Patent Grant
7444786
The invention relates generally to structures composed of log elements. Specifically, the invention relates to structures composed of cast log elements that provide enhanced appearance, structural integrity, insulative properties, and ease of assembly.
Log structures have been instrumental in the history of many cultures. As a result, such structures have become symbolic in many places, going beyond mere shelter and into the realm of cultural icon. Log structures, specifically log homes, have therefore become desirable due not only to their natural beauty, but because of their historical and cultural feel as well.
Unfortunately, log construction is not particularly well adapted to modern building standards. Log structures are often dark and closed-in by modern standards, and have a tendency to “settle” as the logs age. Furthermore, log construction fails to provide the insulation values available in standard modern construction methods.
It can thus be expected that the improvement of log structures, and the emulation of certain aspects of log structures using alternative materials, has been the subject of inventive activity. For example, U.S. Pat. No. 4,503,648 to Mahaffey is directed to a lightweight composite building module capable of being readily attached to other correspondingly shaped modules for providing a wall of a building. The module includes a pair of spaced elongated wooden side boards joined by a wooden top board. The side boards have right angle cutouts removed from the inside corners thereof producing upper and lower horizontally extending ledges. Polyurethane foam is provided in the cavity defined by the side boards and top boards with said foam extending below the lower horizontally extending ledges. Elongated wooden bolts extend between the top boards of adjacent stacked modules drawing said modules tightly together under compression so that the top board of the next lower module compresses the foam extending below the lower horizontally extending ledges of the module carried directly therebelow producing a rigid sealed joint therebetween.
U.S. Pat. No. 5,163,259 to Hunsaker et al. discusses a modular building component made of solid wood, capable of being fitted onto other correspondingly shaped modules to provide a wall of a building. The module includes a core made of horizontally laminated wood with a lengthwise groove cut along the top and vertically at one end for utility purposes, to which side boards are attached in a manner which allows each module to lock into adjoining modules both vertically and horizontally. The upper edges of side boards are attached a short space from the top of the core, the lower edges extending past the bottom of the core, creating both a male and female fitting for adjoining modules. In the same manner side boards are offset a short space from one end of the core and extend past the core at the opposite end to allow the ends of modules to lock as well. The side boards are attached at the factory with adhesive bonding material and secured with fasteners. To form walls, the modules are stacked a row at a time and locked together using adhesive and metal fasteners for which holes have been pre-drilled in the laminated cores.
In another example, U.S. Pat. No. 4,433,519 to Jenkins shows a hollow cylindrical prefabricated modular construction element formed by generally circular supports and a sheath. These hollow cylinders are connected, using simple carpentry tools, at a building site to create walls, having a simulated log appearance.
U.S. Pat. No. 4,288,954 to O'Donnell is directed to simulated log siding in which wire metal lath is shaped to the generally semicircular configuration associated with a length of log used in a log wall structure. Several layers of cement-plaster are applied to the metal lath to waterproof it, and to lend texture and color to it. The effect of the layered and colored cement-plaster is to render the appearance of an actual log with its bark in place. A simulated log wall siding is made up of multiple lengths of such cement-plaster coated, simulated logs.
U.S. Pat. No. 3,552,079 to Mortensen discusses a building element including a panel-shaped insulating material extending between two timber half-beams, the whole element being formed as a beam with one or more tongues and grooves and with the insulating material extending in the full height of the beam from the bottom of a groove or surface between two tongues to the opposite edge of the beam, and an angle joint between two walls made of building elements having notches round a neck section for mutual connection of the elements.
While each of these patents show some advantages, it can be seen from the foregoing that the need exists for a simple, inexpensive construction system that provides the aesthetic advantages of log structures without sacrificing the functional advantages of modern building practices and materials.
All patents, patent applications, provisional patent applications and publications referred to or cited herein, are incorporated by reference in their entirety to the extent they are not inconsistent with the explicit teachings of the specification.
A structural system includes a plurality of pre-cast structural elements. Each of the elements includes an interior layer and an exterior layer cast of cementitious material, and an insulating layer between the interior layer and the exterior layer. The pre-cast structural elements are stacked adjacent to one another to form a wall. As the structural elements are stacked, respective cushions are placed between adjacent structural elements. The cushions create airspaces such that there is no direct surface contact between adjacent structural elements. Stacked elements are tied together with poured grout sleeves to create a composite structure. Grout from the sleeves form bearing pads between elements. These grout sleeves and pads allow for lateral and gravity force transfer throughout the composite. The exterior layers of the structural elements can be provided with simulative exterior surfaces, for example, with exterior surfaces simulating the appearance of structural logs.
A structure 10 in accordance with the principles of the present invention is shown in
Each wall 12 of the structure 10 is made up of a plurality of structural elements, joined together as are structural elements 14, 16, and 18 shown in
As seen in
The structural elements 14 includes an interior layer 28, and exterior layer 30, and an insulating layer 32 between the interior layer 28 and the exterior layer 30. The interior layer 28 and the exterior layer 30 can be fabricated by being cast from a cementitious material, such as concrete, and can be held together in a conventional manner, such as by connector rods as described previously. The insulating layer 32 can be fabricated from any known, suitable insulation material as previously mentioned.
A cushion or shim 34 is located between the first structural element 14 and the second structural element 18. The cushion 34 creates an airspace 36 such that there is no direct surface contact between the adjacent structural elements 14, 18. Undesigned contact between adjacent structural elements creates point loading which causes the concrete elements to crack. Preferably, cushions are placed near the ends of each element and are place directly over one another. This provides temporary spacing for each structural element in the stack and insures that each element supports no more than its own weight. Cushions or shims can be made of any non-compressible material including, but not limited to, metal and plastic. In a preferred embodiment, the shims are four inch by four inch square non-compressible rubber disks.
In an alternate embodiment, the cushion 34 includes first and second elongated, resilient cushion elements, 38, 40 extending along a length of the structural elements 14, 18. The first cushion element 38 is secured between the exterior layer 30 of the first structural element 14 and the exterior layer 22 of the second structural element 18. The second cushion element 40 is secured between the interior layer 28 of the first structural element 14 and the interior layer 20 of the second structural element 18.
Flexible synthetic chinking material 42 can be applied between the exterior layer 30 of the first structural element 14 and the exterior layer 22 of the second structural element 18 at a position outside of the first cushion element 38. Fill material 44, which can be identical to the chinking material 42, can be applied between the interior layer 28 of the first structural element 14 and the interior layer 20 of the second structural element 18.
As seen in
The structural elements are secured together at bearing points, here illustrated as grout sleeves 50, 52 extending through the corner joints of the structural elements (
Grout sleeves 50, 52 are formed within the pre-cast layers and preferably the interior, structural layer 28 with pipe material. Piping can be any suitable material including metal pipe and polyvinyl chloride pipe. Sleeve 50 in element 14 is aligned with sleeve 60 in element 18. In a particularly preferred embodiment, a malleable gasket 62 is placed between adjacent elements around the sleeves of each element. When high strength grout is poured or pumped into the aligned sleeves, the gasket dams the grout to form a positive load bearing pad 64. The grout sleeves and bearing pads address tension and shear stress experienced by the composite structure from, for example, high winds or seismic activity. Additionally, the grout sleeves and bearing pads provide gravity load bearing throughout the structure compensating for, for example, a heavy roof snow load. The subject system therefore resists all forces addressed by present day building codes.
The interior and exterior layers of the structural elements can be fabricated from cast concrete material, and can be provided with simulative exposed surfaces. In the illustrated embodiment, the exterior surfaces of the structural elements simulate the appearance of hand-hewn structural logs, including end surfaces 54 (
Walls assembled in accordance with the principles of the present invention are nearly 100% insulated. It is contemplated that their energy efficiency will far surpass that of “real” log structures and other conventional building systems, due to their provision of an interior heat sink. The structural elements can be assembled on site using standard construction equipment in a manner similar to that used in traditional log construction.
Although the present invention has been described with reference to specific embodiments, those of skill in the art will recognize that changes may be made thereto without departing from the scope and spirit of the invention as defined by the appended claims.
This application is a continuation-in-part of application Ser. No. 09/953,678, filed Sep. 15, 2001 now U.S. Pat. No. 6,851,233. The disclosure of this application is hereby incorporated by reference in its entirety, including all figures, tables, and drawings.
| Number | Name | Date | Kind |
|---|---|---|---|
| 1574636 | Sutiter | Feb 1926 | A |
| 1925103 | Loftus et al. | Sep 1933 | A |
| 3462905 | Mordchelles-Regnier et al. | Aug 1969 | A |
| 3552079 | Mortensen | Jan 1971 | A |
| 3902296 | Thomas | Sep 1975 | A |
| 4288954 | O'Donnell | Sep 1981 | A |
| 4344263 | Farmont | Aug 1982 | A |
| 4356676 | Hauptman | Nov 1982 | A |
| 4433519 | Jenkins | Feb 1984 | A |
| 4503648 | Mahaffey | Mar 1985 | A |
| 4936062 | Golston et al. | Jun 1990 | A |
| 5163259 | Hunsaker et al. | Nov 1992 | A |
| 5349798 | Gross | Sep 1994 | A |
| 5519973 | Keith et al. | May 1996 | A |
| 5782050 | Boeshart | Jul 1998 | A |
| 5802792 | Fielding et al. | Sep 1998 | A |
| 6266934 | Houseal | Jul 2001 | B1 |
| 6272802 | Berberich | Aug 2001 | B1 |
| 6851233 | Morgenstern | Feb 2005 | B2 |
| Number | Date | Country | |
|---|---|---|---|
| 20050000176 A1 | Jan 2005 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 09953678 | Sep 2001 | US |
| Child | 10887596 | US |
