This invention relates to the manufacture and construction of wooden log structures, and in particular to the manufacture and construction of wooden log structures using logs of non-uniform shape.
Conventional construction of a log structure involves scribing the bottom of each log being placed successively above the log below to form a rising wall in such a way that it fits closely with the log that it is to be placed above. Scribing is done using various guidelines, and usually involves cutting the desired shape with a manually operated chainsaw. A disadvantage of this method is that it requires “House Logs”, which are expensive to acquire because they must be very straight with limited taper, so that they may be fitted together with a minimal amount of reshaping from the log home builder operating the chainsaw. Such persons have generally trained as a log builder under the guidance of a more experienced teacher with years of experience. Consequently, they are very highly paid workers. This “Scribe Method” for building log structures is still very slow, with only a few logs being prepared each day. This inevitably results in an expensive log structure.
Another method which is more automated involves milling sawn timbers, so the resulting pieces fit tightly together in a vertical stacked relationship. The sawn timbers are shaped to look like small logs. This method is still quite expensive, and results in difficulties in supplying electricity to the dwelling, or hiding plumbing from view. Further, the insulating capacity of the relatively thin wooden walls is relatively low.
There is thus a need for a design of a log structure that is suitable for use with logs of uneven shape, and which permits the concealment of electrical or plumbing infrastructure while providing good insulative capabilities.
The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.
A system for building a log structure is provided. A plurality of logs are provided. Each log has one pair of parallel spaced apart longitudinally extending grooves on one surface, and one pair of parallel spaced-apart longitudinally extending grooves on a second surface of the log opposite the first surface. A plurality of lumber support pieces are provided, first edges of the lumber support pieces being dimensioned to engage the grooves on the first surface of the logs, and second edges of the lumber support pieces being dimensioned to engage the grooves on the second surface of the logs. Inner edges of each groove may be tapered inwardly from the outer surface of the log towards the base of the groove. The grooves may be milled to a uniform shape, regardless of the exterior dimensions of the log. The system may include corner posts having two pairs of longitudinally extending parallel channels dimensioned to receive ends of the lumber support pieces. The system may also include an insert dimensioned to be inserted between the ends of the logs and the channels of the corner posts.
A method for building a log wall is provided. A base log having two parallel spaced apart grooves on an upper edge of the base log is provided, as are a plurality of lumber support pieces dimensioned to fit into the grooves. Each lumber support piece has upper and lower edges and ends. A plurality of logs are provided. Each log has a pair of parallel spaced-apart longitudinally extending grooves on both an upper and a lower surface of the log. A base log is positioned at the desired location of the log wall, and a lower edge of each one of a first pair lumber support pieces is inserted into one of the grooves on the upper edge of the base log. The grooves on a lower surface of a first log are inserted onto upper edges of the first pair of lumber support pieces. Lower edges of each one of a second pair of lumber support pieces are inserted into each of the grooves on the upper edge of the first log. Successive layers of logs and lumber support pieces may be added in like manner until the desired height of the log wall is achieved. The inner edges of the grooves may be provided with an inward taper from the outside of the log toward the base of the groove. The grooves may be milled to a uniform shape, regardless of the exterior dimensions of the logs.
A log structure is provided. The log structure has at least one base log with two parallel spaced apart grooves on an upper surface of the base log. Lower edges of each one of a first pair of lumber support pieces are fittingly engaged with one of the grooves on the base log. The log structure has at least one log with a pair of parallel spaced apart longitudinally extending grooves on an upper surface and on a lower surface of the log, the grooves on the lower surface of the log being fittingly engaged with upper edges of the first pair of lumber support pieces. The log structure has at least a second pair of lumber support pieces, lower edges of each one of the second pair of lumber support pieces being fittingly engaged with one of the grooves on the upper surface of the at least one log. The structure may have further layers of logs and lumber support pieces joined in like manner to provide a log wall of the desired height above each of the at least one base logs.
The structure may have at least one corner post with two pairs of longitudinally extending parallel channels dimensioned to receive ends of the lumber support pieces. First ends of all of the lumber support pieces above a first end of the at least one base log are engaged with the channels of the corner post. The structure may further include at least one insert between the ends of the logs and the channels of the at least one corner post. Spaces defined between adjacent logs and a pair of lumber support pieces may be used to run electrical wiring or plumbing, or may be filled with insulation. An inner edge of each groove may taper inwardly from the outer surface of the log towards the base of the groove. The grooves may be milled to a uniform shape, regardless of the exterior dimensions of the log.
A log wall including a plurality of logs, each log having at least one groove on an upper surface of the log and at least one groove on a lower surface of the log, and also including a plurality of lumber support pieces having edges dimensioned to engage with the grooves on the logs, is also provided. The wall is formed by alternating vertical layers of lumber support pieces and logs, such that the edges of the lumber support pieces are engaged with the grooves of the logs. A second wall portion spaced apart from and extending parallel to a first wall portion and constructed in like manner may be provided.
In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions.
Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.
Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
With reference to
An example of how grooves 24, 26 on a curved log 21 allow curved log 21 to be used in the construction of log wall 10 is shown in
Each of grooves 24, 26 has inner edges, shown respectively as 24A and 26A, and outer edges, shown respectively as 24B and 26B. Outer edges 24B and 26B are vertical or nearly vertical when log 20 is in the installed orientation. Inner edges 24A and 26A may be tapered slightly inwardly from the outside edge of log 20 toward the base of grooves 24, 26. Thus, the opening of grooves 24, 26 may be wider than the base of grooves 24, 26. In some embodiments, the angle θ between the base of the groove 24 or 26 and the inner edge 24A or 26A is 93°. The tapered inner edges of grooves 24, 26 force lumber support pieces 22 towards the outer edges 24B, 26B of grooves 24, 26. This design permits lumber support pieces 22 to be more easily inserted into grooves 24, 26, and also results in log wall 10 becoming tighter as the weight of logs 20 presses down on lumber support pieces 22. This design also has the advantage of permitting less water to leak into the joint on the outside surface of log wall 20 than would be the case if inner edges 24A and 24B were not tapered.
To form a log wall 10, a base log is provided. The base log may be formed in the same manner as logs 20, as illustrated, for example, by base log 36A in
Log wall 10 may then be built upon base log 36A, 36B or 36C by successively inserting lumber support pieces 22 into upper grooves 24 of the base log, then positioning lower grooves 26 of a log 20 over the upper edges of lumber support pieces 22. The weight of log 20, and of log wall 10 as the wall is constructed, will cause lumber support pieces 22 to be tightly inserted into grooves 24 and 26, thereby providing strength to log wall 10. Log wall 10 may be built to the desired height by likewise continuing to provide alternate layers of logs 20 and lumber support pieces 22.
A log wall 10 constructed as described above, i.e. wherein logs 20 have pairs of parallel grooves, provides an open space 40 (see
Open spaces 40 may also be insulated to a higher R factor than the wooden log itself by providing pre-cut holes (not shown) in those lumber support pieces 22 which will be on the interior of the structure. An expanding foam insulation, which may be for example Icynene™, may be blown into spaces 40, and the pre-cut holes thereafter plugged to provide a smooth interior wall surface.
In an alternative wall structure 12 shown in
If it is not necessary or desired to define an open space 55 between the wall portions of wall structure 12, then a single wall portion 52 or 54 may be constructed as described above, to serve as log wall 16, shown in
With reference to
With reference to
While in the illustrated embodiments a corner post 58 providing an approximately 90° angle has been shown to describe the construction of corner 56, it will be appreciated that corner 58 could be constructed to define other angles, depending on the desired shape of log structure 14. For example, as illustrated in
With reference to
To construct a log structure 14, an appropriate number of base logs may be positioned at the desired location of log walls 10 of the structure. Corner posts 58 providing the desired angle of intersection of log walls 10 may then be positioned at the corners 56 of structure 14, so that channels 60 in corner posts 58 are aligned with grooves 24 of base log 36. Corner posts 58 may optionally be coupled to base logs 36, for example with steel guide bolts 62 as described earlier. During construction of structure 14, corner posts 58 are preferably supported in a vertical orientation, to ensure that log walls 10 do not tilt or lean. For example, bridging pieces of lumber (not shown) may be used to secure corner posts 58 in a vertical orientation during construction of structure 14.
Lower edges of a first layer of lumber support pieces 22 may then be slid vertically down channels 60 and inserted into grooves 24. Provided that lumber support pieces 22 are longer than log 20, their ends can extend into channels 60. Of course, the ends 64 of lumber support pieces 22 should not extend past the ends of logs 20 by a length longer than the depth of channels 60. A first layer of logs 20 may then be built up by fitting grooves 26 of a log over upper edges 25 of the lumber support pieces. Successive layers of logs 20 and lumber support pieces 22 may be built up in like manner, to form walls 10 of log structure 14.
As can be seen from
Although the embodiments described above have been described with reference to building materials constructed from wood, it will be appreciated that the construction techniques described above could likewise be applied to logs 20 and support pieces 22 made from any materials suitable for constructing a structure, including metal, plastic or rubber.
Additionally, while the lumber support pieces 22 and grooves 24, 26 have been described as extending longitudinally along the length of logs 20, it will be appreciated that shorter lumber support pieces could be placed longitudinally in end-to-end relationship, continuously or discontinuously, to achieve substantially the same function. Further, while for ease of construction, lumber support pieces 22 will generally be of uniform dimensions (i.e. the width of top edge 25 will generally be the same as the width of bottom edge 27), it will be appreciated that the dimensions of edges 25, 27 could differ, provided that the dimensions of grooves 24, 26 are adjusted accordingly, without departing from the scope of the invention.
It will also be appreciated that in some embodiments, additional support may be provided to log walls 10 by, for example, providing holes that extend vertically through wall 10 and inserting structural steel through the holes. Optionally, the ends of the structural steel may be threaded, and a bolt affixed to each end, so that the bolts may be tightened over time as logs 20 shrink.
While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.