dimensions so that the purchaser is able to calculate how many modules are required to build a wall of given height,.and also to enable the walls to be constructed. The diameter D constitutes a so-called ascending height. However, the width of respective modules and therewith the sides of the modules does not change as the modules are placed one on the '30 other, and the modules thus retain their timber log appearance.
The jointing recesses are provided in the module evenly from four directions and are offset in relation to one another by 90°
around the periphery of the module. The recesses 20, 22 provided in the flat sides of the module have a depth Sd which is equal to D/4 in the double sash sawn embodiment. Seen in the cross-direction of the module, these recesses have two cut surfaces 24, 26 which extend from a flat surface 28 parallel with the sawn sides of the module. The angle E defined by the cut surfaces 24, 26 and the flat surface 28 may vary between 90 ° and 160 ° . The angle E is preferably about 135 ° . When the angle E is greater than 90°, the cut surfaces 24, 26 will slope so that the recess 20, 22 narrows towards the flat surface 28. The recesses 30, 32 which are provided in the original sides of the module, i.e. the unsawn sides, have two cut surfaces 34, 36 which extend in the transverse direction of the module. The cut surface 34 defines an angle C with the selected centering line b in the long direction of the module, while the cut surface 36 defines an angle B with the same centering line. The angle B is equal to 90°+A/2, and the angle C is equal to 180°-A/2; see also Fig. 4 and Fig. 3 in this regard. The module has a further two cut surfaces 38, 39 on respective sides thereof between the cut surfaces 34 and 36 and on both sides of an imaginary plane extending through the module centering line B parallel with the sawn sides. As evident from Fig. 7, these cut surfaces define an angle F with an imaginary plane extending through the centre line of the centre pin parallel with the flat surface 28. The cut surfaces 38, 39 slope for coaction with the cut surfaces 24 and 26, meaning that the angle F is equal to the angle E. The joint centre pin 13 is thus delimited by'two flat surfaces 28 which are horizontal when the module lies horizontally, and the cut surfaces 38, 39 on the unsawn sides of the module. The planar surfaces 28 on the respective upper side and underside of the centre pin 13 have the form of an equal sided parallelogram. In the case of the embodi- ' ment illustrated in Figs. 4, 5 and 6, the joint centre pin 13 is square whereas in the Fig. 3 embodiment, it has a rhomboidal shape. The shape of the centre pin depends on the angle A at which the modules shall cross one another. The height of the joint centre pin is D/2. As before mentioned, the modules in the embodiment illustrated in Figs. 4, 5 and 6 are intended to cross one another at an angle A=90°. B will then be 135° and C will be 135°. It is thought that this will be the angle that is most used, although other angles are feasible.
The length of the sides of the equal-sided parallelogram forming the joint centre pin 13 may vary in accordance with the original measurements of the module or log and also with regard to the angle A. According to one preferred embodiment, the sides have the length D/2. However, the height or thickness of the centre pin will be determined completely by the predetermined ascending height, i.e. the dimension D, and will always be D/2. Alterna tively, it can be said that the ascending height is determined by the chosen sides of the centre pin.
As will be evident from Fig. 6 and also from the broken line illustrations in Fig. 5, the modules may be provided with a number of holes 15 that join together the sawn sides of the module. These holes are situated in the same positions on all modules, so as to lie in register with one another when joining the modules together. These holes are able to receive module fastening devices that extend through several modules. The fastener devices used will preferably be screw fasteners.
As will also be evident from Fig. 6, the sawn sides of the module may be provided with longitudinally extending grooves 54 capable of receiving a loose tongue when joining the modules together.
Alternatively, one of the sawn sides may be provided with a ~30 groove and the other of said sides provided with a tongue so as to obtain mutually coacting tongues and grooves when joining together the modules.

In the aforedescribed preferred embodiment, the modules have two double sash sawn sides. However, the worked sides of the module may alternatively have another form such as the drop-nose form , shown in Fig. 8. In this case, the sloping abutment surfaces of the worked sides of the module have been referenced 46, 48, while details that find correspondence in the earlier described elements have been identified with the same reference signs. The above-described configuration of the centre pin and the jointing recesses can also be applied in this embodiment.
As before mentioned, the building element of the Fig. 1 embodi-ment is a timber log 1 that is cut to provide a module that has two jointing recesses 2, 3 at respective ends of the module. The log is cut so that the distance between the two jointing recesses will have a given predetermined length 1. This length 1 is conveniently a whole number multiple of a predetermined measure-ment L. In the illustrated case, 1 = L. The module illustrated in Fig. 2 is a log 4 which has been cut to a length such as to include three jointing recesses 5, 6, 7. The jointing recesses may be separated equidistantly by the distance 1, which also in this case is a whole number multiple of a predetermined measure-ment L . The log may alternatively have only two j ointing recesses which would then be separated by a distance corresponding to 2L, i.e. the jointing recess 6 would have been omitted. An inventive module building element may also include more jointing recesses than three, such as four or five recesses for instance, in which case the log or module will be correspondingly longer. This enables the length of the modules, or logs, and the number of jointing recesses to be varied constantly. The only condition is that the distance between two jointing recesses will always be a ' whole number multiple of a predetermined measurement L. The measurement L is determined from a starting point with regard to what is desired by the purchaser and also with respect to available log lengths. The result is a set of building elements based on a module conception, where the builder has a great deal of freedom in combining different modules according to her/his wishes. A suitable measurement of L is thought to be 2.5-5 meters, preferably about 1 meter.
A building is constructed from the building element, by placing the building elements cross-wise on top of each other and therewith alternating in directions at an angle A, said angle being predetermined by the configuration of the jointing recess-es, and laying said elements one on the other until a desired wall height is reached. Inner walls can be formed from building elements that have a jointing recess located between the two jointing recesses at respective ends of the building element.
This enables the builder to determine the general layout of the building himself to a large extent. The building is then complet-ed by installing an appropriate ceiling, door openings and window openings, and a floor.
The invention thus enables a log cabin to be constructed readily without requiring the skill of an expert in this field, and also enables the purchaser to decide the general layout himself.
It will be understood that the invention is not restricted to what has been described and illustrated and that modifications can be made within the scope of the following Claims.

Claims (26)

1. A method of manufacturing building elements in the form of logs provided with jointing recesses which delimit a joint centre pin, characterized by cutting the logs into modules (1, 4, 10, 40) and thereafter centering each module in relation to a selectable longitudinal centering line (a, b) which is chosen so that said line will form a longitudinally extending centre line of the joint centre pin (13, 15) in the finished building element.

2. A method according to Claim 1, characterized by working each module (1, 4, 10, 40) in its longitudinal direction on two mutually opposite sides (16, 18, 46, 48) with a starting point from the longitudinally extending centering line (a, b) so as to obtain a predetermined height or thickness D between the worked sides, this height constituting the height of respective modules when joining together horizontal modules, wherein all modules obtain mutually the same height, therewith to form two shape-bound abutment sides (16, 18, 46, 48) for abutment with corre-sponding sides of immediately adjacent modules.

3. A method according to Claim 2, characterized by forming for each joint (2, 3, 5, 6, 7, 12, 14) a centre pin (13, 15) which is centred about the centering line (a, b), wherein said centre pin is formed by forming jointing recesses (20, 22, 30, 32) that are mutually offset through 90° around the periphery of the module;
and in that the depth of cut in the two recesses (20, 22) that are formed from the worked sides of the module is determined by virtue of the height of the centre pin being predetermined to D/2.

4. A method according to Claim 3, characterized in that each of the recesses (20, 22) in the worked sides of the module is produced by providing two cut surfaces (24, 26) in the transverse direction of the module, said cut surfaces defining an angle E
With the module centering line (a, b); and in that said cut surfaces are joined by a surface (28) such as to thereby delimit the centre pin (11, 13) on two of its sides by two of said surfaces (28).

5. A method according to Claim 4, characterized by producing each of the recesses (30, 32) in the unworked sides of the module by providing two cut surfaces (34, 36) in the transverse direc-tion of the module and proving a further two cut surfaces (38, 39) in the longitudinal direction of the module between the first-mentioned cut surfaces and on both sides of the module centering line (a, b) for coaction with respective first-men-tioned cut surfaces (24, 26) in the worked sides of mutually crossing modules.

6. A method according to any one of Claims 2-5, characterized by drilling a number of holes (50) in the module from one of said worked sides, said holes being intended to receive fastener devices.

7. A method according to any one of Claims 2-6, characterized by providing a longitudinally extending groove-like recess (54) in at least one of the worked sides, said groove being capable of receiving a tongue-like member such as to obtain a tongue-and-groove arrangement.

8. A method according to Claim 7, characterized by providing the groove-like recess (54) in only one of the worked sides, and proving a tongue on the opposite side when working said side.

9. A method according to any one of Claims 2-8, characterized by providing a longitudinally extending groove in the worked sides of the module and applying heat insulating material in said grooves.

10. A method according to any one of Claims 2-9, characterized by edge-cutting the modules in their longitudinal directions on two mutually opposite sides, so as to obtain two flat abutment surfaces (16, 18); and by cutting the two recesses (20, 22) provided on the flat edge-cut sides to a depth of D/4.

11. A method according to any one of Claims 1-10, characterized in that the modules (1, 4, 10, 40) may include different numbers of jointing recesses (2, 3, 4, 5, 6; 12, 14), wherein the smallest module is provided with at least two jointing recesses, wherein the smallest distance between two jointing recesses is determined by a preset measurement L and wherein the length of other modules can he varied so that the distance between two jointing recesses is always a whole number multiple of L, so as to enable said modules to be selectively joined together.

12. A building element in the form of a log which is provided with at least two jointing recesses and has a predetermined thickness D obtained by working two mutually opposing sides (16, 18, 46, 48) of the log in its longitudinal direction, thereby to obtain two shape-bound abutment surfaces for abutment with corresponding sides of immediately adjacent logs, characterized in that the log has around its periphery four recesses (20, 22, 30, 32) which are offset in relation to one another through 90°, such as to form a joint centre pin (11, 13), said centre pin being centred around a selected longitudinally extending log centering line (a, b); in that the joint (12, 14) is formed by cross-laying logs provided with said recesses, wherein the logs define an angle A with one another when cross-laid; in that recesses (30, 32) in the unworked sides have two cut surfaces (34, 36) in the transverse direction of the log, of which cut surfaces one surface (36) defines a cut angle B with the log centering line, wherein B=90°+A/2, and the other cut surface (34) defines an angle C with the log centering line, wherein C=180°-A/2.

13. A building element according to Claim 12, characterized in that the vertical thickness of the centre pin (11, 13) between the two worked sides is D/2.

14. A building element according to any one of Claims 12-13, characterized is that the recesses (20, 22) in the worked sides of the log include cut surfaces (24, 26) that define an angle E
with the log centering line (a, b); in that the log includes two further cut surfaces (38, 39) in the longitudinal direction of the log between the first-mentioned cut surfaces (34, 36) of the recess (30, 32) in the unworked sides of the log and on respec-tive sides of a central plane which passes through the log centering line and is parallel with the horizontal plane when the log lies in its use position, wherein said two further cut surfaces (38, 39) define the angle E with said central plane and coact with the first-mentioned cut surfaces (24, 26) of the recesses in the worked sides of a cross-laid log.

15. A building element according to any one of Claims 12-14, characterized in that A=90°.

16. A building element according to any one of Claims 14-15, characterized in that 90°<E<160°.

17. A building element according to any one of Claims 12-16, characterized in that the two mutually opposing, shape-bound abutment sides (16, 18) of the log are comprised of planar surfaces; and in that the depth of the recesses (20, 22) in said sides is D/4.

18. A building element according to any one of Claims 12-16, characterized in that the two mutually opposing shape-bound abutment sides (46, 48) of the log (40) have a drop-nose configu-ration.

19. A building element according to any one of Claims 12-18, characterized in that the log includes holes (50) drilled from one of said worked sides, said holes being intended to receive fastener devices.

20. A building element according to any one of Claims 12-19, characterized in that the log has a groove-like recess (54) in the longitudinal direction of the log in at least one of said worked sides, said groove being able to receive a tongue-like member so as to obtain a tongue-and-groove arrangement.

21. A building element according to Claim 20, characterized in that only one of the worked sides has a groove-like recess (54), and in that the opposite side has a tongue-like member.

22. A building element according to any one of Claims 12-21, characterized in that the worked sides of the log have at least one longitudinally extending groove which is intended to receive heat-insulating material.

23. A building element according to any one of Claims 12-22, characterized in that the centre pin has two mutually opposing planar surfaces (28) which lie in the horizontal plane when the log lies in its use position, wherein the sides of said surfaces form an equal-sided parallelogram and coact with corresponding surfaces on the centre pins (11, 13) of mutually crossing logs.

24. A building element according to Claim 23, characterized in that all the sides of the centre pin parallelogram are equal to D/2.

25. A building element according to any one of Claims 12-24, characterized in that the total length of the building element (1, 2) and the number of jointing recesses (2, 3, 4, 5, 6) can be varied, wherein the jointing recesses are provided so that the distance between two joints will always be a whole number multiple of a preset measurement L.

26. A building constructed by joining together building elements according to any one of Claims 12-25, characterized in that the building elements are placed one on top of the other to a desired wall height, wherein the building elements are joined together cross-wise with the aid of jointing recesses in which joints are established, and thereafter installing a ceiling.