Field of the Invention
DETAILS ON MY NEW HOUSE KIT COMPONENTS AND THE HISTORY OF THEIR DEVELOPMENT
[0001] Presently, we have a situation where there is actual deflation in the cost of most
commodities, but the price of wood fiber for lumber and paper products is increasing
substantially and there appears to be no end to this price escalation. Environmentalists
and governments are making less timber available to harvest and what is left is being
consumed faster than it replenishes itself.
[0002] However, there is a segment of our forest timber that is being trashed and wasted
during the harvesting of sawlogs to make lumber. Included in this waste are small
trees and tree tops of the species harvested and also, so-called "junk" trees that
don't grow to sawlog sizes, or don't grow in sufficient quantities to be economically
harvested, such as alder, aspen, willow, cherry, and in the tropics, bamboo. Small
logs are defined as logs that come from tree stems 8 meters long with 150 mm butts
and 75 mm tops.
[0003] Governmental forest departments such as in British Columbia encourage the harvesting
of small trees and junk trees. Stumpage charges on sawlog harvesting runs from $30
to $80 per M
3. The charges for small trees and junk trees are as low as .25 cents M
3 and such wood fiber is not charged against quotas that limit harvesting. Until recently,
small trees have been more costly to log and small logs have been more expensive to
manufacture into lumber than regular saw logs and thus the apathy about harvesting
small trees. New tree shear equipment has reduced harvesting costs of small logs and
new saw milling machinery have reduced the house manufacturing costs to costs lower
than lumber production from saw logs.
[0004] There is an area of tens of thousands of square kilometers stretching from Idaho,
through British Columbia and into the Yukon that contains many millions of small Lodgepole
Pine trees. This tree is not self thinning, and they grow so close together that 80
year-old trees reach 45M high and only have 150 mm butts. A high percentage are over
mature and dying. Right now they only make pulpwood, firewood and fence posts, but
if handled differently would make excellent material for homes.
[0005] Perhaps most important of all is that various university and governmental forest
departments have developed very fast-growing hybrid trees that grow a now useable
small tree in three to five years that produce wood fiber at less than a third of
the cost of harvesting regular sawlogs. Now a home manufacturer can grow his own small
trees nearby his factory, supply all his lumber needs, control his costs and be independent
of the volatile timber market and have a substantial cut in in-freight costs. Imagine
Chicago, London or Calcutta growing their own houses in nearby tree farms.
[0006] We have all the wood we need in the form of small trees and we have the equipment
to economically use the wood to make houses. But who has ever heard of a house made
entirely from the wood of small trees? My invention teaches how to manufacture houses
using only wood from small tree stems. No lumber as we know it is produced, no floor
joists, no studs, no rafters, no decking, no plywood and no shingles. My houses are
built out of new timber shapes that are sawn directly from the small tree logs in
a one-pass operation. The shapes in cross section are Tees (T), Ells (L), Crosses
(+), Ees (E), Dees (D), Ayches (H) and Double Ayches (HH). Costs are further lowered
by using almost 100% of the small logs to make these special shapes. More than twice
as much of the wood in a log is utilized as compared to the wood recovered from the
same sized logs when standard lumber sizes are manufactured. The cost of a house is
further reduced by the use of new components that serve two or three purposes. A cross-shaped
roof plank that serves as a rafter, roof sheathing and weatherproof shingles. An inverted
tee shape that serves as a ceiling liner and a ceiling joist. An ell shaped molding
that serves as a door or window jamb and also as casing or trim. As done in Scandinavia,
wood from small trees is used to make doors and windows reducing wood cost by 90%.
My invention covers a new jointing system in assembly where special shaped house parts
can be joined together so that most nailing is eliminated, and where nails are used,
they are not visible.
[0007] This invention covers a new method and plant to manufacture houses that can initiate
a whole new industry. Ordinary saw mills cannot handle small logs in an efficient
manner. A new type of mill with special equipment is necessary to produce my special
house components. We have chosen to call it a "House Factory" because its end product
is a complete house package. A house factory like a high production saw mill will
cost from four to six million U.S. dollars. Also, an investment of about a million
dollars will be needed for the latest state-of-the-art log harvesting equipment to
keep the house factory going. Automated manufacture of house sections will be part
of the house factory set up. This machinery substantially lowers field labor costs
in the actual construction of the homes.
[0008] For over forty-five years, I have been trying to produce wood planks that are waterproof
and remain waterproof, thus eliminating the need for shingles, tile or any other roofing
and the labor for the application of roofing materials.
[0009] Back in 1951 a cedar 38mm x 150mm plank with tight or integral knots appeared to
me to be quite impervious to water. All that seemed necessary were waterproof joints
between the planks if they were laid vertically to the slope of the roof, not horizontally.
Experiments taught me that tight tongue-and-groove joints were waterproof for roof
slopes 5 in 12, or steeper. For flatter roofs, I found it was necessary to use a joint
sealant, because even thoroughly kiln-dried planks swell in humid conditions and shrink
in very dry weather. I had a lot of trouble here, because some sealants dried out
in hot, dry weather and became ineffective, and even everelastic sealants like silicone
got squeezed out altogether when the wood expanded in wet weather. I learned to leave
space at the end of the tongue in the groove to hold enough sealant to block the joint
from water entry when the wood planks shrank apart from long periods of dry weather.
Once I had a truly waterproof joint system, I built a series of small sheds using
38mm x 150mm cedar planks laid vertically for roof covering, and no shingles. One
roof was 2 to 12 in slope, one was 4 to 12 and a third was 6 to 12 in slope. The sheds
had weatherproof walls and flooring. The floors were covered with a sensitive paper
that changed color permanently from the tiniest drop of water. A full year of all
kinds of weather, rain, snow and ice produced not a single drop of leaked water. I
decided to demonstrate our waterproof roof plank system to the world and entered the
Canadian National Exhibition in Toronto, Canada (which had three million in attendance)
in the late summer of 1954. I built a small summer home and all there was between
the inside and the sky were 38mm thick planks, no shingles. Heavy rains during construction
and on the first day of the show produced no leaks. Then, we had 10 days of hot, sunny
weather followed with a drenching thunder shower. The roof leaked in several places.
Embarrassed, I snuck in overnight and installed shingles. What happened? The wood
knots shrank more than the wood around them and either split, star checked or crescents
opened up around the knots and the water streamed through for up to a half hour, when
the wood expansion from the moisture closed up the checks and crescents. Unfortunately,
our test sheds were built on the north side of our plant, always out of the sun, and
were kept moist, even in dry weather, from morning dews dripping from the plant roof
and were thoroughly soaked even from small showers from water off the roof.
[0010] I went on to work on roof planks made from clear lumber, free of knots. This proved
to be only marginally successful, because very often the cost of clear wood was so
much more than common lumber with knots that it was cheaper to use shingles with common
lumber. Also, flat grained clear lumber checked and split due to tangential shrinkage,
so more expensive edge grain clear lumber had to be used.
[0011] Then, in 1968, I came up with a species of pine whose knots did not shrink faster
than the wood around them. However, sometimes the wood around the knots shrank so
much that it split right through at the knots producing leaks just as the knots did
in the show house fiasco.
[0012] Then, in the spring of 1994 I happened to notice an outside deck on one of our homes
which was being partly used as dry storage for firewood. The decking planks were covered
with checks and split knots. I asked the owner if the deck really kept the firewood
dry. He said that it was very dry on one side, but leaked too much on the other side
where he had no firewood stored. Puzzled, I examined the deck carefully. I discovered
that the ends of each of the planks on the dry side showed the heart of the log it
was sawn from. There were checks through the knots on the wet side, and some of the
wet side planks had splits in the clear wood right through them. Here I had a solution
to my waterproof, common grade, plank problem. Branches start as tiny specks at the
heart of a tree and show up as knots on the face of lumber sawn from the tree's logs.
If the knots check or split, the split cannot go through the plank if the plank encases
the heart of the tree the plank was sawn from. The shrinkage of wood around the face
of a log is called tangential shrinkage. The shrinkage between the heart of a log
and its surface is called radial shrinkage. It is an axiom that tangential shrinkage
is three times as great as radial shrinkage. Also, the exposed outside of a log will
dry faster. Such checks and splits point to the heart, but do not reach it. Even when
the round log is sawn into square planks, tangential shrinkage is still greater than
radical shrinkage. Faster tangential drying causes the checks and splits. The circumference
becomes less from shrinkage, but the inside does not shrink correspondingly, so the
outside lumber is forced to split or check as its circumference becomes smaller, and
the check lines radiate down toward the wetter center, but stop when they reach the
wetter corewood. My observations during very considerable research was whereas planks
that do not encase the heart of the tree they are sawn from can, and often do split
right through, no small planks with their tree hearts encased split right through.
So small planks that contain hearts do not split through and are waterproof, even
if their surfaces contain many knots and checks. I had waterproof, common planks at
last, as long as they have encased hearts and are small. We can use low-cost common
lumber to keep rain out of houses and even water out of the hulls of house boats and
barges which otherwise now use expensive clear edgegrain lumber. Edgegrain lumber
has radial shrinkage across the planks and tangential shrinkage across the thickness
of the planks and there is no checking because the different shrinkages are not in
conflict. A flat grain plank has both radial and tangential shrinkage across the plank
and can spilt where the two types of shrinkage are in conflict. Planks that encase
the heart of logs have edgegrain wood on either side of the heart so the wood is free
of checks and splits.
[0013] Over the past three years, I have run experiments with small sheds again, but this
time the sheds are out in full sunshine. After prolonged periods of hot, dry weather,
the roof planks (especially the pine samples) were covered with small shallow checks
and every knot was star checked or split and some had shallow open crescents on a
side of them. No leaks have developed. The pine is now black and the cedar is silver
gray. Paint improves the appearance and stops most of the checking. A sample garage
roof nearby is painted a light green and clearly shows that there are no shingles.
(The garage roof hasn't leaked in 3 years.) Besides opening up a new vista in the
exterior decoration, painting a roof gives it extra insulation against heat absorption.
A white painted roof reflects 35 times as much heat as a black asphalt shingle roof,
and 25 times as much heat as a white shingle sloped roof or a silver flat roof. These
statistics are from a well-known journal on cooling.
[0014] In any run of sawn lumber there will be a certain percentage of common lumber with
the tree hearts encased. But naturally, if the logs are small there will be a much
higher percentage, so lumber with encased hearts would not call for a price premium.
On the other hand, lumber sawn to the specification "free-of-heart-center" costs extra.
However, if the logs are very small, with tops 100mm or less, 100% of the planks produced
will include hearts. The cost of small logs is substantially less than for larger
logs.
[0015] Experimenting has improved the quality and usefulness of say, 38mm x 80mm T&G roof
planks out of 87mm logs, producing both the planks (with enclosed hearts), and the
pulp chips by making cross shaped roof components out of the same logs. The horizontal
segment was made into a T&G roof plank and the vertical part of the cross became and
effective roof rafter, greatly increasing the span capability of the roof plank alone.
Also, cutting the four right angle notches at 90º around the log stopped the tangential
shrinkage that produce checks. The 90º angles became larger and the vertical and horizontal
planks acquired thinner ends as the crosses dried out.
[0016] I went further, I made the right angle notches sharper angled at 60º, producing a
shape similar to Maltese cross which, having more wood, became stronger and enables
the interlocking of successive long shingle-like roof planks. This roof was painted
white and being so unusually shaped is truly stunningly different and, of course,
waterproof.
[0017] The Maltese cross shape actually enhances the performance of the roof plank. It is
cheaper if we can avoid having to use everelastic sealants in the T&G joints between
the crosses. The exposed surface is sloped away from the joints between the crosses
so that only a direct hit of a rain drop on the joint has any chance of working through
the joint. Also true to the Maltese cross configuration, the top of the rafter part
is veed downward to stop water that hits the top of the widened cross from spilling
over to the joint area. With the top configuration of the Maltese cross being the
same shape as its bottom, a second tier of roof planks can have its bottom area end
tucked into the top area of the first tier, locking it to the first layer without
the need for nails, making the joint between layers more waterproof. The bottom of
the second layer of planks will cover the nails necessary to nail the top of the first
layer to the cross bearer beam. Of course, the roof planks can be attached to their
bearing cross beams using the key-lock principal taught in my US Patent #5,475,960,
December 19, 1995, where attachment is possible without the need of visible nails.
[0018] Cross-shaped components can also make excellent free-standing walls or partitions
for homes and other buildings. Here the vertical member of the plank will become a
stud instead of a rafter, providing extra stability and strength to the wall. A cross
made from a 100mm log would produce enough stability for a 5M high wall based on the
1 to 50 rule and there would be no need for nails showing.
[0019] If the top of the square angled cross were to be milled off leaving a "T"(tee) shaped
component and leaving the heart encased, a waterproof component for an outside porch,
patio or deck would be produced. This, with the bottom of the cross still attached,
would produce a much stronger tee shaped deck plank, with a sort of built-in joist,
able to span wider spaced bearing beams and having less bounce. This component shape
could produce a partition or wall with enough stability to stand 4 meters tall and
there would be attractive "studs" showing on one side of the wall and could allow
the attachment of drywall on the stud side of the wall, if desired.
[0020] The cross shaped configuration could be modified differently to produce two tees
by splitting the horizontal cross members horizontally. It would still be waterproof
if the split occurred right on the heart, but it would not need to be if the tee shapes
were used for inside flooring or upside down for ceiling liner or for partitions.
It would go twice as far and would approach the cost of drywall, when you consider
the expensive decorating cost of drywall and the cost of such low-cost small logs.
63mm or 75mm logs could be used, which are only good for firewood. Also, components
that are used inside only, can be made from junk trees such as willow and alder.
[0021] This patent application also covers a wood wall system that consists of two or more
layers of unusually shaped plank components which can be employed vertically or horizontally.
These planks are interlocked in each layer by simple tongue-and-groove joints and
are held together with cross ties nailed across the face of the planks. The individual
layers are interlocked together using tee shaped projections cut out of the planks
that project from the middle of facing planks. The planks are offset so that they
can hook on to each other. The resulting shape is an Ayche (H) shaped plank which
has a smaller side of the Ayche shorter by a third than the tongue-and-groove side
to make room for the cross bars of the Ayches when they are offset and hooked together.
In this two layer wall, the cross ties are set in grooves cut across the interlocking
Ayches which cut through the smaller side of the Ayches plus the cross bar of the
Ayches. The cross ties are nailed alternatively from one side to the other as each
Ayche piece is added on each side until a section is formed that is a one man load,
or about 26 kg. Cross ties may be spaced 800mm to 1200mm, say, with 3 in an 2.5M high
wall panel. To produce multiple interlocked layers a new shape is introduced, as a
second layer instead of Ayche pieces, which can be described as a double Ayche because
it is the same shape as if two above noted Ayche pieces have been joined back to back
with the larger part, the tongue-and-groove part being fastened together. Then a third
layer can be hooked on which is composed of the same Ayches as the first layer. A
second series of cross ties would be cut through the short sides of the third layer
and the double Ayche middle layer. The three layer section would be assembled one
piece at a time and individually nailed in place. First, the first layer plank, and
then the double Ayche layer plank, and then the third layer plank. A wall section
can consist of four layers or even five or more layers with all internal layers being
double Ayche layers hooked together lengthwise and fastened together cross ways with
cross ties nailed each way between each layer. A .75M wide section 2.5M high with
five layers would be a two-man load depending on the size of the individual components.
A multi-layered section need not be solid. Voids can be left in the assembly and still
have a very strong wall, The voids can be filled with insulation producing a lighter
and warmer wall. Cross ties can also be limited to the outside layers reducing the
labor to produce the section. Walls can be composed of different species. The outside
layer could be cedar or redwood to withstand bad weather. Center layers can be lower
cost but stronger wood to carry weight and the home's inside layer could be choice
paneling for a rich interior.
[0022] The development of my layered wood wall has taken many years. It started with a plain
log wall that needed chinking and went on to a machined log wall with tongue-and-grooves
between the logs. That sounds easy, but it is difficult to tongue-and-groove tapered
logs together. Log walls are subject to substantial uneven shrinkage and settlement.
I tried to hold back the wall settlement by nailing 38mm x 80mm studs at800mm spacing
to the inside of the walls and covering them with half log siding inside. The log
shrinkage meant open gaps between some logs that were held from settling by the studs.
The log siding inside gave way to a second layer of full logs held in place by in
between studs nailed alternatively to an inside log and the next outside log. Face
nailing to the logs was not satisfactory as there was no resistance to sheer and the
logs were uneven in shape so I cut grooves into the logs and let the studs into the
logs at each side. This was a big improvement but the sheer weight of the logs tended
to pull the two layers of logs apart. Then I developed the tee shaped notched joint
between the logs. This double interlocking and vertical nailed on studs made a firm
wall that did not settle and though there still was shrinkage, the tongue-and-grooves
masked that, and logs shrunk individually on the studs and shrinkage did not accumulate
into substantial settlement . The logs shrank and hung on their nails.
[0023] There was a demand for "D" logs so I sawed the inside log in half and had a smooth
wall finish inside. Recently, I did this on the outside or, in effect, used two half
logs with the inside half log being a better grade. I now had the basis for my current
Ayche Wall System. I went to small logs to reduce the cost of walls when we learned
from our roof plank studies that small logs were much lower cost. We still see a use
for double full log walls. It was the use of full logs that led to my idea of the
double Ayche interlocking components and the multi-layered wall. With the very small
logs being a fraction of the cost of the same weight in large logs it made more sense
to use multi-layered small logs. Though I thoroughly study the present and past art
in wood wall construction, there is nothing in presently known art that led to my
development of the layered Ayche wall system. Right now we favor a vertical half log
system rather than a horizontal log house type of wall. Vertical planks lend themselves
better to section manufacture. Except where large logs are used, it does not make
sense to try to fabricate horizontal small Ayche pieces and small double Ayche pieces
in the field. It would be like trying to sort out different length straws from a haystack.
An average house would take 10,000 small sticks, section manufacture in a plant is
the only way to go.
[0024] This patent application also covers a new so called "key-lock" system for joining
cladding to framing or simply just joining various shapes of wood together. This was
also developed by me over many years of experimenting not directly from the use of
currently established art. In my January 3, 1978 invention U.S. Patent #4,065,902
I taught a system of making waterproof planks by using metal covered planks that had
special waterproof joint means. However, the planks could not be face nailed through
their metal covering and remain waterproof. I had to rely on nails that were on the
edges of the planks and covered by the jointing system. Though these nails could hold
the planks down, they could not produce enough resistance to shear forces (from winds)
to pass very minimal tests. My next step was to cut dado grooves across the planks
to fit over their bearing beams. This gave considerable improvement, but tests proved
unsatisfactory as pressure would cause the roof planks to twist out of the grooves.
The next step was a simple dovetail joint locked over the bearers. This passed the
most severe tests, but in practice I found that it was impractical to have to slide
the roof plank from the end of its bearer to the desired position. With further experimentation,
I developed the key-lock joint which used a male bearing edge that had a slit sawn
into it which could be compressed together to allow a roof plank to be forced over
it forming a locked joint. This system was patented December 19, 1995 U.S. Patent
#5,475,960. The first problem was that builders either did not caulk the open slits
in the bearing timbers between planks in spaced outside decking or they did a poor
job of it. Also, though the hold down of the new joint seemed to work well, it did
not pass satisfactorily in formal shear tests. What happened was that the gaps produced
in the male nobs of the joints that were squeezed together by a mallet blow to make
assembly faster also were squeezed together by the heavy test equipment and accumulatively
across a test panel produced enough "give" to produce poor tests.
[0025] I tried to put the slits into the cladding close to the cross groove. It appeared
to work fine and water could not get into the saw slits, however, the wood between
the cross groove and the slit too often sheared off when the plank was forced over
the nob. The grain of the wood assisted the shear. Next I tried bending the planks
upward to open up the undercut cross groove enough to pass over the nobbed edge of
the bearing joist. This worked OK with some tough and very green wood. Slits to the
side of the groove did not help so I tried small slits right in the cross groove.
This worked and this application is for a patent for this joint system. Shear tests
were comparable to true dovetail joints. The harder the test equipment pushes the
cladding against the stud or joist, the more firmly it is locked in place. the slits
in the groove are not affected.
[0026] My Patent #5,475,960 joint system can still be used to hold components together that
are too thick to be bent to open the cross groove and is very useful to hold assemblies
together until glue hardens or cures.
[0027] The wood of small logs is better than from most saw logs because the branches of
small trees are small and so are the knots in the lumber they produce, also, it is
generally accepted that heartwood is stronger and more resistant to decay than the
rest of the tree. In Scandinavia, wood from small logs is used in the manufacture
of windows and doors. Only clear lumber is used in North America, despite the fact
that Scandinavian millwork is of perfect quality, and once painted will look the same
as clear wood.
[0028] Probably the cheapest wood on earth is bamboo. This basically hollow wood is very
hard and strong. Bamboo is part of the grass family having nodes at varying intervals
where there are diaphragms across the stems. Compared to trees, bamboo stems are quite
small. A 80mm bamboo log is a large log for bamboo. To make a wall or weatherproof
roof out of it, the stems would be cut to 2.5M wall lengths and then sawn vertically
in half. Key-lock grooves would be machined across the exposed edges of the halves,
similar to the key grooves covered in my Patent #5,475,960, December 19, 1995, except
they could be designed to accept an oval shaped cross tie. A plurality of bamboo half
pieces could be set tightly together with their rounded sides down and say, three
cross ties in an 2.5M wall could be snapped in to place, tying the vertical half logs
together, and then a series of similarly sized and milled half pieces could be snapped
on the open side of the wall and onto the same cross pieces, but offset so that the
upper pieces cover the left half of one bottom piece and the right half at the next
bottom piece to the left of the first piece, making a clean bamboo wall on both sides.
If the bamboo is used for a roof, the inside node diaphragms of the bottom pieces
would have to be grooved on center down to the outside shell (to drain water that
can get in between the halves) on center of the half diaphragms and to the depth of
the cross grooves, and also to accept the lips of the opposing half logs and hold
them tightly together.
[0029] Putting all this together, components for a complete home can be produced, giving
the world solid, lower cost homes made from trees that are now only good for wood
pulp, fence posts or firewood, and which are very abundant. Many species of trees
do not grow to sawlog sizes and some, such as logepole pine and bamboo, grow so thickly
that they mature before reaching sawlog sizes. Also, thinnings from plantation timber
can be used, and also the cores from plywood peeler logs can be used. They are waste
wood, but high quality, not cull wood, and always have encased hearts. Now they become
pulp or firewood.
[0030] Manufacturing my homes using only logs from small trees opens up the concept that
such a house factory can have its own nearby tree plantation that can grow trees that
can produce a 8M tree stem with a 75mm top in three to five years, depending on species.
Such a factory could in many locations have its plant and plantations close to large
city market areas and be independent of distant timber barons and the freight involved.
The Christmas tree industry and now the pulp paper industry are doing this. Fluctuating
timber prices have severely hurt home manufacturers in the past few years. It would
be great to be independent. Small logs from plantation trees can reduce the cost of
regular sawlogs by 66%.
[0031] Summarizing the home components from small trees that together can produce a complete
low-cost house:
1. Wood planks containing integral hearts for waterproof planks, eliminating the need
for shingles or other roofing materials.
2. Cross shaped planks that are both waterproof roof planks and rafters containing
hearts.
3. Cross shaped components and tee shaped components that can be outside walls for
a tropical home or stand alone inside partitions.
4. Tee shaped flooring that can span between beams, eliminating the need for floor
joists.
5. Inverted tee shaped ceiling liner that can span across beams without ceiling joists.
6. Tee shaped vertical partition components.
7. Waterproof outside decking planks that have encased hearts.
8. Tee shaped outside decking that can span between beams and not need joists.
9. Sash and door components made from the wood of very small trees that only have
tiny knots, which would be about a tenth of the cost of clear wood usually used. (Not
new, but enables the production of a whole house from small wood.)
10. Interlocking Ayche shaped half log wall components with rounded sides turned inward
and the flat sides forming flat wall surfaces on both sides. This wall solves the
proverbial problem of squaring the circle. Round logs are made into square walls and
over 90% of the log is used as a compared to less than 50% when stock lumber is sawn
from small logs.
11. Interlocking Ayche shaped wall components can be formed into a thicker wall by
inserting a double Ayche log having similar interlocking hooks on both sides which
locks to the two layers of outside and inside half logs. Adding similar layers of
double sided logs could make even thicker solid wood wall assemblies. Five layers
would make a wall approximately 450mm thick.
12. Horizontally applied tee shaped siding resawn from cross shaped components at
a cant to produce interlocking bevel siding.
13. Small squared logs that can be built up to form stair treads and stringers and
also handrails and balustrades. (Not new.)
14. Small wood components which can be remanufactured into low-cost kitchen cabinets
and vanities. (Not new.)
15. Small wood components that can be laminated to form low-cost closet shelving and
single small logs that can be turned to become clothes rods in closets.
16. Turned very small logs that can be cut into quarters to form a quarter-round base
trim.
17. Tee shapes can be formed to make wood doors with cross bars and diagonal braces,
which would be let into notchings of the bases of the tees. A superior door can be
like the solid walls, using Ayche shaped half logs with notched-in cross ties and
diagonal braces hidden inside the doors.
18. Roof beams made from the new wall components that are both interlocked with nails
and glue laminated together.
19. Ell (L) shapes that make special corner molds and combination jamb and trim components.
20. Dee (D) shapes that are not finished like the Tee shapes and can serve as a stronger
floor or ceiling provided that the unfinished round sides face unused space below
the floor or unused attic space above the ceiling.
[0032] This house will come directly from small trees and will eliminate the use of plywood,
solid or glue laminated beams, floor joists, ceiling joists, rafters, trusses, wood
or asphalt shingles, inside and outside doors as we know them, windows and cabinets,
and can eliminate the need or use of drywall finish. A whole house can be produced
from low-cost small logs.
[0033] Single layer waterproof roof planks or crosses, and single layer wall tees can produce
quality low-cost buildings for many uses where insulation against heat or cold is
not a factor: (1) garages of all sizes; (2) three-season room additions and screen
porches for homes; (3) back yard offices, pool houses, play houses and party cabins;
(4) seasonally used second homes of all sizes; (5) stables, cow barns, implement sheds,
chicken houses, storage sheds, all kinds of farm buildings that are usually made from
galvanized sheet iron and wood framing; (6) many types of commercial warehouses or
storage buildings that are not insulated and which would cost less than conventional,
sheet metal covered wood framed buildings and look better.
[0034] A garage building or a three-season room addition at half price would be so much
more affordable, that tens of thousands of extra sales of these small buildings could
result each year. The wood used could mainly come from the junk small trees in our
bushes and cut over forests and of course from small tree plantations.
[0035] A summer home built of these low-cost cross, tee, Ayche and double Ayche components
would be a mansion in many tropical third-world countries. In time, their people could
be taught to use their bamboo and other junk wood trees from their bushland to build
good homes.
REFERENCES EXAMINED
[0036]
U.S. PATENTS |
Patant Number |
Date |
Name |
148,016 |
07-1873 |
Winans |
168,672 |
03-1875 |
Reed |
479,054 |
02-1891 |
Briggs |
502,289 |
08-1893 |
Feldmann |
1,344,181 |
05-1920 |
Mason |
1,943,033 |
07-1932 |
Midby |
2,463,612 |
09-1946 |
Grudda |
4,043,090 |
08-1977 |
Viapiano et al. |
4,065,902 |
01-1978 |
Lindal |
4,356,676 |
11-1982 |
Hauptman |
4,700,524 |
10-1987 |
Addison |
4,896,999 |
01-1990 |
Ruckstuhl |
5,020,289 |
06-1991 |
Wrightman |
PCT/US92/01748 |
03-1992 |
Lindal |
PATENTS - OTHER COUNTRIES |
Patent Number |
Date |
Country |
Name |
390,245 |
02-1924 |
Germany |
von Ausfachungen |
3,408,608 |
09-1985 |
Germany |
Pfister |
25,284 |
09-1951 |
Finland |
Alanko & Stenlund |
529,215 |
12-1982 |
Australia |
Amling |
DESCRIPTION OF DRAWINGS
[0037]
Figure 1 is a green board with a tight knot.
Figure 2 is a very dry board with three knots that have shrunk more than the wood around them.
Figure 3 is the end of a round green log that has been de-barked.
Figure 4 is a clear plank that has been sawn from the log.
Figure 5 is a knotted plank containing the log's heart.
Figure 6 is a plank with a knot that passes through it.
Figure 7 is the end view of a thoroughly dry log.
Figure 8 is a badly split, very dry, plank end view, split through and open to water admission.
Figure 9 is a plank containing the heart of the log it was sawn from and which has no openings
for the passage of water through it.
Figure 10 is a cross section of a plank containing a knot that is split right through and which
will allow water to pass through it.
Figure 11 illustrates a waterproof joint between waterproof roof or outside decking planks
under normal weather conditions. A weep groove is used to drain away water that might
get into the joint.
Figure 12 shows how extremely dry weather can cause the planks to shrink and come apart, opening
up the joints between the planks.
Figure 13 illustrates the use of a sealant or caulking that is everelastic that seals the joints
between waterproof planks and stretches when the planks separate.
Figure 14 illustrates how a sealant acts to stop the passage of water should the joints between
the planks open up in very dry weather.
Figure 15 illustrates the production of an ordinary tongue-and-groove plank from a log having
a 80mm top which leaves a lot of waste.
Figure 16 shows the view of the top of a log and how a cross shaped or a plus sign shaped reinforced
tongue-and-groove plank can be milled directly form the same log with a 80mm top,
leaving much less wasted wood.
Figure 17 illustrates how two pieces of reinforced 25mm x 75mm tongue-and-groove flooring can
be produced from the same 80mm top log.
Figure 18 illustrates how a tongue-and-grooved wood shape that looks on end like a Maltese
Cross can be milled from the same 80mm log.
Figure 19 shows the Dee (D) shape which are stronger than the Tee (T) shapes. They can only
be used where the rounded side is hidden from view.
Figure 20 illustrates two "H" (Ayche) shaped building components that have been milled out
of a small log.
Figure 21 illustrates a double "H" shaped wall component (HH - double Ayche) milled from a
small log having a 80mm top and a 106mm butt.
Figure 38 illustrates a cross section of an inside floor and beam assembly.
Figure 39 illustrates a cross section of an outside waterproof deck and beam assembly.
Figure 40 illustration is the same as Figure 39, except the decking is not tongue-and-grooved,
it is spaced 6.5mm and is open for rain to pass through between the planks.
Figure 41 is a cross section across the joist, 90º to Figure 40. It shows that there is no
slot in the top of the knob of the top of the joist that can take in water from the
space between the decking planks.
Figure 42 shows the application of the decking over the knob on top of the joist assembly.
Figure 43 illustrates a cross section of a ceiling panel.
Figure 44 is a small scale cross section of a ceiling panel.
Figure 45 is a cross section of an inside partition panel or a panel suitable for a garage
or other out-building wall.
Figure 46 is a cross section of the wall panel shown in Figure 45 in small scale.
Figure 47 is a cross section of a wall panel for a house partition or an unheated building
outside wall
Figure 48 is a cross section in full scale of a partition wall for a home or an outside wall
for an unheated building.
Figure 49 shows a wall made up of (Ayche) "H" shaped components interlocked and bound cross
ways by 25mm x 75mm cross ties rabetted into the shorter sides of the Ayche components.
Figure 50 is a cross detail of two "H" components cut from the same 80mm log. One component
is thicker than the other and the combination, as shown in Figure 52, produces a solid
wall that has a board and batten appearance.
Figure 51 shows the top of a 80mm log that has been milled to produce two tee shaped components,
but in this case the log has been resawn at a cant to the base of the tee, producing
bevel siding.
Figure 52 shows a wall averaging 140mm thickness. It is the wall shown in Figure 49 with 80mm
posts (Figure 21) inserted inside and locked into place.
Figure 53 shows an outside wall, the same as Figure 52, except that another tier of posts has
been added making the wall 70mm wider.
Figure 54 shows a post and liner wall combination that has a third tier of posts added. The
drawing is half-scale.
Figure 59 shows two layers of Maltese Cross roof planks interlocked over a beam assembly.
Figure 60 is a cross section of Figure 59 showing Maltese Cross roof planks interlocking over
beams.
Figure 61 illustrates a waterproof roof system using cross shaped components taken out of logs
having 80mm tops.
Figure 63 shows horizontal cross sections of roof and wall panels made from bamboo.
Figure 64 illustrates a vertical cross section at the joint between roof or wall panels shown
in Figure 63.
Figure 65 is similar to Figure 64 except that it shows how the upper half log is slightly bent
upwards which causes the saw slots to open up enough to allow the top half to snap
over the key-lock strip, locking the top half log to the lower half log.
Figure 66 shows a wall or a partition horizontal cross section. This wall differs from the
previous wall shown, in that is uses small solid logs instead of hollow bamboo logs,
but is built similarly to the bamboo wall shown in Figures 63, 64 & 65 using floating
cross ties that lock the two sides of the wall together without nails.
Figure 67 is the vertical section of the wall shown in Figure 66. It clearly shows the floating
cross tie.
Figure 68 is a cross section of part of Figure 70. It basically shows the design of the stud
assembly end, for a wall using the cross tie locking principle.
Figure 69 shows a vertical cross section of Figure 70 at the junction of the siding tee planks
with the stud assembly and the cross tie.
Figure 70 is a conventionally looking outside wall, finished in vertical V-joint siding on
the outside. The wall is tied together with a rounded cornered cross ties that are
nailed to the stud assembly.
Figures 71, 72 and 73 are presented to show how two logs each 100mm in diameter can be manufactured into
useful house components but the one in Figure 72 produces more than twice as much
useful building material as the log in Figure 71. Figure 73 shows how the two components
shown in Figure 72 which we have referred to as Ayche pieces (Figure 20, part 33)
can be built into being part of a wall section (see Figure 49).
Figure 74 indicates a glued up roof beam assembly made up from Ayche pieces (Part 33, Figure
20) and double Ayche pieces (Part 34, Figure 21) and a new shape, part 161 which we
refer to as "E" pieces which are used to square out the beam and which are made up
by splitting double Ayche pieces in half horizontally.
Figure 75 shows how a log can be quartered and made into Ell pieces (L) which can be used as
shown for corner trim and combination door jambs and door trim.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0038] My presentation of the drawings begins with a series of Figures 1 to 10 on the effect
of shrinkage in wood on the wood itself and on live knots in the wood.
Figure 1 illustrates a green board (1) and knot (2) that is part of a live branch and is integral
with the wood.
Figure 2 is a very dry board which shows the wood (3) itself which has suffered a check (10)
due to tangential shrinkage. Tangential shrinkage is in the direction across the surface
of a log, differing from radial shrinkage, which is from the heart of the log to its
outer circumference. Tangential shrinkage is three times as much as radial shrinkage
and it is this difference that causes splits in the clear part of the wood. (4) (5)
and (6) are three knots that have shrunk more than the wood around them causing holes
in the board. Knot (4) has shrunk so that it has become smaller than the hole in the
wood that it formerly occupied, and a crescent shaped opening has occurred (7). Knot
(5) has simply split into two pieces opening up a hole (8) through the board. Knot
(6) has "star checked" opening up a hole (9) in the board. Knots in a green board
contain more moisture than the wood surrounding them and thus shrink more. Even a
sound dead knot which is dry causes problems when a board shrinks, the board itself
will split slightly at the knot when it shrinks and the knot does not.
Figure 3 shows a cross section of a de-barked log that is green right out of the forest. Growth
rings as shown as well as a knot that was a live branch (2) which starts as a fine
point at the heart and spreads, forming a cone shape as it progresses from the center
to the surface of the log. (1) is green wood, (2) is the knot and (11) is the heart
of the log. Figures 4, 5 and 6 show cross sections of boards cut from the log in Figure
3, Figure 3 also shows the parts of the log the boards have been sawn from. These
three boards as shown are waterproof. In these four Figures, 1 is green wood, 2 is
a knot and 11 is the heart of the log.
Figures 7, 8, 9 and 10 show what happens when the log itself (7) and the boards sawn from the log (8), (9)
and (10) shrink. The logs check or split (10) the knot splits (8), and the log itself
and the boards take on a smaller dimensions. The knot does not shrink lengthwise,
so it is left protruding from the log and boards (15). Radial shrinkage is shown as
12 and tangential shrinkage is shown as 13. Boards Figure 8 and Figure 10 are no longer
waterproof as they have holes right through them but board Figure 9, which encases
the heart of the log it came from, is still waterproof as neither the knot nor the
splits pass from the circumference of the log through the heart of the log. The splits
are caused because the circumference of the log shrinks more than the radius of the
log, and something has to go. The lesson is that to have a waterproof plank the plank
must encase the heart of the log it came from. 3 is dry wood, 5 is a knot with a split
in it, 8 is the split in the knot, 10 are splits in the wood, 11 is the heart of the
log, 12 shows radial shrinkage and 13 shows tangential shrinkage. (There is no 14.)
Figures 11 and 12 show how water that gets into the joint between two waterproof planks can be drained
away using what is commonly called a weep groove. The planks are thoroughly dried
and preshrunk before being installed and are machined so that when the planks are
driven tightly together, the vertical top joint (18) will be very snug, aided by slightly
open spaces (19) that assures all the force exerted to close the joint will apply
to the vertical joint (18). The horizontal joints (18) are also very tight. Then,
Figure 12 illustrates a condition that can happen in extremely dry conditions, the
planks shrink and separate, opening up a gap on the surface (21) and further widening
gap 19 to become 22. Water that may get into the opening (21) say from a sudden shower,
will drain away in the weep groove (20) and will not get past the tight horizontal
joint surfaces (18). Moisture from the shower will soon cause the planks to expand
again, and should the shower become more than a half hour long, the opening (21) will
close up. Though the use of a weep groove can not now be Claimed as a new invention,
this illustration is included to show how planks that are waterproof can have waterproof
connections. 11 is the heart of the log the plank was sawn from, 16 is the tongue
side of the first plank, 17 is the groove side of the second plank, 18 are very tight
joints, 19 are loose open joints, 20 is the weep groove, 22 shows how the space (19)
will open up in extreme dry conditions, 21 shows how vertical joint (18) can open
up slightly in very dry conditions, and 25 indicates shrinkage in the very dry planks.
Figures 13 and 14 illustrate how silicone caulking can be used to waterproof a joint. An extra space
(23) is created in the bottom of the groove to receive the sealant and which is designed
so that the sealant will not squeeze out of the joint in severely wet conditions,
which might be the condition if sealant were placed elsewhere in the joint system.
The silicone (24 and 26) shows how the thickness of the sealant can be made thinner
if it is stretched (like chewing gum stretched between the fingers). 11 is the heart
of a log, 17 is the groove side of the 2nd plank and 16 is the tongue side of the first plank, 18 are very tight joints, 19
are loose open joints, 21 is the vertical joint 18 after shrinking, 22 is the loose
joint 19 after shrinkage, 23 is the special groove to contain sealant, 24 is the sealant
and 25 indicates shrinkage. Again, the use of silicone is not a new invention but
is shown how waterproof planks can have a jointing system that is also waterproof.
A doubly sure waterproof joint can be made by combining the weep groove system with
the silicone sealant system in a single joint.
Figure 15 shows a 38mm x 75mm tongue-and-groove plank that is waterproof because it encases
the heart of the 80mm log it was sawn from. 27 indicates the 80mm log, 29 is the 38mm
x 75mm waterproof plank, 11 is the heart of the log and 28 indicates wood that is
wasted in the milling and sawing process.
Figure 16 illustrates a similar 38mm x 75mm waterproof plank that has been expanded to become
a cross shaped component which uses up much of the wasted wood shown in Figure 15
to produce reinforcing ribs that turn the component into a combination waterproof
plank and a rafter which can span greater distances between supports than the 38mm
x 75mm can alone. Wasted wood (28) becomes much less than in Figure 15. This cross
shape can also be used for a wall with the vertical part becoming a stud, producing
a pleasingly decorated wall. 30 is the new cross shaped component, 11 is the heart
of the 80mm log 27 that the cross shape is made from, and 28 is waste wood lost in
the manufacturing process.
Figure 17 illustrates how the cross shaped component 30 in Figure 16 can be ripped into two
tee shaped pieces (31). These are individually machined to have their own tongue-and-groove
connection ability. Because it is likely that only one of the pieces will encase the
heart of the log, this tee shape will not be used as waterproof components. However,
it can be used for inside flooring, or upside down as a ceiling, or vertical as a
wall. In each case, the reinforcing rib will act like a joist or stud and reinforce
the strength of the component by spanning greater distances as joists or stabilize
a higher wall as a stud. 11 is the heart of the log, 27 is the 80mm log, 31 is the
tee component and 28 is the wasted wood.
Figure 18 is a variation of the cross shaped waterproof roof plank shown in Figure 16. It is
made from a 80mm log 27, and encase the heart (11). This component has been called
a Maltese Cross because it resembles one. Its main function is to make the component
more waterproof by channeling rain away from the joints and funneling it downward
in the vee grooves. Only a direct hit of a raindrop on the joint will challenge the
integrity of the joint. The component is reversible, that is, the bottom half is the
same shape exactly as the top half of the cross so it can be spun 180º and be the
same. 32. is the Maltese Cross component. 32a are the reversible joints, 27 is the
80mm log, 11 is the heart, 28 is waste wood and 28a indicates how the reversible top
and bottom points are equilateral triangles, enabling them to be interlocked during
construction, that is, the top half of one log will slide into the vee spaces of the
bottom half of another similar log (see also Figure 59).
Figure 19 shows a Dee (D) component (37) which can be used the same way the finished Tee components
are used for flooring, ceiling planks and partition planks provided that the unfinished
rounded side faces unoccupied space like under a floor or in an unused attic space.
In the case of partitions, the Dee components can have their unfinished rounded side
covered with drywall. Sections made from Dee components are stronger than sections
made from Tees. 28 is waste wood, 11 is the log's heart.
Figure 20 shows the top of a 80mm dry log, (27) and it also shows 36, which is the bottom of
the same log and is larger from 13mm to 25mm in diameter on an 2.5m log, depending
on species and growing conditions. The log is sawn exactly into two similar half logs
33, which are called Ayche (H) components as they have a vague Ayche shape with one
side of the Ayche being shorter and smaller. The Ayche is formed as the tee shape
was formed in Figure 17 except that instead of having a 90º notch cut from the half
log on each side, the notch is a slot cut parallel to the base and to the top of the
tee. With a 80mm log the net base of the Ayche is 75mm. The slots are then 25mm deep
on each side leaving the cross bar of the Ayche to be also 25mm, a third of the width
of the base deep. The width of the notches is about 20% of the net height of the Ayche
piece or 10mm and the thickness of the small side of the Ayche is slightly less than
10mm, assuring a tight fit when the small side of an Ayche is slid into the notch
of another Ayche piece that has been inverted. The taper of the half log can be taken
advantage of to the extent that the small side of the Ayche will get stronger closer
to the bottom of the half log, the improvement is shown as 35. As the placement of
the log's heart is not sure, the Ayche piece is not considered to be waterproof. 11
is the log heart, 27 is the 80mm circumference of the top of a dry log, 36 is the
circumference of the base of the same log, 28 is waste wood which is minimal, 33 is
the new Ayche shape and 35 is the extra wood gained by the use of taper.
Figure 21 resembles Figure 20 because it is in fact 2 Ayche pieces in one. The Ayche pieces
can be finished and glued or otherwise be attached to form the new shape called a
double Ayche (HH) or a single double Ayche can be machined directly from the original
80mm topped log. The only good reason for attaching two Ayche pieces together to form
a double Ayche is that the half log piece dries more than twice as fast as a whole
log and gluing half logs together from different trees inhibits twist and warp. It
should be noted that the tongue-and-grooves have been omitted in Figure 21. This is
also optional. The double Ayche is used as a post or a stud in the inside of a wall
and most often stands alone, making the tongue-and-grooves useless. In the case of
a layered solid wall, tongue-and-grooves on the double Ayche pieces would resist air
infiltration.
Figures 49, 52, 53 and 54 are taken out of numerical sequence because they apply to the Ayche component Figure
20 and the double ache component Figure 21. Figure 49 is a wall, a floor or a roof
panel made up of two layers of Ayche pieces (33), with their finished sides facing
outward on each side of the panel and their other slightly rounded sides solidly interlocked
together. The panel has three types of interlocking; first, the tongue-and-grooves
at the heavy side of the Ayches, and then the interlocking smaller Ayche sides, and
then the cross ties, (113) three for an 2.5M high wall. The three cross ties are set
firmly into notches across each Ayche piece, the notches extend through the smaller
Ayche sides and also through the cross bars of the Ayches. The three cross ties about
19mm by 65mm are firmly nailed to each Ayche piece, first on one side of the section,
and then the other as each piece is slid into place and the nail heads are hidden
inside the section (116). Sections are limited in width to a one man load of about
25 kg. The shaded areas (35) in the drawing indicate wood that is picked up from the
log's taper. 33 is an Ayche section, 35 is a wood taper, 109 indicates the thickness
of the section which for 80mm topped logs is 70mm, 113 is a wood cross tie buried
in the section, 116 is nails.
Figure 52 is similar to Figure 49 except that the section is thicker which is affected by the
insertion of a double Ayche post locked to the two opposing panels like the inner
and outer halves of the panel in Figure 49, with the difference that there are now
two layers of cross ties (113) which are nailed from the inside to each individual
Ayche piece and to the double Ayche posts (34). Assembly will be from one side to
the other the same as the assembly for the section (Figure 49). Another difference
is that to illustrate the use of the components, (110) and (111) (to be described
later) on one side of the wall instead of regular Ayche pieces (33). The use of these
special Ayche pieces Ayche pieces (33). The use of these special Ayche pieces produces
a wall that is styled as a board on board outside siding. The cavity space in the
panels (108) can contain insulation. In this case the double Ayche pieces (34) are
spaced one double Ayche piece width apart, they could be spaced 630mm or even 800mm
apart depending on the use of the panel, wall, floor or (roof with shingles). If they
are used as a solid wall, the double Ayche pieces could be connected sideways by tongue-and-grooves
shown in the original double Ayche drawing (Figure 21). 33 is an Ayche piece, 34 is
a double Ayche piece, 35 indicates log taper, 108 are cavities in the sections, 113
are cross ties, 116 are nails, 110 and 111 are a pair of Ayche pieces machined to
an in and out pattern. 114 and 115 indicates the width of the wall which is approximately
185mm.
Figure 53 is the same as Figure 52 but another layer of double Ayche posts have been added
producing a section that is 210mm wide (117). It is necessary for stability to add
two more posts at each juncture. Spacing here is indicated by 119, which as explained
in the description of 52 can vary. 118 indicated the width of the cavity, which is
115mm.
Figure 54 is drawn in half the scale of Figures 52 and 53. Here, a third layer of double Ayche
posts have been added, making a section that is 11 inches wide (121) and has a 190mm
deep cavity for insulation (122 and 108). Here the five piece post assemblies are
230mm on center (120). Sections this heavy would be made for two man loads about 58
kg. Note that each of these cavity sections have only two layers of cross ties.
Figure 50 is a variation of an Ayche component (33) designed to give an in and out appearance
also called board on board (see Figure 52). This is a more weather tight wall system
but usually is face nailed. My new Ayche type system shown in Figure 52 avoids face
nailing and is stronger than board on board. Component 110 is thicker than component
111, however, when they are locked into an opposing panel of Ayche pieces similar
to Figure 52, their round sides are on the same level which allows the shiplap-like
tongues of 111 to exactly fit in the grooves of the (110) components when assembled
into a section. The tongue-and-grooves are larger and stronger and more weather tight
than the tongues-and-grooves of the regular Ayche pieces (33). 11 is the heart of
the log, 27 is the 80mm circumference of the log, 28 indicates very limited waste
wood, 110 is the heavier part of the pair (from the same log) and 111 is the smaller
part.
Figure 51 is another variation of the Ayche piece, but is shown as a variation of a tee piece
because it is designed for horizontal use and could be locked to a series of studs
using my key-lock joint later described in this application. In this case, the two
pieces (112) are exactly the same being sawn from a log at a cant. The shiplap like
tongues and also the grooves are the same size as shown in parts 110 and 111 respectfully,
but each beveled piece has a shiplap like tongue on one edge and a groove in the thicker
edge. When a plurality of these (Figure 112) components are locked onto a series of
studs with the tongue edges up, and into the grooved edges, these bevel siding components
(112) will lock together forming a bevel siding wall.
Figure 38 shows a series of tee pieces (31) that have been formed into a floor fitted together
using tongue-and-grooves like most floors. They are locked onto the top of a floor
joist assembly (56). The locking system is my key-lock system taught in my U.S. Patent
#5,495,960. 86 is the nob at the top of the joist that extends down to a shoulder
in the joist shape (87) and extends to the underside of the flooring (88).
Figure 39 shows a waterproof outside deck with each deck plank (30a) encasing the heart of
the log it was sawn from. The waterproof joint system used is illustrated in Figure
13. The joist and key-lock system (56, 86, 87 and 88) are the same as in Figure 38,
30a is like the cross shape 30 except it does not have a rib on the top surface.
Figures 40 and 41 are two views of a spaced deck that does not need waterproof planks even though many
may encase hearts as they are made from small logs. Spaced decking is thicker than
flooring, so it is hard to get two pieces from a small log. Here my new key-lock joint
is used to connect the decking to the joist assembly. My key-lock joint (patent 5,495.960)
has saw slits in the top of the nob (86 in Figures 38 and 39). The slits are further
illustrated in the key-lock joint between 59 and 56b (in Figure 41). With water pouring
through the spaces between the deck planks (30b), water would get into the slits and
cause rot. Nob 86a does not have a slit in it , so rot is avoided. 59 is a part of
the joist assembly even though what is shown is not new, and it is not Claimed as
patentable. 56b is a joist component that has a nob (86a) that does not have a slit
in it, 86a is the nob without the slit, 87 is the shoulder of the joist component
56b, 88 is the top of the nob and is also the underside of the decking, 30b is the
spaced decking which has no tongue-and-grooves, 130 shows that the nob is exposed,
116 shows nails that are used to stop the decking from sliding along the nob 86a,
131 shows two saw slits across the decking in the cross groove. These weaken the decking
so it may be bent upwards once to open up the cross groove to snap over the nob 86a.
Figure 42 is an action view of Figure 41 that shows a decking plank (30b) being bent back at
its cross groove (133) so as to open up the under cut cross groove so that it will
snap over the nob of 56b. This action is aided by saw slits (131) that open up (132)
to allow a one time only bending of the deck plank (30b) without breaking it. Usually
it is enough for the carpenter to put his knee at point 133 and lift up the plank
with his right hand, however, the use of the hard rubber mallet (134) may be necessary
to hammer down the plank at point 133. 59 is a joist component, 56 is a modified joist
component, 30b is the deck plank, 88 is the line of the underside of the decking,
131 are the saw slits, 132 indicates that the saw slits have opened up, 133 is the
bending point of the decking and 134 is a hard rubber mallet.
Figures 43 and 44 (44 is a smaller scale than 43) show two views of a ceiling section which is a simple
series of tee (31) components tied together by two cross ties (89). Though rectangular
19mm x 38mm cross ties could be used, illustrated here are shaped cross ties that
have ess (s) shaped lips that fit into an under cut groove in the tee planks that
has the same pattern. In the groove are small slits (100) that aid bending the ceiling
planks to open up the grooves to snap over the cross ties similar to the action in
Figure 42. The cross bars (89) are further held in place with nails(90) that further
fasten the cross ties to each plank. 31 are the ceiling planks, 89 is the cross ties,
90 are nails, 100 is saw slits and 96 is the width of the ceiling sections.
Figures 45 and 46 are two views of a partition section (46 is smaller scale). The section is composed
of tees (31) that are interlocked by their tongue-and-grooves and tied together by
top and bottom plates that are nailed to the ends of the tees. The width of the plates
is the same as the height of the tees. The tees all face the same way giving a smooth
vee joint surface to the partition on one side and an attractive fluted appearance
on the other side. 31 are the tees, 91 is the top plate, 93 is the bottom plate, 92
are the nails that tie the plates to each of the wall planks (31), 94 is the nails
that tie the bottom plate to the floor and the top plate to the ceiling, 95 is the
height of the wall often 2.5m, 97 is the floor line, 98 is the ceiling line and 99
is the quarter round trim.
Figure 47 is a partition panel or section that is similar to Figure 46 except that the base
of the tees have been alternatively turned in and out so that the partition is fluted
on both sides with the flutes being wider spaced than in Figure 46. The top plate
(101) and the bottom plate (102) are wider. This partition is more stable having a
width (103) of 70mm instead of 45mm in Figure 46. 31 are tee planks, 101 is the top
plate, 102 is the bottom plate, 92 are top plate nails, 94 is bottom plate nails and
103 is the depth of the partition.
Figure 48 is Figure 45 with drywall liner applied to its fluted side making a thicker wall
section which (107) is 56mm thick instead of 45mm. The new top plate (106) and the
new bottom plate (106a) are similarly wider. The drywall is attached by drywall nails
(109). Otherwise, 31 are tee planks, 92 and 94 are nails.
Figure 57 is included to only show how the beveled tee planks (112) look when they are applied
to a stud wall. The nails (116) are used only to stop the planks (112) from sliding
along the nob (58).
Figure 59 illustrates how two layers of Maltese Cross roof planks can be interlocked together
for a joint between two roof sections over a roof beam. The bottom layer of the Maltese
Cross planks (32b) are notched over a built up beam (59, 56 and 86 using the key-lock
system of my patent 5,495.960). The second layer of interconnected Maltese roof planks
(32a) are interlocked because the lower points and angles fit in-between the points
of the first or lower layer. Nails are not needed to fasten the top layer 32a's to
the lower layer. 32a and 32b are respectively the upper and lower layers of Maltese
Cross planks, 59 and 56 are roof beam components, 86 is the nobbed top of 56 and has
a slit in it, 11 is the heart of the logs the planks were cut from, 88 is the line
of the top of the nob 86, 108 is void spaces and 87 is the shoulder line of beam component
56.
Figure 60 is a cross section of overlapping Maltese Cross roof section over a built up beam
combination. 130 is the overlap area between two sections, 129 is the cleat, or cross
tie, forming the roof sections, 116 are nails, 59 and 56 are roof beam components,
58 is the locking nob with a slit showing in it, 32 is a Maltese Cross plank, 32a
is an upper portion of a 32 at a junction, 32b is a lower portion and 133 indicates
the pitch of the roof which is 4/12.
Figure 61 shows how cross shaped roof planks can also form a roof system. These planks are
doubly protected against leaks at their joints, 20 shows weep grooves and 23 shows
silicone sealants. 59, 56, 58, 87 and 88 together indicate a supporting beam assembly
that key-locks the roof planks (30) to the beam assembly. 11 is the heart, of the
logs the roof planks were made from.
Figures 63, 64 and 65 show the manufacture of roof and wall sections using half bamboo logs. Both roof
and wall sections are the same except that the lower layer of the roof sections need
to have the diaphragms cut down to their shells to allow water that might get in between
the upper roof halves to drain away. Bamboo is hollow with cross diaphragms occurring
at the nodes. The shell is very hard, so much so that the use of bamboo for posts
is better than any other wood (pound for pound) and is comparable to steel. The bottom
half section (134a) is tied together using cross ties (89) that are oval shaped. These
are forced into grooves across the open half logs one log at a time the grooves are
undercut so that the cross ties cannot be forced into them unless the half logs are
bent back as previously described. The bending back is aided by saw slits (100) that
open up when the logs are bent up. Then the upper half logs (134) are similarly bent
up and are snapped over the same oval cross ties (89) one at a time, the oval strips
are also nailed (116) to the half bamboo logs to prevent sliding and solidify the
assembly, but before they are set the bottom layer of half logs (134a) are nailed
to supporting beams using large nails (142). Figure 63 is a cross section, Figure
64 is a side view and Figure 65 is a side view showing a half log (134) being bent
upward so that the grooves open up to snap over the oval cross tie (89). 134 are the
top logs of a roof section or the half logs for each side of a wall section, 134a
is the lower half log of a roof section, 135 is a bamboo node, 138 is the diaphragm
that occurs at nodes. The notch in the diaphragm 137 is for drainage purposes, the
diaphragm must also be cut down to allow for the cross tie if it occurs where the
cross tie cuts across, 89 is the cross tie, 100 is the saw slits, 134b is the inside
of the bamboo log shell, 108 is void space that can be filled with insulation, 136
indicates a break in the cross strips (89) between sections, 139 indicates the cross
section of Figures 64 and 65, 140 indicates where the sides of the individual half
logs are planed so that they fit tightly together which means shaving down the nodes
(135), 141 is the edge of a log that has passed over the cross tie, 143 indicates
the line of the top edge of the lower log.
Figures 66 and 67 show how a section similar to the basic Ayche section explained in Figure 49 can
be made using tee shapes instead of Ayche shapes by introducing the floating oval
shaped cross tie used in the bamboo sections Figures 63, 64 and 65. Here the tees
(31) and (31a) have oval cross grooves cut into them at the intended level of the
cross ties (89) in the section. These grooves exactly match the oval cross ties but
need to be opened up by bending the tee shapes back so that the cross ties snap over
the cross ties. For a firm section the cross bars need to be also nailed to each tee
piece on each side because the tees can still be slid along the cross ties. The opening
up action is aided by saw slits (100) cut across the tee pieces in the grooves across
the tee sections. The wall section an also be assembled by framing the bottom layer
of tees (31a) by snapping over the tees (31a) over the cross tie. Then the upper tees
(31) are snapped over the cross ties (89) one at a time and locked by its tongue-and-grooves
to an adjacent tee piece (31). This system does not allow the upper layer of tees
(31) to be nailed to the tee piece and rely on their stability by being set between
the lower level of the tee pieces (31a) however there has to be some slack between
the bases of the tees of both sides to allow the tongue-and-grooves to slide into
a locked position. The method of assembly where a (31) tee and a (31a) tee are locked
onto the oval shaped cross bar alternatively one at a time is better because then
every tee piece can be nailed to each cross tie. 31 is a tee component in the upper
layer of the section, 31a is a tee piece in the lower layer of the section, 89 is
the oval shaped cross tie, 100 is the saw slits in the bottom of the cross grooves,
144 is the space between two adjacent tees in the lower level, 145 is the width of
the base of a tee in the upper level, 146 is the thickness of the section which with
80mm topped dry logs would be 65mm, 47 is the space between two cross ties (89) indicating
the junction of two sections.
Figures 70, 68 and 69 show how tee components (31) can be locked onto a stud assembly made from small logs
using the oval shaped cross ties previously referred to forming a house wall. Components
62, 59 and 149 form a small log stud assembly which is not sought to be patented in
this application because its main principle is the interlocking key-lock (47) joints
that are already patented. However, 149 has its top end modified so that it is the
same shape and size of the tees (31) used in the wall. The wall would have at least
three cross ties (89) which are fitted tightly into square cross notches in the stud
ends (149) and firmly nailed into place. The wall pieces or tees (31) are snapped
over the oval cross pieces and can have the cross pieces nailed to them, from the
inside wall, between stud assemblies to further firm up the construction. 31 is a
tee wall component, 62, 59 and 149 is a stud assembly, 47 is a key-locked joint, 89
is the oval shaped cross tie, 151 are heavy nails that fasten 89 to the stud assembly,
109, 125, 108, 153, 152, 35, 126 and 124 are other parts of the wall illustrated that
are not germane to the explanation of this joint system.
Figures 71 and 72 show identical sized logs each (155) are 100mm in diameter. The log in Figure 71
has been manufactured so as to produce the maximum sized piece of stock sized lumber
that a 100mm diameter log can produce a 2x4 (160) scantling which is actually only
1 ½" x 3 ½" or in a metric measure 38mm x 90mm (157 x 156) which amounts to 3420mm2. Figure 72 has been manufactured into two (33) Ayche pieces which fill out the entire
100mm circle, with practically no waste (28) as compared to considerably more waste
(28) in Figure 71.
Figures 73 illustrates how the two "H" pieces (33) in Figure 72 can be combined with
other similar "H" pieces to form a very useful wall panel similar to the wall already
shown in Figure 49. To illustrate and to calculate the amount of useful building material
produced out of log Figure 72, one "H" piece has been designated as ("A") and the
other piece in Figures 72 has been designated as two pieces (B) and (C). Figure 73
shows how these pieces A, B, and C can be rearranged to form a square which is 95.25mm
(158) by 76.2mm (159) totaling 7,258.05mm2, which is more than twice the useful wood produced (3,420mm2) in Figure 71 through standard lumber production procedures.
Figure 74 is a roof beam made up of Ayche (33) and Double Ayche (34) pieces similar to the
wall section shown in Figure 52, except that it is solid wood and the horizontal joints
are held together with glue (162). The three vertical layers are interlocked as in
the wall section. A new shape (161) is introduced which I have called an "E" piece
which is made from a Double Ayche piece split horizontally into two similar pieces.
This produces a square beam and adds strength to the beam. Vertical stiffeners are
used as in the wall part 113 which holds the component parts together until the glue
sets and will give sheer strength to the beam should there be any glue failure. (116)
are nails. 163 indicates the top of the beam with (113) slightly protruding. 164 is
the bottom of the beam which does not have part 113 protruding, giving a more finished
appearance.
Figure 75 introduces the Ell (L) shaped piece (166 and 167). These are made out of quarter
cut log pieces (165) sawn from the quarter pieces in regular quarter cut sawing procedures.
The corner of the Ell pieces are sawn as close to the heart of the log (165) as possible.
This produces edge grained trim and makes the splitting of the Ell molds at their
corners more difficult than if the Ells were sawn from other parts of the log. Part
166 is designed to be corner trim. Part 167 is designed to be a combination door or
window jamb with its trim or casings attached. 168 designates a partition wall. 170
is stock door stop and 169 is a door. 171 indicates whole quarters of log 165 which
can be used to make more Ell shaped trim. 172 indicates wood that needs not be wasted
and can be made into other trim moldings.
[0039] Thus, one particular form of the invention comprises a building materials kit from
which lower cost homes and other buildings can be constructed with the savings coming
from the use of very low cost small logs and certain so-called "junk trees", both
of which are wasted and are left behind in logging operations; further savings are
realised by using up to 90% of the waste lost in saw milling operations and by making
dual use of certain components, for example, roof planks that are waterproof and also
serve as shingles and ceiling planks that have built-in ceiling joists supporting
them which are formed from otherwise wasted material which happens when a log is made
into regular ceiling planks, said kit does not include lumber as we know it, having
no studs, rafters, floor joists, ceiling joists, roof trusses nor plywood sheathing,
said kit introduces new shapes that on end look like tees (T), Ells (L), Ees (E),
Dees (D), Crosses (+), Ayches (H) and Double Ayches (HH) that are manufactured directly
from logs and not from lumber and together form a new type of housing kit, that includes
outside walls, partitions, floors, ceilings, roof and outside decking, said individual
components are formed into sections by nailing cross ties to each component in cross
grooves in each piece, all nailing is accomplished without visible nails showing in
the finished house or building, said kit also includes bamboo logs.
1. A building materials kit from which low cost homes and other buildings can be constructed
comprising low cost small logs and wood from small tree stems, said kit including
shaped sections made from said logs and tree stems and adapted to be connected together
to form components of the building.
2. A kit according to Claim 1 comprising a roof plank that is tongue-and-grooved and
in itself is waterproof and which encases the heart of the log it is sawn from and
which when combined with other like planks having tongue-and-groove joints between
them that are also waterproof forms a waterproof roof surface.
3. A kit according to Claim 1 or Claim 2 including a tongue-and-grooved roof plank made
from a small log that is shaped like a cross so that a vertical member is formed from
otherwise waste wood and which acts like a rafter, said cross shape also encasing
the heart of the log it was made from.
4. A kit according to any preceding claim including a cross shaped roof plank which has
the top surface of its tongue-and-groove cross bar sloped 60° inward from the tongue-and-groove
joints down to the vertical rafter like part of the cross to drain rain water away
from the joints on either side so that only a direct hit on the joint by a raindrop
can challenge the waterproof joint, said cross shaped roof plank encasing the heart
of the log it was made from, said cross shape being further modified by sloping the
sides of its vertical members outward from its base so that there are 60° angles between
the vertical and horizontal members which results in a wider top to the vertical member
which in turn has a vee cut into it forming a 120° vee channel between its top corners
which further sheds water from challenging the joints, said cross being modified so
that it resembles a Maltese Cross by shaping the bottom half of the cross to the same
shape as the top half.
5. A kit according to any preceding claim in which said shaped sections are cross shapes
formed by sawing them into two tee shapes by cutting the crosses through the centre
of the horizontal bar of the cross shapes then separately tongue-and-grooving the
ends of the tops of the tees so formed so that a plurality of such tees can form a
floor, a ceiling or a wall with the vertical parts of the tees acting like floor joists,
ceiling joists or studs.
6. A kit according to any preceding claim in which said shaped sections are tees made
by cutting them directly from half logs instead of making crosses first and then splitting
them, said half logs being left unfinished on the rounded side (not made into finished
tee shapes) and used like the tees except the unfinished rounded side is hidden from
view and having the rounded side slightly flattened to correspond to the flattened
top of the tee shape.
7. A kit according to any preceding claim including an ayche shaped component which is
formed by a slot being cut into each side of the half log parallel to the base of
the tee and the top of the tee, said base in the case of a 80mm topped log being substantially
75mm and the depth of the slots are a third of the base width being substantially
25 mm leaving the thickness of the cross bar of the ayche to be also substantially
25 mm, said notches being 10mm wide and the thickness of the small side of the ayche
being slightly less than 10mm assuring a tight fit when the small side of an ayche
is slid into the notch of another ayche piece that has been inverted, said small side
of the ayche being strengthened towards the base of the half log it is formed from
so that it will take advantage of the log's taper.
8. A kit according to any preceding claim including a double ayche component that is
two ayche pieces fastened together back to back at their wider sides or the double
ayche is formed directly in one piece from a round log, said double ayche pieces also
being formed without centred tongue-and-grooves.
9. A kit according to any preceding claim comprising ayche components that have cross
grooves cut across their shorter faces that reach to the inside edge of the wider
sides of the ayche components and have a width about double their depth, said cross
grooves being located about a component width from the tops and bottoms of the ayche
planks and in between these grooves at spacing averaging 1300mm with a 2.5m wall having
one groove midway between the top and bottom grooves and a 5m component having three
cross grooves between its top and bottom grooves.
10. Wall, partition, roof or floor sections that are fabricated from a plurality of ayche
pieces having cross grooves according to Claim 9 which consist of two layers of ayche
pieces interlocked together and tied together by cross ties set in the cross grooves
with the process of assembly into substantially 2.5m wall sections by the following
steps, the first 2.5m ayche component is laid down with its narrower notched side
facing up, with the groove side to the right and the tongue side to the left, three
cross ties are set tightly into the cross grooves and nailed in place and another
2.5m ayche piece is placed on the other side of the cross ties and is locked snugly
onto the cross ties and slid tightly into the notch of the first piece so that the
short sides of the ayches interlock for their entire length, the assembly is then
turned over and the cross ties are nailed to the second piece, then a third piece
is locked over the cross ties and slid so that its tongue fits tightly into the groove
of the first piece and its shorter ayche side interlocks firmly to the shorter ayche
side of the second piece, the assembly is then flipped over again and the cross ties
are firmly nailed to the third piece, then a fourth piece is set tightly to the cross
ties slid over to interlock doubly with the second and third pieces and the assembly
is flipped again to securely nail the fourth piece in place; said process is continued
until a section of desired width is fabricated which is a one man load of approximately
28 kg.
11. Wall, partition, roof or floor sections according to Claim 10 where a third layer
is introduced between said two layers which is a layer of double ayche components
plus a second set of three cross ties with the double ayche pieces being interlocked
to ayche pieces with the order being first a single ayche piece then three cross ties
then a double ayche piece then three more cross ties and then a single ayche piece
with the process continuing until a 28 kg section is fabricated, said wall being further
thickened by the addition of second, third or even fourth layers of double ayche pieces
without additional sets of cross ties producing sections that are approximately 57
kg or a two-man load.
12. Wall, partition or roof sections according to Claim 11 where voids are left in the
walls, making them lighter and providing space for insulation with single double ayche
components being set 625mm apart in a three layer wall pyramid of three double ayches
being set 625mm apart in a four layer wall, and five double ayche pieces being set
in a 2-1-2 configuration for a five layer wall, and seven double ayche pieces set
in a 2-2-1-2 configuration for a six layer wall.
13. Partition wall sections made up from a kit according to Claim 1 with a plurality of
tee components with their tee bases or studs all facing the same way which are held
tightly together by 25mm thick top and bottom plates firmly nailed to each tee piece
and are the same width as the overall thickness of the wall, said sections are about
20 kg in weight, being limited more by size than weight for ease of handling.
14. Partition wall sections according to Claim 13 which are set together so that their
tongue-and-groove tee bases face alternatively from one side to the other, making
an effectively thicker wall than when the components all face the same way and are
also about 20 kg in weight.
15. A kit according to any of Claims 1 to 9 comprising a pair of ayche components that
have been made from the same small log which is split, off centre enough so that the
heavier side of the ayches so produced have a relation where one is 50% thicker than
the other with the smaller side of the ayches so produced being exactly the same size
and shape, said thicker side has a groove cut into each edge on the centre of the
edges that is approximately one third of the thickness of the thicker side in thickness
and having a depth that is about as deep as it is wide, said smaller thickness ayche
component has a shiplap type of tongue at its wider side at each corner which snugly
fits into either of the grooves of the heavier ayche, so that should the two sizes
of ayches be fitted together with their similar sized smaller ayche parts on the same
plane, the shiplap tongue of the smaller ayche fit into the groove of the heavier
ayche and a plurality of such pairs will produce an in and out appearance usually
referred to as a board on board appearance.
16. A kit according to Claim 15 where the log has been cut into two similar tee shapes
differing from other tees in that the saw cut splitting the log in two is at a cant
to the base of the tees producing tees that have the same size of grooved end on one
side and the same size of shiplapped edge on the other side as the two ayches in accordance
with Claim 15 with the bases of the tees being exactly the same as each other, so
that when the two bevelled pieces are set on the same plane, the shiplap corner of
one piece can fit snugly into the groove of the other plank forming, when a plurality
of pairs are set together in the same plane, the appearance of bevelled siding.
17. A kit, according to any of Claims 1 to 9 or Claims 15 or 16 that has waterproof planks
that have a water resistant tongue-and-groove joint system made by having a rounded
weep groove planed into the top of the tongue at the shoulder of the tongue, being
approximately one quarter of the thickness of the tongue wide and of the same depth,
also to ensure a tight top joint the length of the tongue being less than the depth
of the groove and the bottom of the joint being milled to leave a similar sized space
between the bottom of the planks, as there is between the end of the tongue of one
plank and the bottom of the groove of the next plank.
18. A kit according to Claim 17 in which said waterproof planks that have water resistant
tongue-and-groove connecting joints which have very tight fitting top joints and similar
spaced bottom joints, the space left between the end of the tongue of one plank and
the bottom of the groove of the next plank being as wide as a third of the thickness
of tile tongue and into which an everlastic sealant can be inserted, like silicone,
filling the space.
19. A kit according to any of Claims 1 to 9, or 15 to 18 which has a dove tail like joint
system to firmly lock cladding components such as outside siding, roof planks, decking,
inside flooring, ceiling liner and wall liner to framing members eliminating direct
nailed connections, said joint being effected between say, two 38mm and 155mm planks,
one referred to as a female plank and the other as a male plank with the male plank
having a nobbed edge made by cutting rounded grooves 1.6mm deep and 6.5mm wide on
each face of the male plank 6.5mm from one of the planks edges and rounding the quarter
inch spaces between the grooves and the corner of the plank to match the rounded grooves,
and forming a narrow "s" like combination on one side and a reverse "s" on the other
side, said female plank having a 13mm deep groove cut across it which exactly matches
the nobbed edge of the male plank by under-cutting the sides of the female groove
to fit the nob edge of the male plank said female plank being bent so as to open up
its cross groove wide enough to snap over the nobbed edge of the male plank making
a very solid joint, for species of wood where the female plank is too stiff for workmen
to bend it back by cutting two saw slits in the groove and across the plank with each
saw slit being close to each side of the main groove and being deep enough to enable
a workman to bend the female plank once only to snap it over the nobbed edge of the
male plank without breaking the female plank at the groove, helped where necessary
by using a hard rubber mallet to pound the plank across the groove, said dovetail
locking joint system being also used where the planks concerned may be smaller or
larger than a 38mm x 155mm with all other mentioned dimensions being in proportion
to the dimensions of other sized planks compared to a 38mm x 155mm.
20. A kit according to Claim 19 where the species of wood concerned and the dimension
concerned do not require the two saw slits and an ordinary workman can bend the female
plank enough to snap over the nob of the male plank once without breaking the female
plank at its cross groove.
21. A kit according to Claim 20 that includes the use of a small nail that connects the
two planks together but is only meant to stop the female plank from sliding along
the nob of the male plank and is hidden from sight by being on the edge of the female
plank.
22. A kit according to any of Claims 1 to 9, or Claims 15 to 21 which contains wall and
roof panels made from similar length half bamboo logs which, when laid closely together
side by side with their half round surfaces down, are connected together with a plurality
of oval shaped cross ties that are forced into similar sized oval shaped grooves notched
out of the edges of the half bamboo logs having openings that are too small to ordinarily
admit the oval cross ties, but which can be made to open up enough to do so by bending
back the bamboo which bending is aided by saw slits in the cross grooves that weaken
the bamboo half logs enough to enable them to be bent back once, without breaking
and admit the cross ties which are tapped into place using a rubber mallet, said panels
being doubled up by forcing another similar course of half bamboo logs having their
rounded sides upward with similar edge cross grooves, one at a time, onto the inside
of the first panel and locking the edges of the second layer of half logs onto the
same oval shaped cross ties by bending each half log upward enough to let it snap
over the cross ties, said second layer of half logs each being centred over the junction
of the half logs below, said half bamboo logs having diaphragms at their nodes that
are cut down the thickness of the cross tie if they occur at the cross tie or at an
opposing diaphragm and are notched at their centre to receive the edges of the opposing
half logs and in the case of the lower half of the roof panels are slotted at centre
to the shell to drain away rain water that can come in between the upper half logs,
otherwise the cavity in the bamboo closed panel is filled with foam insulation that
would also help hold the half logs in place and together, said double layer panels
are limited in width to keep their weight to about 28 kg and are attached to beams
and other bearing with lag screws.
23. A two layer wall panel formed from a kit according to any of Claims 1 to 9, or 15
to 21 comprising tee shapes made from ordinary half logs, said tees being connected
at the top of the tees by a tongue-and-groove joint system and being formed into a
panel by at least three oval shaped cross ties, one near the top, one near the bottom
and one across the middle of the panel, said cross ties being tightly set into square
notches cut into the base of the tees right to the top members of the tees and being
firmly nailed to each tee, then individual tee pieces that have similarly spaced notches
that are oval shaped to match the oval cross ties in the other half section and having
openings that cannot fit onto the oval cross ties unless they are opened up by bending
back half logs so that they can snap over the oval cross ties one at a time, said
tees one at a time having their tops joined together by tongue-and-grooves as in the
first layer with the base of each single tee being set between two tee bases of the
first layer limiting their sideways movement and again the double layer panels are
limited in width to about 28 kg weight.
24. Ceiling panels formed from a kit according to any of Claims 1 to 9 or 15 to 21 comprising
tee shapes made from ordinary half logs, said tees being connected at the top of the
tees by a tongue-and-groove joint system and being formed into a panel by at least
three oval shaped cross ties, one near the top, one near the bottom and one across
the middle of the panel, said cross ties being tightly set into square notches cut
into the base of the tees right to the top members of the tees and are firmly nailed
to each tee, then individual tee pieces that have similarly spaced notches that are
oval shaped to match the oval cross ties in the other half section and have openings
that cannot fit onto the oval cross ties unless they are opened up by bending back
half logs so that they can snap over the oval cross ties one at a time, said tees
one at a time having their tops joined together by tongue-and-grooves as in the first
layer with the base of each single tee being set between two tee bases of the first
layer limiting their sideways movement and again the double layer panels are limited
in width to about 28 kg weight, said panels being placed with the tee bases upward
and across ceiling beams and are nailed from above onto supporting beams with nails
that are not in view, said panels being limited in width so that the panel will not
weigh over 20 kg, however, their cross ties not being oval shaped and are made to
match the grooves and serve to hold the sections of tee shapes together.
25. A roof beam formed from a kit according to Claim 9 and in the form of a three-layer
wall system according to Claim 1 except that the joints that are horizontal to the
mass of the beam are glued joints and the ends of the beam unlike the wall are capped
top and bottom with an Ee (E) shaped component which is produced by horizontally splitting
a double ayche component similar to the centre ply of the beam into two similar pieces
and which exactly cap the beam both top and bottom.
26. A building materials kit according to Claim 1 which comprises Ell (L) shaped components
that are sawn from quartered logs that have been sawn so that the cuts cross at or
close to the heart of the log with the Ell (L) shapes being cut from the quartered
log pieces at the 90° corners of the pieces of log.
27. A building materials kit for the construction or buildings or parts thereof comprising
a plurality of sections for forming a building or part thereof, said sections being
connectable to each other, a plurality of cross ties for location in grooves formed
between adjacent sections in use, said cross ties being securable to each section
with a plurality of securement means, said securement means being substantially hidden
from view on assembly of the building material kit.
28. A method of manufacturing houses or other buildings by use of a kit or panels according
to any preceding claim.
29. A method of manufacturing houses or other buildings by use of wood planks incorporating
encased tree or log hearts.