CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of the filing date of U.S. Provisional Application Serial No. 63/376,357 filed September 20, 2022, titled “METHOD AND SYSTEM FOR CONSTRUCTION,” which is hereby incorporated by reference as if fully set forth herein.

FIELD OF THE INVENTION

[0002] This disclosure generally relates to using timber in building construction. Specifically, this disclosure relates to a wood joint for joining wood planks together in the construction of a building or other structure.

BACKGROUND OF THE INVENTION

[0003] Wood has been used as a construction material for more than a thousand years. For example, Horyu-ji Temple in Japan is believed to be the oldest wooden building in the world, which was built more than 1,300 years ago.

[0004] However, for most of the twentieth century, nonresidential buildings have mainly been constructed utilizing reinforced concrete and steel, such as post-tensioned concrete and steel framing. In contrast, nonresidential buildings built out of timber or engineered wood were relatively uncommon for most of the twentieth century. However, globally this began to change in the early 1990s due to the development of cross-laminated timber (CLT), a type of mass timber.

[0005] Mass timber is a family of engineered wood products and is also known as a type of building (similar to a steel building or a concrete building). Mass timber includes but is not limited to CLT (cross-laminated timber), NLT (nail-laminated timber), GLT (glue- laminated timber), MPP (mass-plywood panel), DLT (dowel-laminated timber), and other similar materials. In particular, CLT is a mass timber product that is a multilayer wood panel consisting of several overlying board layers. As a result, mass timber is becoming an increasingly popular material for the structural systems and other portions of buildings.

[0006] In addition, mass timber panels facilitate improved quality and speed of construction by enabling prefabrication workflows. Wall, floor, and roof elements may be manufactured in a climate-controlled facility and transported to construction sites for rapid assembly. Thus, mass timber panel construction dramatically increases efficiency and quality control in the construction process.

[0007] To build a floor assembly, prefabricated wood columns and prefabricated wood planks may be transported to the construction site. Then, to begin assembling the structure, the prefabricated wood columns may be anchored to the foundation of the structure in an upright orientation. In atypical example, the prefabricated columns may be arranged on the foundation to form a grid-like pattern.

[0008] Once the wood columns are anchored to the foundation, a subfloor assembly may be constructed using the prefabricated wood planks. The subfloor assembly may consist of a first group of wood planks which each span between two or more of the columns. More specifically, the first group of wood planks may be arranged parallel to one another to form rows of planks with gaps in between the ends of the planks. Planks from the second group of planks may be inserted into the gaps and coupled to the adjacent planks to fill the gaps between the planks.

[0009] Typically, when joining the planks together, a lap joint may be used. For example, each plank may include cavities in an upper or lower surface of the plank. The cavities may be rectangular-shaped and may extend across the width of the plank at each end of the plank. As a result, the planks may have an L-shaped profile when viewed in a transverse direction. The planks from the first group of planks may be oriented such that the cavities are positioned and located on an upper surface of the plank, and the planks from the second group of planks may be oriented such that the cavities are positioned and located on a lower surface of the plank. Thus, the L-shaped profile of a second plank may be inserted into the cavity on the top surface of a first plank, and the second plank may rest on top of the first plank to form a flat, continuous surface.

[0010] However, typical construction methods involving lap joints are not without deficiencies. For example, when a downward force is applied to the top of the floor (e.g., by an occupant walking across the floor), the planks may have a tendency to rotate downwardly or to bend. As the planks rotate or bend, the planks from the second group may slide out from the cavities in the planks from the first group. As a result, the subfloor may make a squeaking noise, or the planks may come uncoupled from one another causing a safety hazard.

[0011] Accordingly, there is a need for an improved joint for joining planks together in a secure fashion. Preferably, the joint should be compatible with construction workflows involving prefabrication, and the method for joining the planks should be easy to perform.

BRIEF SUMMARY

[0012] A first aspect of this disclosure pertains to a modular plank including a body portion extending in a longitudinal direction, a plurality of protrusions extending outward from a first end of the body portion in the longitudinal direction, wherein the plurality of protrusions each include a cross-section that changes size as the cross-section extends outwardly from the body portion in the longitudinal direction, and wherein the cross-section includes an upper end that is sized differently than a lower end.

[0013] A second aspect of this disclosure pertains to the modular plank of the first aspect, wherein the cross-section of each protrusion is trapezoidal-shaped.

[0014] A third aspect of this disclosure pertains to the modular plank of the first aspect, wherein the cross-section of each protrusion increases in size as the protrusion extends away from the body portion in the longitudinal direction. [0015] A fourth aspect of this disclosure pertains to the modular plank of the first aspect, wherein the upper end and the lower end of the cross-section increase in length as the protrusion extends away from the body portion in the longitudinal direction.

[0016] A fifth aspect of this disclosure pertains to the modular plank of the first aspect, wherein the plurality of protrusions are integrally formed with the body portion of the modular plank.

[0017] A sixth aspect of this disclosure pertains to the modular plank of the first aspect further including a second plurality of protrusions extending outwardly from a second end of the modular plank.

[0018] A seventh aspect of this disclosure pertains to the modular plank of the first aspect further including a plurality of gaps positioned and located between the plurality of protrusions, wherein each gap is sized and shaped to receive an extension sized and shaped similarly to protrusions from the plurality of protrusions.

[0019] An eighth aspect of this disclosure pertains to a joint for coupling a first plank to a second plank, the joint including a first plurality of protrusions extending outward from a first end of the first plank, a second plurality of protrusions extending outward from a second end of the second plank, wherein when the joint is assembled, each protrusion from the first plurality of protrusions is positioned and located adjacent to a protrusion from the second plurality of protrusions, and wherein each protrusion includes a trapezoidal-shaped crosssection extending outward from the first plank or the second plank.

[0020] A ninth aspect of this disclosure pertains to the joint of the eighth aspect, wherein when the first plank and the second plank are coupled together using the joint, the first plank and the second plank are oriented parallel to one another.

[0021] A tenth aspect of this disclosure pertains to the joint of the eighth aspect, wherein when the first plank and the second plank are coupled together using the joint, the first plank and the second plank form a flat and continuous surface.

[0022] An eleventh aspect of this disclosure pertains to the joint of the eighth aspect, wherein the protrusions from the first plurality of protrusions and the second plurality of protrusions are further shaped such that each protrusion increases in size with respect to at least dimension as the protrusions extend away from the planks.

[0023] A twelfth aspect of this disclosure pertains to the joint of the eighth aspect, wherein each protrusion from the first plurality of protrusions and the second plurality of protrusions is bell-shaped or trapezoidal-shaped when viewed in a direction perpendicular to the trapezoidal-shaped cross-section.

[0024] A thirteenth aspect of this disclosure pertains to the joint of the eighth aspect, wherein each protrusion from the first plurality of protrusions includes a wider end that is configured to abut a narrower end of a protrusion from the second plurality of protrusions.

[0025] A fourteenth aspect of this disclosure pertains to a floor assembly including a plurality of columns oriented vertically upright; a plurality of planks oriented perpendicular to the plurality of columns, the plurality of planks including a first group of planks and a second group of planks; a plurality of protrusions extending outward from ends of the planks; and wherein the protrusions extending outward from the first group of planks are configured to be received between the protrusions extending outward from the second group of planks.

[0026] A fifteenth aspect of this disclosure pertains to the floor assembly of the fourteenth aspect, wherein the first group of planks and the second group of planks are coupled together to form a plurality of flat surfaces, each surface extending between a portion of the plurality of columns.

[0027] A sixteenth aspect of this disclosure pertains to the floor assembly of the fourteenth aspect, wherein the plurality of planks are configured to support a plurality of upper flooring boards to form a continuous, planar surface extending between the plurality of columns.

[0028] A seventieth aspect of this disclosure pertains to the floor assembly of the sixteenth aspect, wherein the plurality of upper flooring boards are coupled to the plurality of planks using at least one of nails, woodscrews, or an adhesive.

[0029] An eighteenth aspect of this disclosure pertains to the floor assembly of the fourteenth aspect, wherein the orientation of the planks in the first group of planks is substantially mirrored compared to the orientation of the planks in the second group of planks. [0030] A nineteenth aspect of this disclosure pertains to the floor assembly of the fourteenth aspect, wherein the planks from the first group of planks are oriented such that a wider end of each protrusion is positioned and located proximate to a lower end of the floor assembly and such that a narrower end of each protrusion is positioned and located proximate to an upper end of the floor assembly.

[0031] A twentieth aspect of this disclosure pertains to the floor assembly of the nineteenth aspect, wherein the planks from the second group of planks are oriented such that a wider end of each protrusion is positioned and located proximate to the upper end of the floor assembly and such that a narrower end of each protrusion is positioned and located proximate to the lower end of the floor assembly.

[0032] A twenty -first aspect of this disclosure pertains to a method for coupling planks, the method includes providing a first plank extending horizontally between a plurality of columns; providing a first plurality of protrusions extending outward from a first end of the first plank, the first plurality of protrusions oriented such that a narrower end of each protrusion is positioned and located proximate to an upper end of the first plank and such that a wider end of each protrusion is positioned and located proximate to a lower end of the first plank; providing a second plank with a second plurality of protrusions extending outward from a second end of the second plank; inserting the second plurality of protrusions between the first plurality of protrusions; wherein the step of inserting the second plurality of protrusions between the first plurality of protrusions further includes positioning the second end of the second plank adjacent to the first end of the first plank; and moving the second plank toward the lower end of the first plank such that narrower ends of the second plurality of protrusions move past the narrower ends of the first plurality of protrusions and such that wider ends of the second plurality of protrusions are placed into contact with the wider ends of the first plurality of protrusions.

[0033] In the present application, “plank” is not limited to a subfloor assembly of prefabricated wood planks but includes other types of panels which can be joined together using the structure and method of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] FIG. 1 illustrates a perspective view of a floor assembly according to an example embodiment;

[0035] FIG. 2 illustrates an enlarged partial top view of the floor assembly of FIG. 1 taken generally about perimeter 2’ (see FIG. 1); and

[0036] FIG. 3 illustrates a cross-sectional view of the floor assembly of FIG. 1 taken generally about line A-A (see FIG. 2) in the direction of the arrows.

[0037] Before explaining the disclosed embodiment of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown, since the invention is capable of other embodiments. 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 limiting. Also, the terminology used herein is for the purpose of description and not of limitation. DETAILED DESCRIPTION

[0038] While this invention is susceptible of embodiments in many different forms, there are shown in the drawings and will be described in detail herein specific embodiments with the understanding that the present disclosure is an exemplification of the principles of the invention. It is not intended to limit the invention to the specific illustrated embodiments. The features of the invention disclosed herein in the description, drawings, and claims can be significant, both individually and in any desired combinations, for the operation of the invention in its various embodiments. Features from one embodiment can be used in other embodiments of the invention.

[0039] Referring to FIG. 1, an embodiment of a partially assembled floor assembly 100 is illustrated. The floor assembly 100 includes a plurality of planks 110a, 110b supported by columns 120. The columns 120 may be provided as elongated rectangular prisms made from a wood material, although other suitable columns are contemplated. The columns 120 may be anchored to the foundation of the building using methods known in the art.

[0040] The planks 110a, 110b may be provided as thin, elongated boards made of a wood material (e.g., mass timber panels, plywood sheets, or particle boards). However, in alternative embodiments, the planks 110a, 110b may be made of other suitable materials (e.g., concrete, steel, or plastic). As will be described further herein, the planks 110a, 110b may be assembled together and coupled to the columns 120 to define a lower end 130 of the floor assembly 100. When the planks 110a, 110b are coupled to the columns 120, the planks 110a, 110b may be oriented perpendicular to the columns 120, and the planks 110a, 110b may be oriented parallel to one another. More particularly, the planks 110a, 110b may be oriented to extend in a longitudinal direction 140.

[0041] When the planks 110a, 110b are assembled together, upper flooring boards 150 may be placed on top of the planks 110a, 110b to form a continuous planar surface extending between the columns 120. The upper flooring boards 150 may be shaped as thin, rectangular plates. For example, the upper flooring boards 150 may be provided as mass timber panels, plywood sheets, or particle boards. However, in alternative embodiments, the upper flooring boards 150 may be made of other suitable materials (e.g., concrete, steel, or plastic). The upper flooring boards 150 may be coupled to the planks 110a, 110b using nails or wood screws. However, other suitable means (e.g., an adhesive) for coupling the upper flooring boards 150 to the planks 110a, 110b are foreseeable.

[0042] The planks 110a, 110b may include a first group of planks 110a that are coupled directly to the columns 120 and a second group of planks 110b that are supported by the first group of planks 110a. For example, the first group of planks 110a may each extend between two or more columns 120, and the first group of planks 110a may be coupled to the columns 120 using means known in the art (e.g., brackets, wood screws, dowels, etc.). Furthermore, the first group of planks 110a may be sized and arranged such that there is a gap between the longitudinal ends of the planks 110a.

[0043] The second group of planks 110b may be configured to join the planks 110a from the first group together to form a plurality of flat, continuous surfaces extending between the columns 120. More particularly, the planks 110b may be positioned and located between the longitudinal ends of the planks 110a at the point farthest from the column. The planks 110b from the second group may be sized to extend between the planks 110a from the first group, and a plurality of joints 160 may be used to join the ends of the planks 110a, 110b together.

[0044] As illustrated in FIG. 2, the joints 160 may be formed using a plurality of first protrusions 170a and a plurality of second protrusions 170b selectively engaged with one another. The first protrusions 170a may be solid-body members extending outwardly in the longitudinal direction 140 from the ends of the first planks 110a. Similarly, the second protrusions 170b may be solid-body members extending outwardly in the longitudinal direction 140 from the ends of the second planks 110b. The protrusions 170a, 170b may be integrally formed with the planks 110a, 110b. For example, the protrusions 170a, 170b may be cut into a body portion 112a, 112b of the planks 110a, 110b, respectively. Thus, the planks 110a, 110b may include a plurality of gaps or openings positioned and located between the protrusions 170a, 170b. To join the planks 110a, 110b together, the first protrusions 170a may be received into the openings positioned and located between the second protrusions 170b, and the second protrusions 170b may be received into the openings positioned and located between the first protrusions 170a.

[0045] When viewed from an upper perspective (as illustrated in FIG. 2), the protrusions 170a, 170b may each be bell-shaped or trapezoidal-shaped (e.g., similar to a dovetail joint). More particularly, the protrusions 170a, 170b may be relatively narrow proximate to the body portion 112a, 112b, respectively, and the protrusions 170a, 170b may be relatively wide distal from the body portion 112a, 112b, respectively. Therefore, the protrusions 170a, 170b may widen in size as the protrusions 170a, 170b extend away from the body portions 112a, 112b, respectively. Accordingly, the protrusions 170a, 170b may be selectively engaged with one another to limit longitudinal movement of the second group of planks 110b relative to the first group of planks 110a. In addition, the protrusions 170a, 170b may include a rounded profile. Thus, the protrusions 170a, 170b may be bell-shaped or dovetail-shaped.

[0046] Turning to FIG. 3, the first protrusions 170a may be configured to support the second protrusions 170b when the planks 110a, 110b are coupled with one another. More particularly, the first protrusions 170a and the second protrusions 170b may each include a tapered cross-section extending in the longitudinal direction 140 (as is illustrated in FIG. 3). The first planks 110a may be oriented such that wider ends 172a of the tapered cross-sections are positioned and located proximate to the lower end 130 of the floor assembly 100. Thus, narrower ends 174a of the first protrusions 170a are positioned and located proximate to the upper flooring boards 150.

[0047] In contrast to the first planks 110a, the second planks 110b may be oriented such that wider ends 172b of the second protrusions 170b are positioned and located proximate to the upper flooring boards 150 and such that narrower ends 174b are positioned and located proximate to the lower end 130 of the floor assembly 100. As a result, the narrower ends 174b of the second protrusions 170b may be inserted between the wider ends 172a of the first protrusions 170a. However, the wider ends 172a of the first protrusions 170a may prevent the wider ends 172b of the second protrusions 170b from passing therethrough. Thus, the wider ends 172a of the first protrusions 170a may support the tapered cross-section of the second protrusions 170b and may prevent the second protrusions 170b from falling downward. As a result, the joint 160 may be configured such that the second planks 110b are supported by the first planks 110a. Moreover, the joint 160 may prevent the second planks 110b from coming uncoupled from the first planks 110a.

[0048] To assemble a floor assembly 100, a user may perform a method for coupling a first plank to a second plank. The method may include a step of providing a first plank extending horizontally between a plurality of columns. The method may further include a step of providing a first plurality of protrusions extending outward from a first end of the first plank. The first plurality of protrusions may be oriented such that a narrower end of each protrusion is positioned and located proximate to an upper end of the first plank and such that a wider end of each protrusion is positioned and located proximate to a lower end of the first plank.

[0049] In addition, the method may include a step of providing a second plank with a second plurality of protrusions extending outward from a second end of the second plank. The method may further include a step of inserting the second plurality of protrusions between the first plurality of protrusions. The step of inserting the second plurality of protrusions between the first plurality of protrusions may include positioning the second end of the second plank adjacent to the first end of the first plank and moving the second plank toward the lower end of the first plank. As the second plank is moved toward the lower end of the first plank, narrower ends of the second plurality of protrusions may move past the narrower ends of the first plurality of protrusions. As the second plank continues to move downward, the wider ends of the second plurality of protrusions are placed into contact with the wider ends of the first plurality of protrusions. As a result, the first plurality of protrusions may support the second plurality of protrusions. Thus, the first plank may be coupled to the second plank.

[0050] In alternative embodiments of the floor assembly 100, the upper flooring boards 150 may be coupled with one another. More particularly, the upper flooring boards 150 may include an additional group of protrusions (not illustrated) extending in the longitudinal direction. The protrusions in the additional group of protrusions may be configured similarly to the protrusions 170a, 170b on the planks 110a, 110b, respectively. Thus, the longitudinal ends of the upper flooring boards 150 may be selectively engaged with one another using the additional protrusions, and the upper flooring boards 150 may be coupled to one another by performing a method similar to the method for coupling a first plank to a second plank.

[0051] In other alternative embodiments, the upper flooring boards 150 may additionally or alternatively include a further group of protrusions (not illustrated). The further group of protrusions may be shaped similarly to the protrusions 170a, 170b on the planks 100a, 100b, respectively. However, in contrast to the protrusions 170a, 170b, the further group of protrusions may extend from the upper flooring boards 150 in a lateral direction (i.e., in a direction perpendicular to the longitudinal direction). Therefore, in other alternative embodiments, the lateral ends of the upper flooring boards 150 may be coupled with one another.

[0052] Specific embodiments of a joint for constructing a wooden structure according to the present invention have been described for the purpose of illustrating the manner in which the invention can be made and used. It should be understood that the implementation of other variations and modifications of this invention and its different aspects will be apparent to one skilled in the art, and that this invention is not limited by the specific embodiments described. Features described in one embodiment can be implemented in other embodiments. The subject disclosure is understood to encompass the present invention and any and all modifications, variations, or equivalents that fall within the spirit and scope of the basic underlying principles disclosed and claimed herein.