Patent Grant
8789325
This application claims the benefit of Belgian patent application No. 2010/0744, filed Dec. 16, 2010, which is hereby incorporated by reference in its entirety.
This invention concerns a wall assembly for the construction of a wall element, comprising:
Such wall assemblies most often are part of structures that are constructed from massive timber construction. Such massive timber construction is a building method in which wooden beams are stacked on each other to produce a structure such as a building. These structures can be, for example, chalets, saunas, weekend houses, houses, summer houses, swimming pools, fences, caravans, and so on.
By profile is meant an elongated element having substantially the same cross section over its length.
A known problem with massive timber construction is that by expansion and shrinkage of the beams a wall assembly of approximately 2 meters (6.6 ft.) height can sink by as much as 3 cm (1.2 in) over the course of time, due to the cumulative height shrinkage of the beams stacked on each other. In the case of a sauna, where greater temperature fluctuations occur and the relative humidity fluctuates greatly, a sauna cabin can even sink by as much as 5 cm (2 in) along its height.
A major drawback here is that doors and windows can become heavily loaded by beams that are stacked on them and no longer supported by underlying beams. These doors and windows can become warped or can no longer be opened or closed under this load. A further drawback is that it is not expected of the working of a building etc. that a wall assembly can settle by as much as 3 cm (1.2 in).
Where a roof or a mezzanine is not supported by the walls that are constructed from stacked beams, cracks are also produced, making the structure leaky. In the case of saunas, heat escapes through these cracks, so that great energy losses result.
A number of partial solutions to these problems have already been found.
For sauna and chalet structures, one often tries to fix the beams at their initial height by securing them with the help of screws or pegs, for example, to profiles that extend vertically along either side of the stacked beams as the ends of a wall element. However, in the course of time shrinkage of the beams often causes cracks to appear between these beams, that are now no longer supported by each other, but only supported by these screws and pegs. A major disadvantage of fixing the beams at their initial height in this way is that an extra space is in each case required at the ends of a wall element and next to this wall element in order to be able to secure these beams with these screws or pegs. In order to be able to mount a sauna with a base of 2 m (6.6 ft.) by 1.5 m (4.9 ft.), one needs an installation surface of 4 m (13 ft) by 3.5 m (11.5 ft.) in this way, taking into account the fact that one needs a space of approximately 1 m (3.3 ft.) width around the sauna in order to be able to fix the beams at their initial height with screws or pegs. After the assembly is complete, one then still has to succeed to move the assembled structure to the desired position.
One solution for which no such assembly space is required is to stack the beams on each other across rafters, after which the beams are pulled against each other by means of a tension rafter, so that they are already placed under tension from the start. In practice, however, these beams need to be able to be tensioned to a greater or lesser extent afterwards. Such structures can be used, for example, for swimming pools, but are least suited for saunas or chalets where doors and windows are provided. This solution cannot remedy the mentioned problems resulting from expansion and shrinkage of the beams.
To further remedy these problems in past, one will provide the tension rafters with built-in clamping spring systems as described in DE 38 04 525 A1 and in DE 20 2006 008 U1, with the springs having to ensure a tightening of the beams in case of shrinkage and a relaxation in case of swelling.
As an alternative to remedy the problem of installation space, one can prefabricate massive panels, as described for example in DE 197 39 787 A1. With such a solution, however, everyone needs to keep the temperature and humidity under control during the process. Yet problems resulting from expansion or shrinkage can occur whenever sufficient attention is not paid to the temperature and humidity of the surroundings during transport, storage or delivery.
In DE 198 41 359 C1, a solution is described whereby, according to the preamble of the first claim, the beams themselves are not fixed at their initial height with screws or pegs, but instead fixed wooden rails are placed between the beams and between the profiles, each being fixed at a particular height to these profiles with screws. However, wall elements need to be mounted in advance in order to avoid having to have a space of around 1 m (3.3 ft.) width around a sauna in order to be able to place these elastic positioning elements between the beams with this solution. But because the beams are provided with a groove on two sides, this solution is not suitable for outdoor structures. For precipitation will get into the grooves at the top of the beams and considerably shorten the lifetime of the structure.
The purpose of this invention is to provide a connection system whereby the aforementioned problem is remedied. The purpose is therefore substantially to provide a solution that neutralizes the natural dimensional variations due to shrinkage and/or expansion in such a wall assembly.
This purpose of the invention is achieved by providing a wall assembly for the construction of a wall element comprising:
Thanks to the positioning elements, the height differences for every beam are prevented from accumulating in the event of expansion or shrinkage of the beams, so that large height differences for every wall element no longer occur. The beams can indeed shrink or expand in themselves, without departing from their initially assigned positioning.
Positioning elements that do not extend over the complete length between the profiles, but only extend substantially between positioning ends of the beams, can be secured to the profile from its side against which the beams extend in the mounted state of the wall element, so that extra installation space in the prolongation of the wall element is no longer required to be able to mount this wall element.
Each positioning element is therefore preferably configured so as to be able to be fastened to a profile from the side of the profile against which the beams extend in the mounted state of the wall element.
Preferably, the positioning elements in the mounted state of the wall element extend only between the respective positioning ends of the two beams stacked one on top of the other, so that the beams can adjoin each other as tightly as possible when stacked on each other. When the beams have coinciding dimensions, the height of these positioning elements is then preferably smaller than or equal to the net construction height of a beam, minus the height of its positioning end.
The positioning elements of such a wall assembly are preferably rigid.
In order to be able to assemble a wall element firmly without needing additional fastening means, besides the fastening means that may be used to be able to secure the positioning elements to the profiles, each profile in a preferred embodiment of a wall assembly according to this invention is provided with a slot, in which the respective positioning ends of the beams can be at least partly disposed and in which the positioning elements can be at least partly disposed.
Preferably, then, each profile is provided at least at one end with an entry opening to the aforesaid slot, by which the positioning ends and the positioning elements can be at least partly arranged in this slot. In this way, when mounting a wall element, one can first place the profiles in their correct position, after which one can alternatingly arrange the positioning ends of the beams and the corresponding positioning elements in the slots of the profiles one by one, so as to arrange the beams between these profiles. Also when arranging the positioning elements these are preferably secured to the corresponding profile at the theoretical building height.
Again to achieve a firm structure, the cross section of the positioning ends is preferably complementary to the cross section of the slot.
By complementary is meant that the cross section of the positioning ends and the cross section of the slot are matched to each other, so that the cross section of the positioning ends is somewhat smaller than the cross section of the slot and can be fully taken up in it.
In order to be able to provide maximum support to the positioning ends and thereby also be able to provide maximum support to the beams, the cross section of the positioning elements is preferably complementary to the cross section of the slot.
By complementary is meant that the cross section of the positioning elements and the cross section of the slot are matched to each other, so that the cross section of the positioning elements is somewhat smaller than the cross section of the slot and can be fully taken up in it.
In one specific embodiment of a wall assembly according to this invention, each profile is provided with flanges that partly bound the aforesaid slot, so that they delimit a through opening to this slot.
Each positioning end is then preferably configured at least in part broader than the width of the through opening, in which case the profile then comprises an aforesaid entry opening so that this positioning end cannot be moved in and out of the slot through this through opening, but only via the aforementioned entry opening.
To realize an especially firm fixation of the positioning elements to such a profile, each positioning element in such a specific embodiment is preferably configured so that it can be secured to an aforementioned profile by clamping it against these flanges.
Each positioning end in such a specific embodiment is then preferably provided with a narrowing that has a width that is smaller than or equal to the width of the aforesaid through opening.
In one particular embodiment of a wall assembly according to this invention, at least one profile comprises a second slot, for attachment of two or more beams that are part of a second wall element.
The second slot in yet another particular embodiment is located at an angle with respect to the first-mentioned slot, so that the second wall element in the mounted state of the wall assembly extends at an angle with respect to the first-mentioned wall element.
Of course, the profiles can then be provided with several slots for attachment of several wall elements to the same profile, which can be located at different angles with respect to each other, corresponding to the angles of the slots with respect to each other.
The beams of a wall assembly according to this invention are preferably made of wood. Moreover, these beams are preferably each provided with at least one tongue and at least one groove, so that these beams can be stacked on each other by means of a tongue and groove connection.
The height of these tongues and grooves is preferably chosen such that after shrinkage of the beams there still remains a sufficient overlap of the tongues and grooves so that no cracks occur between the beams.
The profiles of a wall assembly according to this invention are preferably made of metal. More specifically, these profiles can be aluminium profiles, for example, that are made by means of extrusion. For aluminium has a negligible shrinkage and expansion, and suitable surface smoothness, rigidity and strength for the application. Furthermore, no rusting occurs with aluminium, it is user-friendly and fully recyclable.
The positioning elements of a wall assembly according to this invention are preferably made of polypropylene. These could also be made from another plastic, such as PVC, or of aluminium, etc.
The purpose of this invention is likewise achieved by providing a wall element that is constructed from a wall assembly according to the invention as described above. Such wall elements can be incorporated in structures such as summer houses, swimming pools, saunas, fences, houses, caravans, etc.
The purpose of this invention is furthermore also more specifically achieved by providing a sauna cabin that comprises a wall assembly according to this invention as described above.
This invention will now be explained more closely by means of the following detailed description of some preferred wall assemblies according to this invention. The purpose of this description is solely to give illustrative examples and point out further advantages and features of these wall assemblies, and thus can in no way be interpreted as a limitation of the area of application of the invention or the patent rights asserted in the claims.
In this detailed description, reference numbers make reference to the enclosed drawings, where
A wall assembly (1) according to this invention is intended for the building of wall elements (14, 15) that can be incorporated in all kinds of structures made of massive timber construction. These structures can be, for example, summer houses, swimming pools, saunas, fences, houses, caravans, etc.
Such a wall assembly (1), as depicted in the figures, always comprises at least two profiles (3) which in the mounted state of the wall element (14) extend substantially vertically as ends of the wall element (14). In
The profiles (3) depicted are extruded metal profiles. Such extruded aluminium profiles that are currently available on the market are only suited to connection with other metal elements. The slots are narrower and less deep. In order to be able to make use of them as extruded profiles (3) for a wall assembly (1) according to the invention with wooden beams (2), the slots (8) need to be deep and broad enough. Depending on the application, these profiles (3) could also be manufactured from plastic, for example. It is also possible to make profiles for a wall assembly according to this invention from wood, for example, in which case one needs to take account of the material strength and the risk of splitting of this wood for a particular tensile strength and when using fastening elements to attach elements to these profiles (3).
In the mounted state of the wall element (14), several beams (2) that are stacked on each other extend substantially horizontally between these profiles (3). These beams (2) can be made from massive timber with the known techniques. For alternative applications, these could also be made, for example, from composite material or laminated wood, or plastic etc.
In
The beams (2) of the first embodiment of a wall assembly (1) as depicted in
The beams (2) of the depicted embodiments are moreover symmetrical in construction, so that when these beams are mounted in a wall assembly (1) one can choose which flat side to turn inward or outward.
Besides the profiles (3) and the beams (2), a wall assembly (1) according to this invention also comprises two positioning elements (4) for every two beams (2) to be stacked on one another. Such positioning elements (4) are also shown separately in
The depicted positioning elements (4) are made of polypropylene. However, it is also possible to make such positioning elements (4) from another plastic, or from metal etc. The material used is preferably sufficiently firm so that, after fastening of these positioning elements (4) to the profiles (3), the respective beams (2) can be supported by means of these positioning elements (4).
As is clearly shown in
The depicted profiles (3) each comprise four slots (8), in which the positioning elements (4) and the positioning ends (6) of the beams (2) can be arranged. For this, the profiles (3) are provided on their top side with entry openings (12) to these slots (8), by which the positioning elements (4) and the positioning ends (6) can be arranged in the slots (8). Each profile (3), moreover, is provided with flanges (9) that partly border on the slots (8), so that they delimit at least partly a through opening (13) to this slot (8).
As can clearly be seen in FIGS. 6 and 12-14, the positioning elements (4) in such embodiments can be arranged so that they are removed from view in the mounted state of the wall assembly (1). These positioning elements (4) furthermore fill up the opening between positioning ends (6) of stacked beams (2) as much as possible, so that the connection becomes water and wind-tight and energy losses are limited.
The cross sections of both the positioning elements (4) and the positioning ends (6) of the beams (2) in the various depicted embodiments of wall assemblies (1) are each time fashioned to be as complementary as possible to the cross section of the corresponding slots (8), to enable a maximum supporting of the beams (2). As is clearly shown in
The slots (8) in the second embodiment are designed so that a wall assembly (1) according to this second embodiment can handle greater lateral tensile forces than a wall assembly (1) with the slots (8) from the first embodiment.
When building a wall element (14, 15) with these depicted wall assemblies (1), one first arranges a positioning element (4) in the desired slots (8) of the profiles (3) in which beams (2) are to be arranged. After this, a beam (2) is arranged between two profiles (3) by arranging it with the help of its positioning ends (6) in the slots (8) of these profiles (3) via the entry openings (12). Then on top of each positioning end (6) a positioning element (4) is placed in the corresponding slot (8) via the corresponding positioning opening (12). These positioning elements (4) are fixed at the desired height by tightening the socket set screws (5) until the positioning elements (4) are drawn tight against the flanges (9). As is clearly shown in
The beams (2) of the depicted wall assemblies (1) each time have coinciding dimensions. The positioning elements (4) in this case have a height that coincides with the net construction height of a beam (2), minus the height of its positioning end (6), so that all elements of the wall assembly (1) can initially join to each other in order to produce a firm unit that remains a firm unit even upon shrinkage and/or expansion of the beams (2).
The profiles (3) depicted in
In
In the profile (3) of the embodiment depicted in
In the profile (3) of the embodiment depicted in
In the profile (3) of the embodiment depicted in
In the profile (3) of the embodiment depicted in
In most profiles (3) depicted, a through recess (16) is provided at the centre, with small raised edges at the margin. In this, one can secure feet for the profiles (3) with an M8 screw thread, for example, which can be adjustable in height, or adjoining profiles (3) can be attached, and so on, as is already known for such profiles in metal structures.
Moreover, the additional cavities (17) that are present in these profiles (3) can be used to take up wiring, for example, as is also already known for such profiles in metal structures.
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| 2010/0744 | Dec 2010 | BE | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/IB2011/002979 | 12/9/2011 | WO | 00 | 6/14/2013 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2012/080801 | 6/21/2012 | WO | A |
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