NL2015940B1

NL2015940B1 - Method of producing a framing member of alternate layers of structural members and insulating material interconnected by wooden dowels.

Info

Publication number: NL2015940B1
Application number: NL2015940A
Authority: NL
Inventors: Hero Olthof Willem; Jacob Trooster Thomas
Original assignee: Hero Olthof Willem; Jacob Trooster Thomas
Priority date: 2015-12-10
Filing date: 2015-12-10
Publication date: 2017-07-03
Also published as: NL2015940A

Abstract

The invention relates to a method of producing a framing member (10) and to the framing member (1 0) comprising alternate layers of a first structural member (1 ), an insulating material (3) and a second structural member (2) interconnected by dowels (4) of sawable material. The method comprises the steps of: making holes in the structural members for receiving a dowel; sharpening each dowel; arranging the insulating material between the structural members facing the holes; Piercing the insulating material with the dowels whereby the first outer ends of the dowels are 1 o received in the holes of the first structural member and second outer ends of the dowels are received in the holes of the second structural member.

Description

METHOD OF PRODUCING A FRAMING MEMBER OF ALTERNATE LAYERS OF STRUCTURAL MEMBERS AND INSULATING MATERIAL INTERCONNECTED BY WOODEN DOWELS

The present invention relates to a method of producing a framing member comprising alternate layers of a first structural member, an insulating material and a second structural member interconnected by a number of fixing elements of sawable material, comprising the steps of: a) Making a number of holes in a surface area of each of the structural members, each hole being arranged for receiving part of a fixing element;

The present invention further relates to a framing member, comprising a first and a second structural member and an insulating material laying against inside facing surface areas of the structural members, wherein the framing member further comprises one or more fixing elements for interconnecting the structural members and the insulating material, wherein the fixing elements extend from the first structural member through the insulating material into the second structural member.

Framing members, such as studs or rails, with an integrated thermal break are known in the art and allow achieving the prescribed values for the total thermal resistance Rc even in thin constructions.

In the field of building and framing construction materials said framing members with an integrated thermal break can be used in various construction applications, such as in walls, roofs, door frames, window frames, floors and other load bearing and non-load bearing elements where a framing member is used.

In many construction applications high structural loads are carried by said framing members. As the known framing members are manufactured from layers of non-homogenous materials, they may pull apart or de-laminate over time due to these loads and forces acting thereon.

The present invention provides a solution to the problem by providing a framing member that comprises one or more fixing elements that are each in contact with the insulating material and the adjacent structural members, wherein the material of the fixing elements is sawable.

By connecting the alternating layers of structural members and the insulating material therein between the strength of the framing member is significantly enhanced.

It is noted that a method according to the preamble of claim 1 and a framing member according to the preamble of claim 14 are known from W02007/069908.

The known framing member is a building element comprising two outer elements made of wood and at least one insulating element of polyurethane mounted between the outer elements and wooden bolts for connecting the outer elements and the insulating element. According to the known method the bolts are passed through through-going holes in the outer elements and the insulating element and the wooden bolts are at their outer ends provided with concealing plugs.

The invention has for its purpose to provide an improved reinforced insulated framing member and a more efficient method of producing such a reinforced insulated framing member.

The method according to the invention distinguishes over the known method by the characterizing steps of: b) Using dowels as fixing elements and sharpening a first outer end of each dowel; c) Arranging the insulating material between the structural members, such that the insulating material faces the holes; d) Piercing the insulating material with the dowels whereby the first outer ends of the dowels are received in the holes of the first structural member and second outer ends of the dowels are received in the holes of the second structural member.

The framing member according to the invention distinguishes over the known framing member in that the fixing elements are dowels having at least one sharp outer end for piercing the insulating material.

Advantageously the method according to the invention is more efficient than the known method by using processed dowels both as fixing elements and as a tool to make the holes in the insulating material necessary to receive the dowels. The improved efficiency shortens production time as well as production costs and improves production safety.

According to a first preferred embodiment the framing member according to the invention is entirely made of natural materials, preferably wood based natural materials. Preferably the dowels are wooden dowels. The choice of wood for the fixing elements allows for optimal processing of the framing members as it can be cut quickly into any desired dimensions using conventional wood processing tools. Preferably the insulating material is wood wool. Preferably the material of the structural members is: wood, structural composite lumber, oriented strand board (OSB), plywood, pressed wood, laminated layered board, synthetic wood or hardboard.

In a preferred embodiment of the method according to the invention step a) comprises choosing structural members having a generally elongated shape and making the holes in the edge faces. The resulting framing member has improved reinforcement characteristics.

In another preferred embodiment of the method according to the invention step b) comprises cutting the at least one outer end of each dowel, preferably into a pointed shape. Cutting is a suitable wood processing technique to change the dowel into a sharp hole making tool.

According to a practical preferred embodiment of the method according to the invention step c) comprises placing the structural members and the insulating material on a generally horizontal working surface.

According to an elegant preferred embodiment of the method according to the invention step d) comprises placing the dowels on a support, such that the dowels lie substantially in line with the holes.

According to a first preferred embodiment of the production method according to the invention step d) comprises: 1) Positioning the dowels between the insulating material and the second structural member such that the sharpened first outer ends face the insulating material; and 2) Pressing the second structural member in the direction of the first structural member.

According to a second preferred embodiment of the production method according to the invention step d) comprises pressing each of the dowels through one of the holes in the second structural member and through the insulating material into one of the holes in the first structural member. Advantageously the resulting connection of the layers in the framing member is even stronger. Consequently, more insulating material can be placed between the structural members.

Preferably a pneumatically or hydraulically or mechanically driven pressing tool is used to perform pressing.

The invention will now be elucidated in more detail herein below with reference to the drawings, in which:

Figure 1 schematically shows a first preferred embodiment of the framing member according to the invention in cross-section;

Figure 2A and 2B illustrate steps of a first preferred production method for a framing member according to the invention; and

Figure 3A and 3B illustrate steps of a second preferred production method for the framing member according to the invention.

The external view of a first preferred embodiment of a framing member according to the invention is illustrated in figure 1. Framing member 10 has a typical elongated shape like a beam. Framing member 10 is layered of non-homogeneous material. Framing member 10 comprises a first structural member 1 and a second structural member 2 and an insulating material 3 lying there in between. The structural members 1, 2 provide the majority of the mechanical properties of the framing element. The insulating material 3 provides the insulation property to the framing element, serving as a thermal break between the two structural members.

Framing member 10 comprises two structural members 1,2 and an insulating material 3 lying against the inside facing surface areas of the structural members 1, 2. Fixing elements 4 are each in contact with the insulating material 3 as well as with the structural members 1, 2 adjacent to the insulating material. In the preferred embodiment shown the fixing elements 4 are wooden dowels.

In the first preferred embodiment the fixing elements 4 are generally elongated. The fixing elements 4 extend completely through the insulating material 3 into the adjacent structural members 1, 2. Each fixing element 4 interconnects the two structural members 1, 2 and the insulating material 3 therein between. Preferably the fixing elements 4 are spaced apart at a regular distance. In the first preferred embodiment the structural members 1, 2 comprise holes 1A, 2Afor receiving the outer ends of the wooden dowels 4.

Figures 2A and 2B schematically illustrate steps of a first preferred production method for the framing element.

In a first preparation step at least one hole 1A is made in a surface area of the structural member 1 and at least one hole 2A is made in a surface area of the structural member 2. Each hole 1A respectively 2A is arranged for receiving part of a wooden dowel 4.

Preferably the holes 1 A, 2A are made in edge faces of the structural members 1, 2. A conventional wood processing technique, such as drilling, can be used. The structural members 1,2 may have a generally elongated shape and the holes may be made in the longitudinal sides.

In a following preparation step wooden dowels 4 are used as fixing elements. At least one of the outer ends of each wooden dowel 4 is sharpened by a suitable wood processing technique, such as cutting. Preferably at least one outer end of each wooden dowel 4 is cut into a pointed shape 4A.

Next the insulating material 3 is placed between the structural members 1, 2, such that the insulating material faces the holes 1A, 2A. In Figure 2A the insulating material 3 is arranged adjacent the edges of the structural member 1. Preferably the structural member 1 and the insulating material 3 are placed on a first generally horizontal working surface 6. Preferably the structural member 2 is placed on a second generally horizontal working surface 7. The second working surface 7 is movable with respect to the first working surface 6.

The wooden dowel 4 is positioned between the insulating material 3 and the second structural member 2, such that the at least one sharpened outer end 4A faces the insulating material 3. Preferably the wooden dowel 4 is placed on a first support 5A and a second support 5B to align the wooden dowel 4 with the holes 1A and 2A. The first support 5A is located between the first working surface 6 and the second working surface 7. The second support 5B is located between the first working surface 6 and the second working surface 7. The first and second support 5A, 5B are movable.

Finally, the framing member is assembled. Thereby the wooden dowel 4 is moved through the insulating material 3, piercing the insulating material 3 with the outer end 4A until the outer end 4A is received in the hole 1A of the structural member 1. Preferably the movement of the wooden dowel 4 is realized by movement of the structural member 2 and the supports 5A, 5B. The second working surface 7 is moved towards the wooden dowel 4 thereby moving the second structural member 2 until the outer end 4B is received in the hole 2A. The support 5B is moved towards the support 5A. When the dowel 4 is largely received in the insulating material 3 (see figure 2B) the supports 5A, 5B are removed. The assembling step may be performed by suitable pressing tools, such as pneumatically or hydraulically driven pressure tools.

Figures 3A and 3B schematically illustrate steps of second preferred production method as an alternative to the first preferred production method for the framing element. The second preferred production method corresponds largely to the first preferred production method described above. Only the differences are described here. A first difference can be found in making the holes. In the first preparation step the holes 1A and 2A are made at a different angle to the respective surface area. The angle is not 90 degrees (nor zero), but preferably lies between 30 and 60. More preferably the angle is substantially 45 degrees with the surface areas. A further difference between the alternative, second preferred production method and first preferred production method lies in the positioning of the materials. Here the insulating material 3 is sandwiched between the first structural member 1 and the second structural member 2.

During assembly the materials need to be fixed in position using suitable fixation tools. Next assembly takes place by pressing each of the dowels 4 through one of the holes 2A in the second structural member 2 and through the insulating material 3 into one of the holes 1A in the first structural member 1.

In the preferred embodiment of the production method shown a first series of holes forms first passages for dowels 4 in a first direction and a second series of holes forms second passages for dowels 4 in a second direction, such that pairs of adjacent dowels 4 form a V. The pattern of the dowels 4 is similar to that of a parallel chord truss, but the dowels 4 are not interconnected.

Materials for structural members used in the invention can be selected from a variety of wood used commonly in the art. Lumber may be obtained from timber. Timber cut and prepared into boards planks or other ready for market pieces. Engineered wood (combined particles, strands, or veneers with a glue, polymer, composite or similar bond) may be used. Generally, the material of the structural members comprises: wood, structural composite lumber, oriented strand board (OSB), plywood, pressed wood, laminated layered board, synthetic wood or hardboard.

Insulation is a low energy transmission material used in construction or manufacturing to slow the transfer of heat, sound, or other energy through materials. Typically, strong structural materials have a high capacity to transfer heat and other energies through walls, roofs, and floors and insulation is added to structure so the combined transfer of energy is reduced and the structure becomes more energy efficient, less noisy and otherwise more comfortable. Wood wool and mineral wool are examples of natural insulation materials. Other suitable types of insulating materials are non-mineral wool, foam, cellulose material or combinations thereof.

Suitable materials for the dowels include all types of wood from all kinds of vegetation, including bamboo. Another suitable sawable material for the fixing elements is plastic, such as nylon.

The foregoing examples are intended to be illustrative and not exclusive. Other suitable materials known in 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 or figures as provided herein.

The invention is of course not limited to the described and shown preferred embodiments, but also explicitly includes all combinations thereof. The invention relates generally to any embodiment falling within the scope of protection as defined in the claims and as seen in the light of the foregoing description and accompanying drawings.

Claims

A method for producing a frame component, comprising alternating layers of a first structural component, an insulating material and a second structural component, interconnected by means of a number of fastening elements of sawable material, comprising the steps of: a) making a plurality of holes in a surface area of each of the structural members, each hole being adapted to receive a portion of a fastening element; characterized by the steps; b) Using dowels as fixing elements and sharpening a first end of each dowel; c) Applying the insulation material between the structural components, such that the insulation material faces the holes; d) Piercing the insulating material with the dowels wherein the first ends of the dowels are received in the holes of the first structural part and second ends of the dowels are received in the holes of the second structural part.

A method according to claim 1, wherein step a) comprises making the holes in the surface areas at an angle of 30 to 60 degrees, preferably 45 degrees, with the surface areas.

3. Method as claimed in claim 1 or 2, wherein step a) is carried out such that a first set of holes forms first passes for dowels in a first direction and a second set of holes forms second passes for dowels in a second direction, such that pairs of adjacent dowels form a V.

Method according to one or more of the preceding claims, wherein step a) comprises choosing structural components with a generally elongated shape and making the holes in the longitudinal sides.

Method according to one or more of the preceding claims, wherein step b) comprises choosing wooden dowels.

Method according to one or more of the preceding claims, wherein step b) comprises cutting the first end of each dowel, preferably in a point.

Method according to one or more of the preceding claims, wherein step d) comprises: 1) Positioning the dowels between the insulating material and the second structural component such that the sharp first ends face the insulating material; 2) Pressing the second structural component in the direction of the first structural component.

The method of claim 7, wherein step c) comprises placing the first structural component and the insulating material on a generally horizontal first working surface and placing the second structural component on a generally horizontal second working surface, the first and second working surfaces being at least be movable relative to each other.

Method according to one or more of the preceding claims 1-6, wherein step d) comprises pressing each of the dowels through one of the holes in the second structural part and through the insulating material in one of the holes in the first structural part.

10. Method as claimed in one or more of the foregoing claims, wherein step d) comprises placing the dowels on a support, such that the dowels are substantially in line with the holes.

Method according to one or more of the preceding claims, wherein the pressing is carried out with the aid of pressing tools, which make use of pneumatic, hydraulic or mechanical pressing pressure.

The method according to one or more of the preceding claims, wherein the insulating material is wood wool.

Method according to one or more of the preceding claims, wherein the material of the structural components is: wood, structural composite lumber, oriented wood chip board (oriented strand board), plywood, pressed wood, laminated laminated board timber , synthetic wood or hardboard.

A frame member, comprising a first and a second structural member and an insulating material, which abuts against facing inner surface areas of the structural members, wherein the frame member further comprises a plurality of fastening elements for interconnecting the structural members and the insulating material, wherein the securing elements extend from the first structural component through the insulating material to the second structural component, characterized in that the securing means are wooden or plastic dowels and each dowel has at least one pointed end for piercing the insulating material.

The frame member of claim 14, wherein a first set of dowels extends in a first direction and a second set of dowls extends in a second direction such that pairs of adjacent dowels form a V.

The frame member according to claim 14 or 15, wherein the dowels extend at an angle of 30 to 60 degrees, preferably 45 degrees, with the surface areas of the structural members.

17. Frame component according to claim 14, 15 or 16, wherein the insulating material is wood wool.

18. Frame component as claimed in one or more of the foregoing claims 14-17, wherein the material of the structural components is: wood, structural composite lumber, oriented wood chip plate (oriented strand board), plywood, pressed wood, laminated laminated board wood, synthetic wood or hardboard.