Kit for defining a recess for a single or multi-way joint

Abstract

A multi-panel kit defining one or more recesses for a structural joint. The kit including first and second panels for respectively defining first and second faces of the one or more recesses in use. One or more intermediate panels, each defining an intermediate face of at least one, of the one or more recesses in use, and one or more pairs of slots, each comprising a first slot through the first panel and a second slot through the second panel. The one or more recesses are intermediate the first and second panels, and the intermediate faces of each recess extending between the first and second faces of that recess. Each pair of slots is for receiving one of the one or more intermediate panels in use, and each of the one or more intermediate panels includes a first notch and a second notch for receiving an edge of the first slot and an edge of the second slot of a pair of slots respectively in use.

Claims

1. A structural joint, in a building frame, made from a kit, defining one or more recesses in said joint, said recesses configured to accept and attach to structural elements of said frame when portions of the structural elements of the frame are placed within the recesses and attached to said joint, the kit comprising: first and second panels for respectively defining first and second faces of the one or more recesses between the first and second panels in use; one or more intermediate panels, each defining an intermediate face extending between the first and second faces of at least one of the one or more recesses in use; one or more pairs of first and second slots, wherein each slot is contained completely within and extending through each of the first and second panels respectively, configured to receive one of the one or more intermediate panels in use; wherein, each of the one or more intermediate panels comprises first and second notches configured to receive edges of the first and second pair of slots respectively in use, and further comprising locking means located between an edge of a slot and a respective notch, for securing edges of the first and/or second slots within the first and/or second notches, so as to form an interlocked configuration of the first and second and intermediate panels; a support panel for connecting the first and second panels as a unit to one or more external structural elements outside of the one or more recesses and wherein the first and second panels each comprise a notch for receiving a portion of the support panel in use; and, wherein, the interlocked panels define the one or more recesses having said first and second faces within the joint, and which recesses are configured to receive and attach structural elements of the frame.

2. A kit according to claim 1 wherein the first, second and intermediate panels are substantially flat.

3. A kit according to claim 1 wherein the first and second panels are identically shaped.

4. A kit according to claim 1 wherein the arrangement of first slots through the first panel is identical to the arrangement of second slots through the second panel.

5. A kit according to claim 1 wherein the first and second slots are substantially rectangular.

6. A kit according to claim 5 wherein the width of each of the rectangular first and second slots is equal to the thickness of each of the intermediate panels.

7. A kit according to claim 1 wherein the first and second notches are substantially rectangular.

8. A kit according to claim 7 wherein the width of each of the rectangular first and second notches is equal to the thickness of each of the first and second panels.

9. A kit according to claim 1 wherein the one or more intermediate panels is a plurality of intermediate panels.

10. A kit according to claim 1 wherein there is a plurality of pairs of first and second slots through each of the first and second panels.

11. A kit according to claim 1 wherein the first and second notches in each of the one or more intermediate panels are defined by generally L-shaped extensions from a square or rectangular portion of the intermediate panel.

12. A kit according to claim 1 wherein the support panel comprises a notch for receiving a portion of the first panel in use and a notch for receiving a portion of the second panel in use.

13. A kit according to claim 1 wherein the at least one locking means is an element for fitting into one or both of the first and second slots of the first and second panels between the one or more intermediate panel received therein and the edge of the one or both slots opposite the edge of the slot received by the notch of the intermediate panel in use.

14. A kit according to claim 1 wherein the locking means is of equal dimensions to one of the first and second notches.

15. A kit according to claim 1 formed from engineered timber, steel, concrete, glass reinforced plastic, plastic, carbon fibre, and/or carbon fibre augmented materials.

16. A unit constructed from a kit according to claim 1 which defines one or more recesses.

17. A system comprising a plurality of kits according to claim 1.

18. A corner unit joint within a structure made from structural elements, the unit comprising: first and second L-shaped corner frame elements defining at least two limbs, each limb having at least one aperture contained completely within said limb, each aperture being dimensioned and configured to receive a stave whereby staves locate in corresponding apertures to connect the respective limbs, and include locking means located between an edge of an aperture and a respective stave, for securing edges of the apertures against said stave, and thereby maintain the frame elements parallel to each other such that outer edges of the frame elements define planes which in use are parallel to walls of the structure, wherein respective opposed faces of the frame elements and a face of at least one of the staves connected therebetween, form three sided recesses configured to receive and attach structural elements of the structure within the recesses.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIG. 1 is an overall view of an unassembled kit according to the present invention for constructing a unit defining two recesses for joints at right angles to each other;

(2) FIG. 2 is a first overall view of a unit constructed from the kit of FIG. 1;

(3) FIG. 3 is a second overall view of the unit of FIG. 2;

(4) FIG. 4 is a third overall view of the unit of FIG. 2;

(5) FIG. 5 is an overall view of an unassembled kit according to the present invention for constructing a unit defining three recesses for joints;

(6) FIG. 6 is an overall view of a unit constructed from the kit of FIG. 5;

(7) FIG. 7 is a partial view of a unit partially assembled from the kit of FIG. 5;

(8) FIG. 8 is an overall view of an unassembled kit according to the present invention constructing two small recesses for joints at right angles to each other;

(9) FIG. 9 is an overall view of a unit constructed from the kit of FIG. 8;

(10) FIG. 10 is a plan view of one of the upper and lower panels of the kits of FIGS. 1 and 8;

(11) FIG. 11 is a plan view of one of the upper and lower panels of the kit of FIG. 4;

(12) FIG. 12 is a plan view of one of the intermediate panels of the kits of FIGS. 1 and 4;

(13) FIG. 13 is a plan view of the support panel of the kits of FIGS. 1 and 4;

(14) FIG. 14 is a plan view of one of the intermediate panels of the kit of FIG. 8;

(15) FIG. 15 is a plan view of the support panel of the kit of FIG. 8; and

(16) FIG. 16 is a plan view of a locking means for the kits of FIGS. 1, 4 and 8;

(17) FIG. 17 is an overall view of a ridge support for use with kits according to the present invention;

(18) FIG. 18 is an overall view of a rafter hanger for use with kits according to the present invention; and

(19) FIG. 19 is an overall view of a joist hanger for use with kits according to the present invention.

DETAILED DESCRIPTION OF THE FIGURES

(20) Referring to the figures generally there are shown multi-panel kits 100,200,300 according to the first aspect of the present invention and units 101, 201, 301 constructed from the kits 100, 200, 300. The units 101, 201, 301 each define a plurality of recesses 180 for receiving other structural elements so as to define joints.

(21) FIG. 1 shows a first multi panel kit 100 for constructing a unit 101 with recesses 124 at right angles to each other. The kit 100 comprises two identical panels 110, two identical intermediate panels 140, and a support panel 160.

(22) The panels 110 are identically shaped flat panels of constant thickness which are arranged horizontally, parallel and one above the other when the kit is assembled in use. The upper and lower panels 110 are generally L-shaped and comprises two generally rectangular arm portions 122 extending at right angles to each other.

(23) Two elongate rectangular slots 124 are formed through each of the upper and lower panels 110. The slots 124 are each located within and parallel to one of the two arm portions 122, such that the two slots are at right angles to each other.

(24) A single elongate rectangular notch 126 is formed in an edge of each of the upper and lower panels 110, 120. Each rectangular notch 126 is parallel to and aligned with one of the two slots 124 of its panel 110 and perpendicular to the other slot 124 of the other panel 110. The notches 126 are therefore formed in an edge of each of the upper and lower panels 110 in the corner between the two extending arm portions 122.

(25) In use, the slots 124 through the upper and lower panels 110 define two pairs of slots 124, each comprising a first upper slot 124 and a second lower slot 124. In use the first upper slot 124 of each pair is arranged directly above and parallel to the second lower slot 124 of the pair, and each pair of slots receives and holds one of the intermediate panels 140.

(26) A corner kit comprises two intermediate panels 140 which are identically shaped flat panels of constant thickness which are arranged vertically in use, each within one of the pairs of slots 124.

(27) The intermediate panels 140 each comprise a generally square central portion 142 which in use is arranged between the upper and lower panels 110 and two generally L-shaped outer portions 144 which fit into and through the pair of slots 124 which receive the intermediate panel 140. Each of the two L-shaped outer portions 144 defines a notch 146 between itself and the central portion 142, the closed base end of the notch 146 being approximately half along the length of the L-shaped portion 144 and of the central portion 142.

(28) The lengths of the L-shaped outer portions 144 are substantially equal to the lengths of the slots 124 through the first and second panels 110 such that the outer portions 144 can be inserted through the slots 124 with the intermediate panel 140 orthogonal to the first and second panels 110 such that the notches 146 are coplanar with the first and second panels 110.

(29) In use the intermediate panels 140 are inserted into the slots 124 with the open ends of their notches 146 facing towards the ends of the arm portions 122 in line with or at right angles to the first or second panel's central notch 126.

(30) The length of the central portion 142 of each intermediate panel 140 in the direction of the length of that intermediate panel's notches 146 is greater than that of the L-shaped portion 144 and of the upper and lower slots 124. Consequently, the central portion 142 of the intermediate panels 140 is too large to fit through the slots 124 of the upper and lower panels 110.

(31) As a consequence of the difference in length between the central portion 142 and the outer portions 144 of the intermediate panel 140, the outer portion of the intermediate panel 140 has indented corners 148 at one end of the outer portion 144. The indented corners 148 comprise rectangular indents 146 with edges parallel and/or at right angles to the edges of the intermediate panel 140. The indented corners 150 define shoulders on the edges of the central portion 142 on the closed side of the L-shaped portion 144. When the L-shaped outer portions 144 of the intermediate panel 140 are inserted into the upper and lower slots 124, the shoulders 150 will abut the lower face of the upper panel 110 and the upper face of the lower panel 110, thereby preventing the central portion 142 of the intermediate panel from being displaced into the slot 124 and aligning the notches 146 of the intermediate panel 140 with the first and second panels 110.

(32) After the intermediate panel 140 has been inserted into the slots 124 of the first and second panels 110, the intermediate panel 140 may be slid lengthways within the panels such that the open ends of the notches 146 in the intermediate panel 140 are slid into the slots 124 until the end of the slot 124 contacts the base of the notches 126. As such a portion of each of the first and second panels 110 parallel to and extending from the end of the slots 124 towards the end of the arm portion 122 comprising the slot will be received within the notch 146. The intermediate panel 140 thereby interlocks with the first and second panels 110 at right angles to them.

(33) The thickness of the intermediate panel 140 is substantially equal to the width of the slots 124 through the first and second panels 110 and the thicknesses of the first and second panels 110 are substantially equal to the width of the notches 146 in the intermediate panel 140. As such the intermediate panel 140 is unable to rotate within the slots 124 and the first and second panels are unable to rotate within the notches 146, therefore the intermediate panels 140 are held and maintained at right angles to the first and second panels 110.

(34) The length between the edge of the central portion 142 of the intermediate panel 140 at the open end of the notches 146 and the closed base end of the notches 146 (which is the length of the interior lengthwise edge of the notch 146 plus the length of a shoulder 150 of the intermediate panel 140) is equal to the length between the end of each of the arm portions 120 of the upper and lower panels 110 and the closest end of the slot 124 aligned with and formed through that arm portion 120. As such, when this end of the slots 124 is slid into the notch 146, the edge of the central portion 142 of the intermediate panel 140 is aligned with the end edge of the arm portion 122 of the first and second panels with which it interlocks.

(35) In use, each of the intermediate panels 140 interlocks with an arm portion 122 of the upper and lower panels 110 to define an arrangement with an “F”-shaped profile and cross-section when viewed along the length of the notches 146 and slots 124. As such, each intermediate panel 140 and upper and lower arm portion 122 defines two]-shaped recesses 180, each with a first upper face defined by the upper panel 110, a second lower face defined by the lower panel 110 and an intermediate face extending between the upper and lower faces defined by the intermediate panel 140.

(36) In use, external structural elements, such as the ends of beams may be inserted into one of the recesses 180 defined between each upper and lower arm portion 122 and secured therein so as to define joints. Such external structural elements are preferably dimensioned to substantially fill the recess and to contact the upper, lower and intermediate faces of the recess 180 face to face. The assembled unit 101 may therefore interconnect two such external structural elements at right angles to each other.

(37) In the one of the illustrated embodiments, the two intermediate panels 140 each comprise four circular apertures 152 extending through their central portions 142. In use, bolts may be arranged to extend through the apertures and corresponding apertures in external structural elements received within the recesses 180, so as to secure the external structural element within the recess. The four illustrated apertures 152 are arranged in a square arrangement. It is envisaged that the intermediate panels may be provided without apertures (for example, such that screws may be used to secure external structural elements within the recesses) or with a different number or arrangement of apertures.

(38) The kit comprises a single support panel 160 for securing the assembled unit 101 to external structural elements outside of the recesses 180 defined between the first upper and second lower panels 110, 120. In particular, the support panel is for securing the unit 101 to vertical structural elements at right angles to those received within the recesses 180 (such as posts or columns used in framing operations).

(39) The support panel 160 is a flat substantially rectangular panel of constant thickness which is arranged vertically in use orthogonal to the first panel 110, the second panel 110 and one of the intermediate panels 140, and coplanar with the other of the intermediate panels 140.

(40) The support panel 160 comprises two parallel elongate rectangular notches 162 formed in one of the long edges of the panel 160. In the illustrated panel each of the notches 162 is formed approximately one-third of the way along that edge from opposite ends of the panel 160, such that the support panel comprises a substantially square central portion 164 between the two notches 162 and two substantially square outer portions 166 each on the opposite side of one of the notches 162 from the central portion and at opposite ends of the panel 160. The separation between the notches 162 of the support panel 160 being equal to the separation between the notches 146 of the intermediate panels 140.

(41) Alternative support panels and intermediate panels with different separations between their notches may be substituted for the intermediate and support panels 140, 160 so as to define recesses 180 of different sizes. Such an arrangement is shown in FIG. 9 with smaller intermediate panels 240 and a smaller support panel 260.

(42) In use the central portion is located between the first and second panels 110, one of the outer portions 166 is located on the far side of the first panel 110 from the second panel 110 (above the first panel 110 as shown in FIG. 2) and the other of the outer portions is located on the far side of the second panel 110 from the first panel 110 (below the second panel 110).

(43) Apertures 168 for bolts are formed through each of the central and outer portions 163, 166 of the illustrated support panel 160 in square or offset square arrangements. In another embodiment the support panels may be provided without apertures (for example, such that screws may be used to secure external structural elements to the panel) or with a different number or arrangement of apertures.

(44) In order to assemble the kit, the support panel 160 is arranged orthogonally the first and second panels 110 and is inserted into the notches 126 in the first and second panels 110 such that the closed base ends of the notches 126 in the first and second panels 110 contact the closed base ends of the notches 162 in the support panel. The notches in the first, second and support panels 110, 160 consequently define joints known as halved joints, cross lap joints or edge lap joints.

(45) In the assembled configuration portions of the first and second panels extending from the ends of the notches 126 are received within the notches 162 of the support panel and portions of the support panel extending from the ends of the notches 162 are received within the notches 126 of the first and second panels. As such the support panel 160 is unable to rotate within the notches 126 and the first and second panels are unable to rotate within the notches 162, therefore the support panel 160 is held and maintained at right angles to the first and second panels 110.

(46) External structural elements, such as the ends of beams may be received within the recesses 180 and secured therein (for example, using bolts passing through the apertures 152 through the intermediate panel 140) so as to define joints. A beam received by the recess 180 with an intermediate face parallel to the support panel 160 may be arranged extending through the recess 180 such that its end is adjacent and face to face with the central portion 164 of the support panel 160, to which it may be secured (for example by bolts passing through apertures 168). Such an arrangement may advantageously prevent the support panel from becoming displaced away from the intermediate panel 140 and out of the notches 126 in the first and second panels 110.

(47) Other external structural elements, such as posts, columns or rafters may be secured face to face to the outer portions 166 of the support panel 160. For example, by bolts passing through apertures 168.

(48) FIGS. 2 to 4 show overall views of the kit 100 assembled to define a unit 101 with recesses 180 at right angles to each other.

(49) FIG. 5 shows a second multi panel kit 200 for constructing a unit 201 with recesses in a T-shaped arrangement. The kit 200 comprises a first upper panel 210, a second lower panel 220, three intermediate panels 140, and a support panel 160.

(50) The three intermediate panels 140 are identical to the two intermediate panels 140 of the first multi-panel kit 100 described above and the support panel 160 is identical to the support panel 160 of the first multi-panel kit 100 described above with reference to FIGS. 1 to 4.

(51) The first upper panel 210 and second lower panel 210 are similar to the upper and lower panels 110 of the first multi-panel kit 100 described above with reference to FIGS. 1 to 3 but differ in that they comprise three arm portions 222 and three slots 224 in a T-shaped arrangement.

(52) The upper and lower panels 210 are identically shaped flat panels of constant thickness which are arranged horizontally, parallel and one above the other when the kit is assembled in use. Each of the upper and lower panels 210 is generally T-shaped and comprises three generally rectangular arm portions 222 extending from a central intersection point, two of the arm portions 222 extend parallel to each other in opposite directions from the intersection point and the third extends at right angles to the other two.

(53) Three elongate rectangular slots 224 are formed through each of the upper and lower panels 210. The slots 224 are each located within and parallel to one of the three arm portions 222, such that the two slots are parallel and aligned with each other and the third is at right angles to the other two.

(54) A single elongate rectangular notch 226 is formed in an edge of each of the upper and lower panels 210. Each rectangular notch 226 is located at right angles to and between the two parallel slots 224 such that it is parallel to and aligned with the third slot 224 of its panel 210. The notches 226 are therefore formed in an edge of each of the upper and lower panels 210 at the intersection point of the three arms 222.

(55) In use, the slots 224 through the upper and lower panels 210 define three pairs of slots 224, each comprising a first upper slot and a second lower slot. and each pair of slots 224 receives and holds one of the intermediate panels 140.

(56) In use the first upper slot 126 of each pair is arranged directly above and parallel to the second lower slot 126 of the pair, and each pair receives and holds a support panel 160.

(57) The second kit 200 is assembled in the manner as the first kit 100 so as to define a unit 201 with three pairs of recesses in a T-shaped arrangement. FIG. 6 shows the second unit 201 fully assembled.

(58) FIG. 8 shows a third multi-panel kit 300 for constructing a unit 301 with recesses 180 at right angles to each other, the recesses 180 defined by the unit 301 being smaller than the recesses defined by the units 101 constructed from the kits 100 for timber such as 145 mm×45 mm, and 200 which could be for timber sizes of 95 mm×45 mm described above. The kit 300 comprises a first upper panel 110, a second lower panel 110, two intermediate panels 240 and a support panel 260.

(59) The first upper and second lower panels 110 are identical to those of the first kit 100 described above with reference to FIGS. 1 to 4.

(60) The intermediate panels 240 and the support panel 260 are similar to the intermediate and support panels 140, 160 of the kits described above with reference to FIGS. 1 to 7 but differ in that their central portions 242, 264 between their notches 246, 262 are smaller rectangular portions with two apertures 252, 268 therethrough rather than being larger substantially square portions 142, 162 with four apertures 152, 168 therethrough. The first upper and second lower panels 110 are therefor held closer together when the unit 301, which is shown in FIG. 9, is assembled. The unit 301 therefor defines smaller recesses 180 for receiving smaller beam ends such as 75 mm×45 mm.

(61) The smaller intermediate and support panels 240,260 may also be used with the T-shaped upper and lower panels 210 of the second kit 200 described with reference to FIGS. 5 to 7 so as to define a fourth kit with smaller recesses in a T-shaped arrangement.

(62) FIGS. 10 to 15 show the panels 110, 120, 140, 160, 210, 220, 240, 260 of the kits described above in detail.

(63) FIG. 16 shows an optional locking means 800 which may be inserted into the slots 124, 224 of the upper panel 110 of a unit as described above 101 such that it is supported on the shoulder 150, 248 of the intermediate panel 140, 240 received within that slot 124. The locking means is in the form of a cuboid block of substantially equal dimensions to the interior of the notch 146, 246 of the intermediate panel 140, 240, such that it fills the portion of the slot 124, 224 which is not filled by the outer portion 144, 244 of the intermediate panel 140, 240. As such the intermediate panel 140, 240 is prevented from sliding within the slot 124, 224 and as such is locked within the slot 124, 224 as a consequence of the portion of the first panel 110 received within its notch 146, 246.

(64) Multiple kits 100, 200, 300 may be provided together as a system for constructing a structure such as a shed. For example, such a system may comprise eight kits for constructing L-shaped corner joints such as the kits 100, 300 described with reference to FIGS. 1 to 4 and FIGS. 8 and 9, which in use may define the vertices of a rectangular structure; an additional four kits for constructing T-shaped joints such as the kit 200 described with reference to FIGS. 5 to 7 could be provided so as to extend the structure.

(65) Such systems may further comprise ridge supports 400, joist hangers 420 and/or rafter hangers 440. Examples of such additional components are shown in FIGS. 17 and 18.

(66) FIG. 17 shows a multi-panel ridge support comprising a primary panel 402 which is arranged vertically in use and two secondary panels 404 which are received in slots 406 in the primary panel 402. The secondary panels 404 comprise notches 408 defined by L-shaped portions which each receive an edge of the slot 406 receiving them. The secondary panels define a sloped surface orthogonal to the primary panel which supports the upper end of a rafter in use.

(67) The primary panel 402 is substantially pentagonal and comprises an upper notch 410 for receiving and supporting a ridge board. A pair of apertures 412 for bolts are provided adjacent and above each slot 406 for connecting rafters supported by the secondary panels 404 to the primary panel 402. Four further apertures 412 are formed through the primary panel below the notch 410 for connecting to a column post or stud in use.

(68) FIG. 18 shows a multi-panel joist hanger 420 and FIG. 19 shows a multi-panel rafter hanger 440. The joist hanger 420 and rafter hanger 440 each comprising a primary vertical panel 422, 442 and a secondary horizontal panel 424, 444. The primary vertical and secondary horizontal panels 422, 424, 442, 444 each comprising a notch 426, 446 which defines a halved joint with the notch 426, 446 of the other panel in use. The vertical panels 422, 442 having apertures 428, 448 formed therethrough for connecting to other structural elements.

(69) Throughout the detailed description the terms upper lower, above and below have been used to describe the relative locations of the components of the kits 100, 200, 300 and units 101, 201, 301. It will be appreciated that the kits 100, 200, 300 and units 101, 201, 301 may be reoriented or used at other angles without departing from the scope of the invention.

(70) Any variations of timber depth can be provided for. In practice, European timber sizes are standard throughout the region and many other parts of the world. In the United States the timber sizes differ from European sizes, but are standard throughout the United States.

(71) The invention has been described by way of example only and it will be appreciated that variation may be made to the above described embodiments without departing from the scope of the invention as defined by the claims.