Technical Field

The invention relates to apparatus and methods for manufacturing a building structure, and in particular, although not exclusively, a timber building structure.

Background

It is known to manufacture timber building structures for buildings such as houses, offices, schools, care homes and hotels. Such building structures may be made from prefabricated timber panels which are manufactured in a factory. The timber panels, such as wall, floor and ceiling panels, are transported to a building site for assembly into a building structure on preprepared concrete foundations. The timber panels typically comprise a frame of wood which is provided with a front and rear skin of Oriented Strand Board (OSB). The OSB is typically Grade 3 OSB having a thickness of up to 2cm, which is an engineered wood product formed of layered strands of wood in specific orientations. The fixtures, fittings and finishings of the building are installed to complete the building after the timber building structure has been assembled at the building site.

Such a way of constructing a building has many advantages when compared to more traditional building structures primarily constructed of bricks or blocks. These advantages typically include speed of construction, improved overall efficiency of construction, reduced cost, improved insulation and reduced environmental impact of construction of the building structure. The known timber building structures are generally constructed in a similar manner to traditional brick or block buildings whereby the building is designed, and the component parts of the building are transported to a building site and assembled to form the building. Whereas such timber building structures allow buildings to be assembled more quickly when compared to traditional brick or block buildings, there are still numerous disadvantages and problems with their manner of construction.

Building sites are notoriously difficult places in which to operate, and to project manage the construction of buildings in an efficient manner. The requirement to transport the timber panels to the building site for construction of the building does not promote the efficient running of the building site, or the efficient construction of the building. A further demand being placed on new buildings is the increasing amount of legislation relating to improved energy efficiency, the use of sustainable building materials, and generally reducing the carbon footprint for constructing the building, and the use of the building throughout its lifetime. Such legislation is becoming increasingly important for new- build domestic housing. Whereas the known way of manufacturing timber building structures may provide an improvement in some of these areas, the manner in which they are constructed introduces a limitation on the possibility to control the costs of manufacture, which includes the financial and environments costs. Furthermore, since the known way of manufacturing timber building structures requires assembly of building panels onto concrete foundations on a building site, the tolerance of dimensions and the overall quality control of the building structure may be compromised, which may cause gaps between panels and thereby heat or air to escape. This may have a consequential effect on limiting the energy efficiency for the overall building process, and for the finished building during use.

A further demand being placed on new buildings is the increasing requirement for affordable and high quality living accommodation. Such a requirement may be a particular need in relatively poorer regions or countries. For example, third world countries may have “shanty towns”, which may be small informal settlements or may house millions of people. There is a great demand for suitable living accommodation in such areas, which has the potential to greatly improve the life quality and life chances of residents.

It is broadly an object of the present invention to address one or more of the above mentioned disadvantages of previously known timber building structures.

Summary

What is required is a way of readily permitting additional stages of timber building structures to be manufactured in a more controlled manner or environment, which may reduce or minimise at least some of the above-mentioned problems.

According to a first aspect of the invention, there is provided an apparatus for manufacturing a building structure comprising a support, a frame rotatably mounted to the support, and a drive device for rotatable movement of the frame relative to the support, the frame adapted to receive at least one building panel for assembly into a building structure. Such an apparatus permits building structures, such as timber building modules, to be manufactured in a more controlled manner. The rotatable frame permits building panels to be readily handled and manipulated prior to joining them to each other. The apparatus may be located at a factory location such as a yard or warehouse. Accordingly, the building structure may be finished with fixtures and fittings, and decorated away from a building site and then transported to the building site, which means that the building structure may be manufactured with improved efficiency and with a reduced environmental impact. The apparatus may further permit the building structure to be manufactured with an improved tolerance for dimensions of the building structure, which may further assist with control of quality of the building structure. This has a consequential effect on improving the energy efficiency of the finished building structure due to a reduction of gaps in joints of the building structure, or adjacent building structures when many building structures are assembled adjacent to one another at a building site. Such an improvement in the tolerances of dimensions of the building structure may reduce draughts and thereby heat loss from the finished building. Using such an apparatus further permits the building structure to be manufactured to an appropriate financial and environmental cost. The finished building structure may therefore be manufactured with a reduced environmental impact. The frame may be suitable for receiving at least one building panel for assembly into a building structure.

Preferably the frame comprises at least one track provided on an outer extent thereof, and the support has at least one roller, the track for rolling engagement with the roller to provide said rotatable mounting of the frame to the support. Preferably the frame comprises at least two tracks on an outer extent thereof, and the support has at least two rollers for rolling engagement with a respective track to provide said rotatable mounting of the frame to the support. Such a track and roller arrangement has the advantage of permitting the frame to rotate about an outer extent which leaves at least one end of the frame open to receive a building panel.

Preferably the tracks are provided at respective ends of the frame. Preferably the support has at least four rollers, wherein a respective two of the rollers are for rolling engagement with a respective track so that each track sits on its associated rollers. Such an arrangement provides a way of permitting the frame to sit on the rollers under the action of gravity. Preferably each track is a channel. Such a channel may assist with location of the roller within its associated track. Preferably the frame is cylindrical in shape. Preferably the frame is arranged to receive at least one building panel via an end of the cylinder.

Preferably the support is cuboid in shape and the frame is substantially within said cuboid shape. Such an arrangement permits a convenient way to package the frame and support of the apparatus. Preferably the at least four rollers are located at respective lower corners of the support. Preferably the support has at least eight rollers, a respective four of the rollers for rolling engagement with a respective track, wherein at least four rollers are located at respective upper corners of the support.

In one embodiment the frame is rotatable in portions of substantially 90° with the drive device, the frame adapted to receive consecutive building panels after a said portion of rotation for assembly into a building structure. Such an arrangement permits ready handling of building panels so that they can be manipulated with the apparatus and formed into the shape of a building structure.

Preferably the support includes a first flip device arranged at an end of said rotatable frame, the first flip device for pivotable movement of a building panel by substantially 90° for assembly into a building structure. Preferably the support includes a second flip device arranged at an opposite end of said rotatable frame, the second flip device for pivotable movement of a building panel by substantially 90° for assembly into a building structure. Such flip devices permit the closing of a building structure. Preferably at least one of the first and second the flip devices comprises at least one actuator arm which is pivotably connected to the support.

The apparatus may further include incremental adjustment means for movement of adjacent building panels relative to each other. Such a means permits accurate placement of adjacent panels prior to joining them. Preferably the support further includes at least one fastener device for fastening adjacent building panels to one another.

Preferably the at least one fastener device is further operable to clamp adjacent building panels to one another prior to fastening them. Such clamping may improve the accuracy with which adjacent panels are joined together. Preferably the at least one fastener device is movably mounted to the support so that it is movable along a joint between adjacent building panels when they are received in the frame, the at least one fastener device for fastening adjacent building panels along at least a portion of the length of the joint. Preferably the at least one fastener device is movable mounted on a beam of the support. Preferably the beam is movably mounted to the support. Preferably the fastener device is provided with a drive device for providing said movable mounting to the support Such movable arrangements of the beam and or fastener improve the versatility of the apparatus to join building panels and assemble them into building structured.

Preferably the at least one fastener device includes a drill tool. Preferably the at least one fastener device includes a hammer tool. Preferably the drill tool and the hammer tool are located on a tool carriage of the fastener device. Such tools may permit the use of impact driven fasteners to be used for joining adjacent building panels. Preferably the tool carriage is movably mounted on the fastener device in a direction perpendicular to the direction of travel of the fastener device. This has the advantage of providing an improved versatility to the fastener device when joining adjacent building panels.

The apparatus may be provided as a portable trailer. Such an arrangement permits the apparatus to be transported to a building site for manufacture of the building structures on site. This may reduce some of the problems at a building site when assembling building panels into building structures.

The apparatus may further include a plurality of conveyor line means for providing building panels to the apparatus. Such conveyor line means may provide different sized panels to the apparatus, and help to improve the efficiency of operation of the apparatus when manufacturing building structures. Preferably the plurality of conveyor line means are connected to one another at an end thereof. Connecting the conveyor line means in this way may be useful when locating building panels of different sizes into the apparatus.

According to a further aspect of the invention there is provided a method of assembling a building structure using an apparatus comprising a support, a frame rotatably mounted to the support, and a drive device for rotatable movement of the frame relative to the support, the method including: receiving a first building panel in the frame; rotating the frame; receiving a second building panel in the frame; and joining the first and second building panels together to form a building structure.

Such a method permits building structures, such as timber building modules, to be manufactured in a more controlled manner. Loading building panels into the apparatus after rotation of the frame permits building panels to be readily handled and manipulated prior to joining them to each other. The building structure may be manufactured with improved efficiency and with a reduced environmental impact. The apparatus may further permit the building structure to be manufactured with an improved tolerance for dimensions of the building structure, which may further assist with control of quality of the building structure. This has a consequential effect on improving the energy efficiency of the finished building structure due to a reduction of gaps in joints of the building structure, or adjacent building structures when many building structures are assembled adjacent to one another at a building site. Such an improvement in the tolerances of dimensions of the building structure may reduce draughts and thereby heat loss from the finished building. Using such a method further permits the building structure to be manufactured to an appropriate financial and environmental cost. The finished building structure may therefore be manufactured with a reduced environmental impact.

Preferably the method further includes providing the frame as a cylinder, the method including receiving at least one panel in the frame via an end of the cylinder. Such a method is an advantageous was of receiving panels within the frame.

Preferably the method further includes rotating the frame in successive portions of substantially 90°, and receiving consecutive building panels in the frame after a said portion of rotation. Such a method can be used to manufacture a building structure comprising four sides to be manufactured within the frame. The successive portions of substantially 90° may be two portions of substantially 90° or in other words 180°.

Preferably the method further includes providing the apparatus with at least one flip device arranged at an end of the rotatable frame, the method including pivoting a building panel by substantially 90° using the at least one flip device to at least partially close the building structure. Preferably the method includes using incremental adjustment means for moving of adjacent building panels relative to each other prior to joining them together. Such a means permits accurate placement of adjacent panels prior to joining them.

Preferably the method includes using at least one fastener device for joining adjacent building panels to one another with fasteners. Preferably the method includes clamping adjacent building panels to one another prior to joining them. Such a method may improve the accuracy with which adjacent panels are joined together. According to another aspect of the invention there is provided a building structure produced using an apparatus of the first aspect of the invention, or produced using a method of the second aspects of the invention.

The building structure may further include at least one gasket between at least one pair of adjacent building panels.

According to a further aspect of the present invention there is also provided a method of assembling a building structure using an apparatus comprising a support, a frame rotatably mounted to the support, and a drive device for rotatable movement of the frame relative to the support, the method including: receiving a building panel in the frame; rotating the frame through at least a part of a circle; receiving another building panel in the frame; and joining the two building panels together to form a building structure.

According to a further aspect of the present invention there is also provided a timber building module production system for assembling timber building modules. The timber building module production system comprising: a conveyor system; a panel production station disposed along the conveyor system for production of prefabricated timber building panels; and an assembly station disposed along the conveyor system, the assembly station configured to receive prefabricated timber building panels from the panel production station and assemble the prefabricated timber building panels into timber building modules. In examples, the assembly station may comprise a support, a frame rotatably mounted to the support, and a drive device for rotatable movement of the frame relative to the support. The frame may be adapted to receive a first prefabricated timber building panel, rotate the first prefabricated timber building panel, and receive a second prefabricated building panel for fastening to the first prefabricated timber building panel for assembly into timber building modules.

In examples, the assembly station may comprise at least one fastener device for fastening the first and second prefabricated timber building panels to one another.

In examples, the conveyor system may comprise multiple conveyor branches. In examples, the assembly station may be disposed on a first conveyor branch, and the panel production station may be disposed on a second conveyor branch. In examples, the multiple conveyor branches may be discontinuous and connected to one another by way of a transfer device for transferring the prefabricated timber building panels between each of the multiple conveyor branches. In examples, the transfer device may comprise a turntable. In examples, the multiple conveyor branches may extend radially from the turntable. In examples, the conveyor system may be configured to enable the prefabricated timber building panels to roll or slide along the conveyor system. In examples, the conveyor system may comprise a plurality of trolleys configured to roll or slide along the conveyor system, and wherein the prefabricated timber building panels can be carried on the plurality of trolleys. In examples, the conveyor system may comprise a first rail, a second rail, and at least one intermediate rail. In examples, the first and second rails may be connected to the at least one intermediate rail. In examples, the at least one intermediate rail may be disposed closer to the first rail than to the second rail.

In examples, the panel production station may comprise a rotating device configured to rotate a prefabricated timber building panel or a part thereof during production of the prefabricated timber building panel. In examples, the rotating device may comprise a support, a frame rotatably mounted to the support, and a drive device for rotatable movement of the frame relative to the support. The frame may be adapted to receive a prefabricated timber building panel or a part thereof. In examples, the frame may comprise a support frame for supporting the prefabricated timber building panel or part thereof, and wherein a longitudinal axis of the support frame is aligned to a rotational axis of the frame. In examples, the drive device is hydraulically powered.

In examples, the timber building module production system can be disassembled. For example, the timber building module production system may be a temporary structure.

In examples, the conveyor system comprises an output conveyor for receiving timber building modules from the assembly station.

In examples, the timber building module production system further comprises at least one fitting station disposed along the conveyor system for assembling fittings and fixtures to the prefabricated timber building panels.

According to a further aspect of the present invention there is also provided a method of producing a timber building module, the method comprising: producing a plurality of prefabricated timber building panels at a panel production station, the panel production station disposed at a first position along a conveyor system; conveying the plurality of prefabricated timber building panels along the conveyor system to an assembly station disposed at a second position along the conveyor system; and assembling the plurality of prefabricated timber building panels into a timber building module at the assembly station.

In examples, the assembly station comprises a support, a frame rotatably mounted to the support, and a drive device for rotatable movement of the frame relative to the support. In such examples, the method may include: receiving a first prefabricated timber building panel in the frame; rotating the frame; receiving a second prefabricated timber building panel in the frame; and fastening the first prefabricated timber building panel to the second prefabricated timber building panel to form a timber building module.

In examples, the method may comprise using at least one fastener device for fastening the first and second prefabricated timber building panels to one another with fasteners. In examples, the panel production station comprises a rotating device for rotating a prefabricated timber building panel or a part thereof. In such examples, the method may comprise partially assembling a prefabricated timber building panel, rotating the partially assembled prefabricated timber building panel using the rotating device, and completing assembly of the prefabricated timber building panel.

In examples, the conveyor system comprises multiple conveyor branches, and wherein the multiple conveyor branches are discontinuous and connected to one another by way of a transfer device. In such examples, the method may comprise transferring prefabricated timber building panels between conveyor branches using the transfer device.

In examples, the method may further include assembling fittings and fixtures to the plurality of prefabricated timber building panels at an at least one fitting station, the at least one fitting station disposed at an intermediate position between the first position and the second position along the conveyor system.

According to another aspect of the invention there is provided a building comprising a building structure produced using the apparatus and/or method according to any other aspect of the invention.

Brief Description of the Drawings

Other features of the invention will be apparent from the following description of preferred embodiments shown by way of example only with reference to the accompanying drawings, in which;

Figure 1 shows a perspective view of an apparatus for manufacturing a building structure according to an embodiment of the invention;

Figure 2 shows a side view of the apparatus of Figure 1;

Figure 3 shows a perspective view of an arm and actuator arrangement of Figure 1 in an open condition;

Figure 4 shows a perspective view of the arm and actuator arrangement of Figure 3 in a closed condition;

Figure 5 shows a perspective view of a corner joint of a building module according to an embodiment of the invention;

Figure 6 shows a side view of the corner joint of Figure 5; Figure 7 shows a perspective view of a fastening device shown in Figure 1;

Figure 8 shown a perspective view of the fastening device of Figure 7 in situ on a beam together with a comer joint;

Figure 9 shows a diagram of a method according to an embodiment of the present invention;

Figure 10 shows a perspective view of an apparatus for manufacturing a building structure according to another embodiment of the invention;

Figure 11 shows another view of the apparatus of Figure 10

Figures 12a-g show seven perspective views of the assembly of the building module using the apparatus;

Figures 13a-b show an example prefabricated timber building panel;

Figures 14a-b show perspective views of a timber building module production system for assembling timber building modules;

Figures 15a-b show a perspective view of an example conveyor branch of the conveyor system of the timber building module production system of Figure 14a-b;

Figures 16a-b show perspective views of an example conveyor branch of the conveyor system of the timber building module production system of Figure 14a-b;

Figure 17 shows a perspective view of an example assembly station of the timber building module production system of Figure 14a-b;

Figures 18a-c show perspective views of an example panel production station of the timber module production system of Figure 14a-b;

Figure 19a-b show methods of producing a timber building module;

Figure 20a-c show perspective views of the timber building module during assembly;

Figure 21 shows a perspective view of multiple timber building modules;

Figures 22a-b show perspective views of an insulation block for the prefabricated timber building panels of Figure 13;

Figure 23 shows a perspective view of a prefabricated timber building panel of Figure 13 comprising multiple insulation blocks of Figures 22a-b;

Figures 24a-b show perspective views of a plurality of interlocking construction blocks of Figure 22a-b for constructing a building element; and

Figures 25a-b show perspective views of a horizontal prefabricated timber building panel of Figure 13 to a building element. Detailed Description

Figure 1 shows a perspective view of an apparatus for manufacturing a building structure according to an embodiment of the invention, generally designated 10. The apparatus 10 has a body 12 that is cuboid in shape and which is defined by a perimeter frame. The body 12 has four vertical steel beams 14 which are connected together at a top region by four horizontal steel beams 16. The four vertical steel beams 14 are also connected at a bottom region by four horizontal beams 18. Together, the steel beams 14, 16 and 18 comprise the body 12 and define an inner space 19 of the body 12. The body 12 has dimensions of about 8m in height, 7m in width, and 9m in length.

The body 12 has a sub-frame 20 located in the inner space 19 and which is rotatably mounted to the body 12. It is envisaged that the sub-frame 20 is fully rotatable about 360° relative to the body 12, however it will be appreciated that the sub-frame 20 may be pivotable mounted to the body 12 such as up to 360°, or more than 360°. The sub-frame 20 is substantially cylindrical in shape and is defined by a perimeter frame of steel which comprises two circular end beams 22 which are connected together by eight horizontal beams 24. Together, the two circular end beams 22 and the eight horizontal beams 24 comprise the sub-frame 20 and define an inner space 21 of the sub-frame 20. The steel beams 14, 16, 18, 22, 24 are I-beams having a suitable section to provide structural rigidity and dimensional stability to the body 12 and the sub-frame 20. Connection of the steel beams 14, 16, 18, 22, 24 to one another is provided by bolting and/or welding as appropriate.

Each of the circular end beams 22 comprises a track 26 on an outer circumferential part thereof. Each track 26 sits on two rollers 28 of the body 12, and each roller 28 is substantially at a lower comer of the body 12. In Figure 1 only one roller 28 can be seen due to the particular perspective view shown. It can also be seen that each track 26 comprises an inner part of the I-beam of each circular end beam 22. Together the sub-frame 20 is supported in the body 12 by the four rollers 28 to provide said rotatable mounting of the sub-frame 20 to the body 12. It will be appreciated that one or more of the rollers 28 may be provided with a drive mechanism 30 so that the sub-frame 20 can be rotated within the body 12 as required. Alternatively the sub-frame 20 or the body 12 may be provided with a separate drive mechanism to rotate the sub-frame 20 in the body 12. It will also be appreciated that the rollers 28 may be gear wheels having teeth, and the tracks 26 may be shaped to correspond with the teeth (e.g., to form a rack and pinion arrangement). Such an arrangement may provide an advantageous way of rotating the sub-frame 20 and providing grip between the gear wheels and the tracks. Alternatively, the rollers 28 may be termed wheels. Alternatively bearings may be used instead of, or as well as, the rollers 28.

Each end of the cylindrical sub-frame 20 is substantially open so that it can receive panels via the open ends. A building structure, such as a timber building module 32, can then be assembled within the inner space 21 of the sub-frame 20. Figure 1 shows the timber building module 32 partially constructed so that it has a floor panel, a ceiling panel and two long sidewall panels already in place. The timber building module 32 has dimensions of about 2.5m in height, 4.5m in width, and 8m in length. The floor panel, the ceiling panel and the two long side-wall panels are fed into the inner space 21 of the sub-frame 20 from three conveyor belts in a horizontal manner and in a direction indicated by arrow 34. After one panel is fed into the inner space 21, the sub-frame 20 is rotated through 90° before inserting another panel into the inner space. The apparatus 10 has incremental adjustment means to move one panel relative to another panel so that they are positioned next to one another to an accuracy of ±lmm, or up to ±10mm. Such an incremental adjustment means may be provided by actuator devices or hammer devices to move one panel relative to another panel.

Once the floor panel, the ceiling panel and the two long side-wall panels have been fed into the inner space 21, they are clamped and fastened together with fastener devices 36 which are movable on horizontal beams 38 of the body 12. The sub-frame 20 has bearing means along the length of the horizontal beams 24 so that the panels can be inserted into the inner space 21. The panels which form the timber building module 32 comprise a frame of wood which is filled with insulating material and clad with a front and rear skin of Oriented Strand Board (OSB). Structural members may also be contained within the panels to form Structurally Insulated Panels (SIPs). Such panels are described in relation to Figure 13a and 13b. It will be appreciated that the panels would be constructed with door openings and/or window openings. Such openings have been omitted for the purposes of clarity. The panels which form the timber building module 32 are wooden panels, but it will be appreciated that the apparatus 10 is capable of handling any type of panel, having any type of construction and generally made from any type of building material.

The horizontal beams 38 are arranged on the body 12 such that there are two horizontal beams 38 at each end of the cylindrical sub-frame 20, and two horizontal beams 38 on either side of the cylindrical sub-frame 20. In total there are eight horizontal beams 38, and eight fastener devices 36 Each horizontal beam 38 is connected to the body 12 so that they are movable in the vertical direction. Such vertical movability is provided by a rack and pinion arrangement 42 at each end of the horizontal beams 38. Each rack and pinion arrangement 42 is provide with a drive arrangement to permit incremental adjustment and accurate positioning of the fastener devices 36 relative to the timber building module 32. It will be appreciated that this arrangement of fastener devices 36 and horizontal beams 38 permit the fastening of panels to each other along all joints as required. The arrangement of horizontal beams 38 permits fastening of panel joints in the x and y directions of the timber building module 32. Rotation of the sub-frame 20 about 90° permits the fastening of panel joints in the z direction of the timber building module 32. In this manner all panel joints in all three dimensions can be fastened. Further details of the fastening arrangements are shown in Figures 7 - 11. Figure 1 also shows an end panel 44 that is about to be flipped though 90° by actuator arms 46 which are mounted in respective arm frames 48 of the body 12. The actuator arms 46 and arm frames 48 are located at an end of the body 12 and further details are provided in Figure 3. When the end panels 44 are flipped through 90° they are clamped and fastened in position by the fastener devices 36 to provide the timber building module 32 with six sides.

Figure 2 shows a side view of the apparatus of Figure 1. In Figure 2 like features to the arrangements of Figure 1 are shown with like reference numerals. In Figure 2 it can be seen that at another end of the body 12 there is also an arrangement of two actuator arms 46 and two arm frames 48 for flipping an end panel 44 through 90° for attachment to the timber building module 32. Further details of this arrangement are described in Figure 3.

Figure 3 shows a perspective view of an arm and actuator arrangement ofFigure 1 in an open condition. In Figure 3 like features to the arrangements ofFigure 1 and 2 are shown with like reference numerals. In Figure 3 each actuator arm 46 is shown to pivot about a pivotable connection 50 of an end frame 52 which is a part of the body 12. Also shown is the arrangement of the track 26 of the circular end beam 22 which sits on the roller 28. The I- beam which comprises the circular end beam 22 has side-cheeks 54 which at least partially envelop the roller 28 to form a guide or channel. This arrangement ensures that the roller 28 remains in contact with the track 26. In Figure 3 the roller 28 is shown to be a pneumatic tyre or a solid rubber tyre having a tread or gripping surface to inhibit slipping of the surface of the roller 28 relative to the track 26. It will be appreciated that the roller 28 may be of another suitable material to limit slippage such as steel

Figure 4 shows a perspective view of the arm and actuator arrangement of Figure 3 in a closed condition. In Figure 4 like features to the arrangements of Figures 1 - 3 are shown with like reference numerals. In Figure 4 an end of each actuator arm 46 is shown to be connected to a flipping plate 56 which is connected to the body 12 by the pivotable connection 50. The other end of each actuator arm 46 is shown to be connected to its associated arm frame 48. Each actuator arm 46 is shown in an extended condition so that the end panel 44 is flipped through 90°. The end panel 44 can then be fastened to the side wall panels, the ceiling panel, and the floor panel to form the timber building module 32.

Figure 5 shows a perspective view of a corner joint of a building module according to an embodiment of the invention, generally designated 60. The corner joint 60 comprises a side wall panel 62, and a floor panel 64. The skin 66, 68 of OSB of each panel 62, 64 is also shown. The panels 62, 64 are joined together using known HELIFIX™ fasteners 70, which are known to the skilled person, and comprise an elongate pin having two helical flutes terminating at a cutting end. The fasteners 70 are inserted by firstly drilling a pilot hole from a surface of the floor panel 64, through the depth of the floor panel 64, and into a plane of the side wall panel 62. The fasteners 70 are then driven into the pilot hole using a reciprocating power driven tool which engages the fastener 70 without a driven torque. The helical flutes of the fastener 70 cause the fastener to rotate while confined within the pilot hole, which j oins the panels 62, 64 together. Pairs of fasteners 70 are inserted along the length of the joint between the panels 62, 64. One pair of fasteners typically has a spacing of 0.2 - 0.3m from the adjacent pair of fasteners 70.

Figure 6 shows a side view of the corner joint of Figure 5. In Figure 6 like features to the arrangements of Figure 5 are shown with like reference numerals. In Figure 6, the OSB skin 66 of the side wall panel 62 is shown to have an extension part 72 which covers an end of the floor panel 64. A gasket 74 is also shown between the extension part 72 and the end of the floor panel 64. Another gasket 76 is shown between an end of the side wall panel 62 and an upper surface of the floor panel 64. The gaskets 74, 76 extend along the whole length of the panels 62, 64 and assist in reducing the air flow between inner and outer parts of the timber building module 32. The gaskets 74, 76 are of a rubber like material which conforms to the panels 62, 64 which are intended to provide an hermetic seal between an exterior and interior of the timber building module 32. The gaskets 74, 76 may assist with closing gaps between the panels 62, 64.

Figure 7 shows a perspective view of a fastening device 36 shown in Figure 1. In Figure 7 like features to the arrangements of Figure 1 - 6 are shown with like reference numerals. In Figure 7, the fastening device 36 comprises a body 80 which has a first set of rollers 82 and a second set of rollers 84. The rollers 82, 84 sit on the horizontal beam 38 and permit movement of the fastening device 36 on it. The rollers 82, 84 are provided with drive means located in the body 80. The body 80 also has a fastener magazine 86 that is movable on the body 80 by a drive means 88 in a direction parallel to the direction of travel of the body 80 on the horizontal beam 38. Whereas the drive means 88 is shown to be outside the body 80 it will be appreciated that it may be inside the body 80. The fastener magazine 86 hold fasteners 70 which are selectable by a selection device 90. The body 80 also has a tool carriage 92 that is movable on the body 80 in a direction perpendicular to the direction of travel of the body 80 on the horizontal beam 38. The tool carriage 92 has a drive means to move it which is located within the body 80. The tool carriage 92 has a first set of tools 94 for drilling pilot holes, and a second set of tools 96 for engaging and securing fasteners 70. The selection device 90 picks up fasteners 70 from the fastener magazine 86 and locates them into the second set of tools 96. It will be appreciated that the first set of tools 94 are drill devices which operate with a rotational action and without a hammer action to drill pilot holes in timber building panels. The second set of tools 96 are impact hammer device which operate without a rotational action and with a hammer action to drive fasteners 70 as per the arrangements of Figures 5 and 6.

Figure 8 shows a perspective view of the fastening device 36 of Figure 7 in situ on a beam 38 together with a comer joint 60. In Figure 8 like features to the arrangements of Figure 1 - 7 are shown with like reference numerals. In Figure 8, the rollers 82 are rollable on inner surfaces 98 of the horizontal beam 38 with the I-beam being located in its normal orientation so that a bar of the I is vertical. The rollers 84 are shown to be rollable on an upper surface 100 of the horizontal beam 38. The body 80 is substantially the shape of a chair and the corner joint 60 is arranged within a free space defined by a back of the chair and a seat of the chair. In operation the apparatus 10 is provided with clamping means which may be a part of each fastening device 36. The clamping means are operable to clamp up to six wall, floor and ceiling panels before they are fastening together with the fastener device 36 as shown with reference to Figures la-d.

In alternative examples the apparatus 10 may not include the fastening device 36. In such examples the apparatus 10 may provide access, for example through a window, for an operator to manually fasten the panels to each other. The panels may be connected to each other using fasteners, in particular nails or threaded fasteners such as screws. In one example each fastener may comprise a U-shaped clamp that is fed from within one panel, through holes in both panels, and having threaded ends that are secured with nuts to clamp the panels together in a perpendicular arrangement. It will be appreciated that the panels may be attached to each other in various ways, including by use of fasteners, clamps, and adhesive. Two panels may be attached to each other at a plurality of spaced locations along their length.

In an alternative embodiment the apparatus 10 may be transported to a building site so that timber building modules 32 can be manufactured at the building site and placed in situ on concrete foundations and assembled to form a building. In one embodiment the apparatus 10 is provided as a movable trailer that may be transported to a building site. The panels comprising the timber building module 32 may be manufactured away from the building site and transported to the apparatus 10 at the building site for assembly into timber building modules 32. Alternatively the panels may be manufactured at the building site. These arrangements avoid the requirement to have a factory location, and the requirement to store the assembled timber building modules 32 at a factory location. Instead, the timber building modules 32 can be manufactured and placed in situ directly at the building site. Furthermore, the assembled building may be fitted out with house fixtures, fittings and furnishings at the building site using a local workforce. This arrangement may have the advantage of avoiding the requirement for a dedicated workforce at a factory location.

Figure 9 shows a diagram of a method according to an embodiment of the present invention, generally designated 180. The method 180 is a method of assembling a timber building module 32 using an apparatus 10 comprising a body 12, a sub-frame 20 rotatably mounted to the body 12, and a drive device 30 for rotatable movement of the sub-frame 20 relative to the body 12. The method includes receiving a first building panel in the frame as shown at 182. The method includes rotating the sub-frame 20 by a required angle, for example substantially 90°, as shown at 184. The method includes receiving a second building panel in the sub-frame 20 as shown at 186. The method includes joining the first and second building panels together to form a building structure 32 as shown at 188.

The method includes providing the sub-frame 20 as a cylinder and receiving 182 at least one panel in the sub-frame 20 via an end of the cylinder. The method further includes rotating 184 the sub-frame 20 in portions of substantially 90°, and receiving consecutive building panels in the sub-frame 20 after a said portion of rotation. The method further includes at least one actuator arm 46 arranged at an end of the sub-frame 20 for pivotable moving a building panel by substantially 90° to at least partially close the building structure 32. The method further includes using incremental adjustment means for moving adjacent building panels relative to each other prior to joining them together. The method further includes using at least one fastener device 36 for joining adjacent building panels to one another with fasteners. The method further includes clamping adj acent building panels to one another prior to joining 188.

The manner of construction of the complete building described above permits timber building modules 32 to be manufactured at a factory location, such as a warehouse or a yard, and then transported by lorry to a building site. Alternatively they may be manufactured at the building site by transporting the apparatus 10 to the building site. The building modules 32 can then be lifted into place on concrete foundations, using a crane.

Figure 10 shows a perspective view of an apparatus for manufacturing a building structure according to another embodiment of the invention, generally designated 200. In Figure 10 like features to the arrangements of Figures 1 to 4 are shown with like reference numerals. In Figure 10 it can be seen that there are eight rollers 28 of the body 12 for the two tracks 26 such that each track 26 has four rollers 28. Four rollers 28 are substantially at a lower corner of the body 12. Four rollers 28 are substantially at an upper corner of the body 12. In Figure 10 only seven rollers 28 can be seen due to the particular perspective view shown. The subframe 20 is supported in the body 12 by the eight rollers 28 to provide said rotatable mounting of the sub-frame 20 to the body 12. In the embodiment of Figure 10 the rollers 28 are not drive rollers, and instead a separate drive device is provided to rotate the sub-frame 20. The separate drive device comprises a drive mechanism 30 with a cord 202 (for example a belt or chain etc), which acts on a wheel 204 of one of the tracks 26. The wheel 204 being secured to one of the tracks 26. Alternatively one or more of the rollers 28 may be gear wheels having teeth, and the corresponding wheel 204 may be shaped to engage with the teeth. The wheel 204 is a driven wheel, and may be termed a cog, a pulley, or gear etc Alternatively bearings may be used instead of, or as well as, the rollers 28. It will be appreciated that the apparatus 200 shown in Figure 10 is illustrated in a “stripped back” form without a conveyor apparatus (see Figure 11) that allows SIP panels to be inserted into the apparatus 200 and joined together to form housing modules using fastener devices 36 (also not shown in Figure 10). Figure 11 shows another view of the apparatus of Figure 10. In Figure 11 like features to the arrangements of Figure 10 are shown with like reference numerals. In Figure 11 the apparatus 200 is shown with a cage-like structure 206 comprising a conveyor apparatus to transport SIPs into the apparatus 200 and to hold the SIPs in place when they are joined together. In other words, each SIP comprising the four walls, the ceiling, and the floor are sequentially conveyed into position. The conveyor apparatus comprises, for example, rollers or other bearings to allow the SIPs to be moved into place on top of one of the sides of the cage-like structure 206 when horizontal. The cylindrical sub-frame 20 is systematically rotated through 90° or 180° to enable positioning and fixing of the two side-walls, the ceiling and the floor.

It will be appreciated that an end gable wall is the first SIP to be loaded into the cylindrical sub-frame 20 via a portion 207 of the conveyor apparatus as shown by arrow 208. This first SIP passes through the cylindrical sub-frame 20 and is ‘parked’ on another portion 210 (i.e. the portion 210 is horizontal when the first SIP is ‘parked’ on it) of the conveyor apparatus until the two side-walls, the ceiling and the floor are secured together. The portions 207, 210 of the conveyer apparatus are not part of the apparatus 200, and are instead a part of a production line for transporting the SIPs in a factory in which the apparatus 200 is located. The portions 207, 210 are moved into position as shown by arrow 212, for example by hydraulic actuators and arms (see Figure 3), so that they are substantially vertical. In this manner the two end gable walls are positioned horizontally prior to securing them to the rest of the housing module structure. In other words, the four long sides of the building module (i.e. the two side-walls, the ceiling and the floor) are fixed to one another and are structurally stable before the two end gable walls are secured. After assembly of the six SIPs the building structure is ready for transport and ‘fit out’ with housing fixtures, fittings and/or furnishings.

Figures 12a-g show seven perspective views of the assembly of the building module using the apparatus 200. In Figures 12a-g like features to the arrangements of previous embodiments are shown with like reference numerals. In Figure 12 the cage-like structure 206 shown in Figure 11 has been omitted for clarity, and all views in Figure 12a-g are from the same end of the apparatus 200 The first stage of assembly of the building module is to position a far end gable SIP onto the portion 210 of the conveyor apparatus, as previously described with reference to Figure 11. As shown in Figure 12a ceiling panel SIP 214 is then moved into the sub-frame 20. The ceiling panel SIP 214 is positioned by digital location sensors and is secured by temporary or sacrificial fixings (e.g. strops or fasteners etc). The sub-frame 20 is then rotated anticlockwise by 90° as shown by arrow 216 in Figure 12b, where it is locked in place so that it is secure, for example with failsafe electromagnetic solenoid bolts . A first side-wall SIP 218 is then moved into the sub-frame 20 as shown in Figure 12c. The side-wall SIP 218 is positioned by digital location sensors and is secured by temporary or sacrificial fixings (e.g. strops or fasteners etc). The sub-frame 20 is then rotated clockwise by 180° (i.e. two portions of 90°) as shown by arrow 221 in Figure 12d and locked in place. A second side-wall SIP 220 is then moved into the sub-frame 20 as shown in Figure 12e. The second side-wall SIP 220 is positioned by digital location sensors and is secured by temporary or sacrificial fixings. The sub-frame 20 is then rotated clockwise by 90° as shown by arrow 222 in Figure 12f and locked in place. A floor SIP 224 is then moved into the sub-frame 20 as shown in Figure 12g. The floor SIP 224 is positioned by digital location sensors and is secured by temporary or sacrificial fixings. The four SIP panels 214, 218, 220, 224 are now secure and are ready to receive the gable end walls (one of which is shown at 4 in Figure 1).

From Figures 12a-g it can been seen that the four SIP panels 214, 218, 220, 224 are inserted into the sub-frame 20 when they are horizontal, which allows them to be supported by the conveyor apparatus as they are moved into place within the sub-frame 20 and secured together. It is to be noted that less energy may be used for some of the rotation steps due to the mass of one or more SIPs already secured together. For example, the rotation step shown by arrow 221 may require relatively less energy.

Manufacture and assembly of the building in such a manner means that the timber building modules 32 can be manufactured in a more controlled way using the apparatus 10, 200. This is a more efficient way of constructing the building and provides a timber building module of an improved quality when compared to the prior art which requires assembling panels directly onto concrete foundations to form a building at the building site. Manufacturing the timber building modules 32 using the apparatus 10, 200 provides the advantage of reducing the time to manufacture the building. With the embodiment having the apparatus 10, 200 located at the factory building, the build process is even more controlled, which provides a further improvement in the quality of manufacture of the building. Using such a method of manufacture reduces the environmental impact of constructing the building, and may improve the overall energy efficiency for such a building. This may further improve the overall efficiency and reduced environmental impact for the building over its lifetime.

The embodiments described above can be used to provide high-volume manufacturing of timber building modules 32, such as the manufacture of up to 1000 timber building modules 32 per month. At least one of the technical features of the apparatus 10, 200 the sub frame 20, drive mechanism 30, the fastener devices 36, the drive arrangement of the rack and pinion arrangement 42 of horizontal beams 38, the actuator arms 46, the drive means 88 of the fastener devices 36, the selection device 90, the tool carriage 92, may be controlled by an automated control system. The automated control system is a computer apparatus which provides control signals to the technical features of the embodiments of the invention. The computer apparatus has a computer program for controlling the efficient running of the technical features of the embodiments of the invention. Such a computer program may also include adaptive learning sub-routines and/or neural network software to maintain an efficient operation for the technical features of the embodiments of the invention. The computer apparatus may also include Computer Aided Design (CAD) and Computer Aided Manufacture (CAM) apparatus to further assist with the construction of the timber building modules 32.

It will be understood that in one embodiment the apparatus 10, 200 is part of a production line at a factory location (i.e. a factory building). The production line may assemble and handle the SIPs 44, 214, 218, 220, 224 and deliver them to the apparatus 10, 200 for manufacture into the timber building modules 32. The production line may also transport the finished timber building modules 32 in and around the factory where the apparatus 10, 200 is located. It will be understood that the apparatus 10, 200 is secured to the ground (i.e. a foundation) of a factory floor so that the forces generated by operation thereof (e.g. rotation of the sub-frame 20) do not cause the apparatus 20, 200 to move substantially.

Figures 13a and 13b show an example prefabricated timber building panel 300, such as the timber building panels 44, 214, 218, 220, 224 described above. The prefabricated timber building panels 300 may comprise a number of joists 320 that extend over the width of the prefabricated timber building panel 300. Each joist 320 may be substantially identical. In other examples, the joists 320 may be non-identical (for example, the joists 320 may comprise different thicknesses in order to accommodate structural requirements). The joists 320 may comprise a length between about 1 metre and about 3 metres, for example about 1.2 metres. The timber building panel 300 has a corresponding width. At first and second ends of the joists 320, the joists 320 are connected to horizontal members 324 that extend over the length of the prefabricated timber building panel 300. The horizontal members 324 may comprise a length between about 1 metre and about 5 metres, for example about 1.2 metres, or about 2.4 metres, or about 2.7 metres, or about 3 metres. The thickness of the timber building panel 300 may be between about 100mm, and above 300mm, for example about 100mm, or about 125mm, or about 150mm, or about 175mm, or about 200mm, or about 225mm, or about 250mm thickness if required. As will become apparent hereinafter, the dimensions of the timber building panel 300 can be determined based on the intended timber building module, so can vary.

The joists 320 may be connected to the horizontal members 324 by nails, adhesives, joints, or any of fixing means known in the art. Each horizontal member 324 may comprise the same material properties (e.g., type of timber, grade of timber, composition) as the joists 320. In other examples, the horizontal member 324 may comprise different material properties than the joists 320 (for example, horizontal members 324 may comprise a material with higher strength properties than joists 320). The joists 320 may be connected to the horizontal members 324 such that gaps 322 are formed between each joist 320 along the length of the prefabricated timber building panel 300. The gaps 322 may be equal in dimension over the length of the prefabricated timber building panel 300. Alternatively, in some instances the spacings 322 may be unequal (for example, to accommodate incoming services).

As shown in Figure 13b, each joist 320 may comprise a top chord 336a, a bottom chord 336b spaced from the top chord 336a, and web elements 322 that extend between the top chord 336a and bottom chord 336b. At first and second ends of the top chord 336a and the bottom chord 336b, the top chord 336a and bottom chord 336b may extend between, and connect to, the horizontal members 324 (as described in relation to Figure 13a). The web elements 322 may be disposed at a number of points along the length of the top chord 336a and the bottom chord 336b. At a first end of the web element 322, the web element 322 may be fixed to the top chord 336a, and at a second end of the web element 322, the web element 322 may be fixed to the bottom chord 336b. The web element 322 may be connected to the top chord 336a and bottom chord 336b by nails, adhesives, joints, or any of fixing means known in the art. The top chord 320a and bottom chord 320b may comprise timber. The web elements 322 may comprise a metal (e g., steel, iron, or a composite material), or, alternatively, timber. The top chord 336a and bottom chord 336b may be configured to transfer the load applied to the prefabricated timber building panel 300 to the horizontal members 324. Whereas, the web elements 322 may spread the load applied to the prefabricated timber building panel between the top chord 336a and bottom chord 336b, and ensure that the top chord 336a and bottom chord 336b act compositely.

Figures 14a and 14b show perspective views of a timber building module production system 1000 for assembling timber building modules 350, such as timber building modules 32 (as described in relation to Figures 1 to 12). The timber building module production system 1000 comprises a conveyor system 400 for conveying prefabricated timber building panels 300 (such as timber building panels 44, 214, 218, 220, 224, 300, as described in relation to Figures 1 to 13), a panel production station 500 disposed along the conveyor system 400 for production of the prefabricated timber building panels 300, and an assembly station 600 disposed along the conveyor system 400. The assembly station 600 is configured to receive the prefabricated timber building panels 300 from the panel production station 500 and to assemble the prefabricated timber building panels 300 into timber building modules 350. The conveyor system 400 may also be suitable for conveying a part of a prefabricated building panel 300.

The conveyor system 400 may comprise multiple branches. For example, the conveyor system 400 may comprise seven conveyor branches 402a-g, as shown in Figure 14a. It will be appreciated, however, that the conveyor system 400 may comprise more or fewer than seven conveyor branches 402. The multiple conveyor branches 402 of the conveyor system 400 may be discontinuous or, in other words, not directly connected to one another. The multiple conveyor branches 402 may however be connected to one another by way of a transfer device 404 for transferring the prefabricated timber building panels 300 between each of the multiple conveyor branches 402. The transfer device 404 may be connected to each conveyor branch 402 at a first end of each conveyor branch 402. The transfer device 404 may be a turntable, or any other suitable means for transferring prefabricated timber building panels 300 between each of the multiple conveyor branches 402. The turntable may comprise a rotation mechanism to allow the prefabricated timber building panel 300 to rotate about a point, and align with a given conveyor branch 402. The prefabricated timber building panel 300 may subsequently be transferred onto a further conveyor branch of the multiple conveyor branches 402 For example, the prefabricated timber building panel 300 may be transferred from a first conveyor branch 402a, comprising the panel production station 500, to a second conveyor branch 402d, comprising the assembly station 600, by way of the transfer device 404. The multiple conveyor branches 402 may extend radially from the turntable, such that the conveyor branches are orientated at different angles of rotation about the turntable. In such examples, the multiple conveyor branches 402 may be spaced at equal spacings around the turntable (as shown in both Figures 14a and 14b), and in other examples, the multiple conveyor branches 402 may be spaced at unequal spacings around the turntable.

The multiple conveyor branches 402 may be of the same length, or, as shown in Figure 14a, of different lengths. At second ends of the multiple conveyor branches 402 (i.e., the end of the conveyor branches 402 not connected to the transfer device 404), the multiple conveyor branches 402 may terminate, or be connected to a further conveyor branch for transferring the prefabricated timber building panels 300 to a further location. The conveyor branch 402 may be connected to the further conveyor branch by way of a further transfer device (for example, a further turntable). Each of the multiple conveyor branches 402 may be configured for a distinct function, relating to the production of the timber building modules 350. As shown in Figure 14a, for example, the assembly station 600 may be disposed on a first conveyor branch 402a, and the panel production station 500 may be disposed on a second conveyor branch 402d. The conveyor branches 402 may also comprise a fitting station 700 for assembling fittings and fixtures 302 to the prefabricated timber building panels 300. In some examples, the conveyor branches 402 may comprise multiple fitting stations 700 for different purposes (e.g., fitting kitchens, electrics, or plumbing). The conveyor branches 402 may also be used for temporary storage of the prefabricated timber building panel 300 before and/or after being received in either of the panel productions station 500 or the assembly station 600. At least one of the multiple conveyor branches 402 may be a goods inward conveyor on which goods, for example, building materials, are loaded (e.g., from a haulage vehicle). A lifting device, such as a crane, may be provided for moving the goods onto the conveyor branch 402. The conveyor system 400 may then be operated to move the goods to the required position in the timber building module production system 1000. At least one of the multiple conveyor branches 402 may be an output conveyor for outputting fully or partially assembled timber building modules 350. A lifting device, such as a crane, may be provided for lifting timber building modules 350 from the conveyor system 400 for movement onto the construction location of the building.

In other examples, the conveyor system 400 may be continuous, or comprise a singular conveyor branch 402. The conveyor branch 402 may be linear, curved, or any shape suitable for transferring the prefabricated timber building panels 300. Both the assembly station 600 and the panel production station 500 may be disposed on the singular conveyor branch 402 of the conveyor system 400. The assembly station 600 and the panel production station 500 may be spaced from one another along the length of the singular conveyor branch 402. Preferably, the panel production station 500 may be ordered before the assembly station 600 along the length of the singular conveyor branch 402, such that the prefabricated timber building panels 300 are transferred from the panel production station 500 to the assembly station 600. Where the timber building module production system 1000 comprises a fitting station 700, the fitting station 700 may be disposed between the panel production station 500 and the assembly station 600 along the length of the singular conveyor branch 700, such that the prefabricated timber building panels 300 are transferred to the assembly station 600 via the fitting station 700.

The timber building module production system 1000 may comprise multiple of any of the panel production station 500, assembly station 600, or fitting station 700. The timber building module production system 1000 may be modifiable such that any of the panel production station 500, the assembly station 600, or the fitting station 700 may be mounted and/or demounted from a conveyor branch 402 of the conveyor system 1000. Further, in some examples, the conveyor branches 402 and/or transfer device 404 of the conveyor system may be removed, replaced, or adjusted such that the conveyor system 400 is of a different configuration than that shown in Figure 14a.

As shown in Figure 14b, at least part of the conveyor system 400 of the timber building module production system 1000 may be substantially enclosed. For example, a portion of the length of the conveyor branches 402 of the conveyor system 400 may be enclosed. The at least part of the conveyor system 400 of the timber building module production system 1000 may be substantially enclosed with a tunnel system 416. The tunnel system 416 may protect any of the prefabricated timber panels 300, the timber building module 350, the panel production station 500, the assembly station 600, or the fitting station 700 from the elements (e.g., wind, rain, dust). The tunnel system 416 may comprise a cage-like structure with a covering (as diagrammatically shown in Figure 14b). As further shown in Figure 14b, in some examples, the tunnel system 416 may terminate towards the first end of the conveyor branches 402 of the conveyor system 400 (i.e., the end of the conveyor branches 402 connected to the transfer device 404), such that the transfer device 404 may not be enclosed. Alternatively, the tunnel may be configured such that the transfer device 404 of the conveyor system 400 may also be enclosed. In further examples, the entire timber building production system 1000 may be enclosed. For example, the timber building production 1000 may be enclosed by a tunnel system 416. The tunnel system 416 may be permanently, or temporarily, affixed to the conveyor branches 402, such that the conveyor system 400 may be easily manipulated (e.g., transported or rearranged).

Advantageously, the timber building production 1000 can be temporarily constructed at a construction site for production of timber building modules that are then assembled to provide buildings. The timber building production 1000, and in particular the tunnel system 416, can be assembled, used for production of timber building modules, and then disassembled and moved from the construction site. Therefore, the timber building production 1000 may be a temporary installation. Production of timber building modules onsite, including production of timber building panels 300 onsite, eliminates the need for transport of timber building modules and the like from offsite manufacturing locations, improving the efficiency of transport associated with the construction of the buildings and reducing the likelihood of damaging the timber building modules.

Figures 15a and 15b show a perspective view of an example conveyor branch 402 of the conveyor system 400 of the timber building module production system 1000, comprising a prefabricated timber building panel 300. The conveyor branch 402 comprises a first rail 408a and a second rail 408b, wherein the first rail 408a and the second rail 408b are spaced from one another. In some examples, the conveyor branch 402 comprises at least one intermediate rail 408c, for example, one intermediate rail 408c (as shown in Figures 15a and 15b). The first rail 408a and the second rail 408b may be connected to the at least one intermediate rail 408c. The first rail 408a and the second rail 408b may be connected to the at least one intermediate rail 408c by transverse members 409, the transverse members 409 disposed at points along the rail 408 and extending perpendicular to the rails 408. The transverse members 409 may be spaced at equal spacings along the length of the conveyor branch 402, or as shown in Figure 15a, at unequal spacings.

The rails 408 (including the first rail 408a, second rail 408b, and intermediate rail 408c) may comprise a substantially ‘inverted T-shape’ profile, as shown in Figures 15a and 15b, or any other suitable profile. Where the rails 408 comprise an ‘inverted T-shape’ profile, the flange of the ‘inverted T-shape’ profile may rest against a surface (e g., the ground or a foundation), and the web of the ‘inverted T-shape’ profile may support the prefabricated timber building panels 300. In some instances, as described in relation to Figures 16a and 16b, the web of the ‘inverted T-shape’ profile may support the prefabricated timber building panels 300 via a plurality of trolleys 406. The rails 408 may be constructed of a metal, for example, steel, iron, or a composite alloy.

As shown in Figures 15a and 15b, the at least one intermediate rail 408c may be closer to the first rail 408a than the second rail 408b. The distance between the first rail 408a and the second rail 408b may be between about 1 metre and about 3 metres, for example about 1.2 metres or about 2.4 metres. The distance between the at least one intermediate rail 408c and the second rail 408b may be between about 0.5 metres and about 2 metres, for example about 0.9 metres. Where the at least one intermediate rail 408c is disposed closer to the first rail 408a than the second rail 408b, this allows the conveyor branch 402 to accommodate prefabricated timber building panels 300 of a range of widths. The width of the prefabricated timber building panels 300 may be equal to, or greater than, the distance between the intermediate rail 408c and the first rail 408a and/or the second rail 408b. Alternatively, the width of the prefabricated timber building panels 300 may be equal to, or greater than, the distance between the first rail 408a and the second rail 408b. In some examples, the prefabricated timber building panel 300 may be supported on the first rail 408a, the second rail 408b, and the intermediate rail 408c (as shown in Figure 15b). In other examples the prefabricated timber building panel 300 may be supported on only the first rail 408a or second rail 408b, and the at least one intermediate rail 408c only (as shown in Figure 15a). The rails 408 of the conveyor system 402 may also support a part of a prefabricated timber building panel 300, or a timber building module 350 (as described in relation to Figure 17). Figures 16a and 16b show further perspective views of an example conveyor branch 402 of the conveyor system 400 of the timber building module production system 1000. The conveyor system 400 may be configured to enable the prefabricated timber building panels 300 to roll or slide along the conveyor branches 402 of the conveyor system 400. As shown in Figures 16a and 16b, the conveyor branches 402 may comprise a plurality of trolleys 406 configured to roll or slide along the conveyor system 400. The prefabricated timber building panels 300 may be substantially supported on the plurality of trolleys 406 and, in turn, be transferred by the plurality of trolleys 406 along the length of the conveyor branches 402. The conveyor branches 402 may be lubricated, or be constructed of a material which enable the plurality of trolleys 40 to roll or slide, for example, stainless steel. To enable the plurality of trolleys 306 to roll or slide along the conveyor branches 402, the plurality of trolleys 406 may be connected to a pulley 410, which, in turn is connected to an actuator 412 (for example, a motor). In other examples, the plurality of trolleys 406 may be roll or slide along the conveyor branches 402 using propulsion or electromagnetism, for example. The actuator 412 of the conveyor system 400 may be powered hydraulically, electrically, or by any means known in the art. The actuator 412 may be disposed on the conveyor branch 402, for example, disposed on the intermediate rail 408c, as shown in Figure 16b, and connected to the pulleys 410 of both the first rail 408a and the second rail 408b.

Figure 17 shows a perspective view of an example assembly station 600 of the timber building module production system 1000, comprising prefabricated timber building panels 300a and 300b. The assembly station 600 may comprise similar features, and operate in a comparable manner, to the apparatus 10, 200, as described in relation to Figures 1 to 12. Accordingly, the assembly station 600 may similarly comprises a support 602, a frame 604 rotatably mounted to the support 602, and a drive device 606 for rotatable movement of the frame 604 relative to the support 602, the frame 604 adapted to receive a first prefabricated timber building panel 300a, rotate the first prefabricated timber building panel 300a, and receive a second prefabricated building panel 300b for fastening to the first prefabricated timber building panel 300a for assembly into timber building module 350. The assembly station 600 may comprise at least one fastener device 610 for fastening the first prefabricated timber building panel 300a and the second prefabricated timber building panel 300b to one another. The conveyor branch 402d which comprises the assembly station 600 may comprise an input conveyor 402di for conveying prefabricated timber building panels 300 to the assembly station 600, and an output conveyor 402dz for receiving and conveying timber building modules 350 from the assembly station 300. As shown in Figure 17, the prefabricated timber building panels 300 may be fitted with fixtures and fittings 302 (for example, partition walls or stairs), prior to being received in the assembly station 600. The prefabricated timber building panels 300 may be fitted with fixtures and fittings at the fitting station 700 of the timber building module production system 1000.

Figures 18a shows a perspective view of an example panel production station 500 of the timber module production system 1000, comprising a prefabricated timber building panel 300. Timber building panels 300, such as those described with reference to FIGS. 13A and 13B, are assembled at the panel production station 500. The panel production station 500 comprises a rotating device 502 configured to rotate a prefabricated timber building panel 300, or a part thereof, during production of the prefabricated timber building panel 300. The rotating device 502 comprises a support 504, a frame 506 rotatably mounted to the support 504, and a drive device 508 for rotatable movement of the frame 506 relative to the support 504.

The frame 506 is adapted to receive a prefabricated timber building panel 300, or a part thereof. As shown in Figure 18a, the frame 506 may comprise a support frame 507 for receiving and/or supporting the prefabricated timber building panel 300, or part thereof. The prefabricated timber building panel 300 may be conveyed along the conveyor branch 402a and into the support frame 507. Prior to receiving the prefabricated timber building panel 300, the first side 507a of the support frame 507 may be offset from the second side 507b of the support frame 507. The first side 507a and second side 507b of the support frame 507 may be offset from one another by a distance less than, equal to, or greater than, the thickness of the prefabricated timber building panel 300. Where the offset between the first side 507a and second sides 507b of the support frame 507 is greater than, or less than, the thickness of the prefabricated timber building panel 300, the offset between the first side 507a and second sides 507b of the support frame 507 may be adjusted such that the offset is suitable for receiving the prefabricated timber building panel 300 (e.g., equal, or substantially similar, to the thickness of the prefabricated timber building panel 300).

On receiving the prefabricated timber building panel 300 from the conveyor branch 402, a first side 507a of the support frame 507 may support a first side 304a of the prefabricated timber building panel 300, and a second side 507b of the support frame 507 may support a second side 304b of the prefabricated timber building panel 300. The first side 507a and second side 507b of the support frame 507 may be adjusted such that first side 507a and second side 507b of the support frame 507, respectively, abut the first side 304a and second side 304b of the prefabricated timber building panel 300. The offset between the first side 507a and the second side 507b of the support frame 507 may be further adjusted such that the support frame 507, respectively, apply a compressive force to first side 304a and the second side 304b of the prefabricated timber building panel 300. Applying a compressive force to the prefabricated timber building panel 300 ensures that the prefabricated timber building panel 300 is secured in place during rotation of the prefabricated timber building panel 300 in the rotating device 502. The offset between the first side 507a and the second side 507b of the support frame 507 may be controlled using hydraulic pistons of the rotating device 502 production station 500.

The first side 507a and second side 507b of the support frame 507 may comprise a first rail, a second rail, an intermediate rail, and a plurality of trolleys. The rails of the support frame 507 may align with the rails 408 of the conveyor branch 402, such that the prefabricated timber building panel 300 can be effectively conveyed between the conveyor branches 402 and the support frame 507 of the production station 500. As shown in Figure 18a, the rails of the second side 507b of the support frame 507 align with the rails 408 of the conveyor branch 402. Whereas, the rails of the first side 507a of the support frame 507, which is offset from both the second side 507b of the support frame 507 and the conveyor branch 402, are not aligned with the rails 408 of the conveyor branch 402. In particular, the intermediate rail of the second side 507b of the support frame 507 is not aligned with the intermediate rail 408c of the conveyor branch 402.

The prefabricated timber building panel 300 is received in the rotating device 502 with the first side 304a of the prefabricated timber building panel 300 orientated substantially away from the conveyor branch 402 (i.e., upwards). As illustrated, the first side 304a of the prefabricated timber building panel 300 is shown in a finished state (in this example, comprising boarding), whereas, as shown in Figure 18c, the second side 304b of the prefabricated timber building panel 300 is in an un-finished state (in this example, comprising exposed studs, without boarding). In order to attach fixtures and finishes (e.g., boarding) the second side 304b of the prefabricated timber building panel 300, the prefabricated timber building panel 300 requires rotating using the rotating device 502, such that the second side 304b is orientated substantially away from the conveyor branch 402 (i.e., upwards).

Figures 18b and 18c show further perspective views of the prefabricated timber building panel 300 being rotated in the rotating means 502 of the panel production station 500 of the timber building production module 1000. The longitudinal axis 510 of the support frame 507 is aligned to the rotational axis 512 of the support frame 507. Thereby, following rotation of the prefabricated timber building panel 300, the prefabricated timber building panel 300 is substantially parallel with the adjacent conveyor branch 402. This configuration enables the prefabricated timber building panel 300 to be effectively conveyed from the support frame 507 to the conveyor branch 402. As shown in Figure 18c, on rotation, the prefabricated timber building panel 300 is rotated through 180 degrees, such that the second side 304b of the prefabricated timber building panel 300 is orientated substantially away from the conveyor branch 402 (i.e., upwards), enabling the second side 304b of the prefabricated timber building panel 300 to be accessed for attaching fixtures and finishes (e.g., boarding). The rotating device 502 of the production station 500 may rotate in either a clockwise or anti-clockwise direction. The rotating device 502 may be connected to a power supply to execute the rotation of the prefabricated timber building panel 300. The power supply of the rotating device 502 may be powered hydraulically, electrically, or by any means known in the art. Where the power supply is hydraulically powered, the rotation of the rotating device 502 may be controlled using the kinetic energy generated during rotation.

Following rotation of the prefabricated timber building panel 300, the prefabricated timber building panel 300 may be released from the support frame 507 of the production station 500. Where the prefabricated timber building panel 300 has been compressed by the support frame 507 during rotation, the compressive force may be relieved by adjusting the offset between the first side 507a and the second side 507b of the support frame, enabling the prefabricated timber building panel 300 to be released from the support frame 507. The prefabricated timber building panel 300 may be conveyed out of the support frame 507 using the plurality of trolleys of both the support frame 507 and the conveyor branch 402. The prefabricated timber building panel 300 may subsequently be conveyed to a finishing station 700 of the timber module production system 1000 for attaching fixtures and fittings to the prefabricated timber building panel 300 (e.g., applying boarding to the exposed studs of the second side As can be seen in Figures 18a and 18b, prior to rotation of the prefabricated timber building panel 300, the rails of the first side 507a of the support frame 507 did not align with the rails of the conveyor branch 402. However, as shown in Figure 18c, following rotation, the rails of the first side 507a of the support frame 507 subsequently align with the rails of the conveyor branch 402, and the second side 507b of the support frame 507 no longer align with rails of the conveyor branch 406. For the following prefabricated timber building panel 300 that is received in the rotating means 502, the side of the panel that is substantially facing away from the conveyor branch (i.e., upwards) will be supported by the second side 507b of the support frame 507, as opposed to the first side 507a of the support frame 507 (as shown in Figures 18a and 18b).

In some examples, the prefabricated timber building panels 300 are rotated through an angle less than 180 degrees, for example, 90 degrees. The prefabricated timber building panels 300 may be rotated to an angle less than 180 degrees such that the prefabricated timber building panel 300 may be accessible to attach fixtures and fittings 302 to the prefabricated timber building panel 300. For example, rotating the prefabricated timber building panel 300 to an angle less than 180 degrees may be preferable when attaching electrical wiring or plumbing fittings. Whilst attaching the fixtures and fittings 302 to the prefabricated timber building panel 300, the prefabricated timber building panel 300 may be temporarily held, or fixed, at the given angle of rotation. Following attaching the fixtures and fittings 302 to the prefabricated timber building panel 300, the prefabricated timber panel 300 may continue to be rotated to 180 degrees, such that the second side 304b of the prefabricated timber building panel 300 is orientated substantially away from the conveyor branch 402 (i.e., upwards). Alternatively, the prefabricated timber building panel 300 may be rotated to return to its original rotation, where the first side 304a of the prefabricated timber building panel 300 is orientated substantially away from the conveyor branch 402 (i.e., upwards).

Figure 19a shows a method 800 of producing a timber building module 350. The method 800 comprises the step 802 of producing a plurality of prefabricated timber building panels 300 at a panel production station 500 of the timber building module production system 1000 (as described in relation to Figures 18a, 18b, and 18c). The panel production station 500 is disposed at a first position along a conveyor system 400 of the timber building module production system 1000 (as described in relation to Figure 18a, 18b, and 18c). The method 800 further comprises the step 804 of conveying the plurality of prefabricated timber building panels 300 along the conveyor system 400 to an assembly station 600 of the timber building module production system 1000 (as described in relation to Figure 17). The assembly station 600 is disposed at a second position along the conveyor system 400. The method 800 further comprises the step 806 of assembling the plurality of prefabricated timber building panels 300 into a timber building module 350 at the assembly station 600.

As described in relation to Figures 18a, 18b, and 18c, the panel production station 500 of the timber building module production system 1000 comprises a rotating device 502 for rotating a prefabricated timber building panel 300 or a part thereof. The method step 802 may further comprise the steps of: partially assembling a prefabricated timber building panel 300, rotating the partially assembled prefabricated timber building panel 300 using the rotating device 502, and completing assembly of the prefabricated timber building panel 300.

As described in relation to Figure 14a to 16b, the conveyor system 400 of the timber building module production system 1000 comprises multiple conveyor branches 402, and the multiple conveyor branches 402 are discontinuous and connected to one another by way of a transfer device 404. The method step 804 may further include the step of transferring prefabricated timber building panels 300 between conveyor branches 402 using the transfer device 404. For example, the prefabricated timber building panel is transferred from a first conveyor branch 402a, comprising the panel production station 500, to a second conveyor branch 402d, comprising an assembly station 600, by way of the transfer device 404.

As described in relation to Figure 17, the assembly station 600 of the timber building module production system 1000 comprises a support 602, a frame 604 rotatably mounted to the support 602, and a drive device 606 for rotatable movement of the frame 604 relative to the support 602. The method step 806 may further include the steps of: receiving a first prefabricated timber building panel 300a in the frame 604; rotating the frame 604; receiving a second prefabricated timber building panel 300b in the frame 604; and fastening the first prefabricated timber building panel 300a to the second prefabricated timber building panel 300b to form a timber building module 350 (as shown in Figures 20a, 20b, and 20c). The first prefabricated timber building panel 300a and the second prefabricated timber building panel 300b may be fastened to one another with fasteners using at least one fastener device 610. Figure 19b shows a further method 850 of producing a timber building module 350. The method 850 comprises the steps 802, 804, and 806 of method 800, however, further includes the steps 803a and 803b between steps 802 and 804. Method step 803a comprises conveying the plurality of prefabricated timber building panels 300 along the conveyor system 400 to a fitting station 700 of the timber building module production system 1000 The at least one fitting station 700 may be disposed at an intermediate position between the first position (comprising the panel production station 600) and the second position (comprising the assembly station 500), along the conveyor system 400. Method step 803b comprises assembling fittings and fixtures 302 to the plurality of prefabricated timber building panels 300 at the at least one fitting station 700.

Figure 21 shows a perspective view of multiple timber building modules 350. The multiple timber building module 350 are arranged in a layout suitable for a housing estate. It would be understood, however, that the timber building modules 350 may be erected as a single timber building module 350, in combination with multiple timber building modules 350 (like that shown in Figure 21), or with (for example, next to) pre-existing structures. As shown in Figure 21, the timber building modules 350 are complete with at least external walls, a ridged roof, and dormer windows. The timber building modules 350 may further include, but are not limited to including, internal walls, internal floors, and fixtures and fittings. It is preferred that a majority of, or all of, the features (structure, and fittings and fixtures 302) are assembled into the timber building modules 350 within the timber building production system 1000, and that the timber building modules 350 are assembled to a foundation and/or to each other to complete construction. However, some additional assembly and fitting may be required after erecting the timber building modules 350. Where the timber building modules 350 are produced by the timber building production system 1000 without a required feature, for example internal walls, the timber building module 350 may be fit out with said features following erection of the building module 350.

The timber building module production system 1000 may be controlled by an automated control system. The automated control system may be a computer apparatus which provides control signals to the technical features of the embodiments of the invention. The computer apparatus has a computer program for controlling the efficient running of the technical features of the embodiments of the invention. Such a computer program may also include adaptive learning sub-routines and/or neural network software to maintain an efficient operation for the technical features of the embodiments of the invention. The computer apparatus may also include Computer Aided Design (CAD) and Computer Aided Manufacture (CAM) apparatus to further assist with the construction of the timber building modules 350.

Figures 22a, 22b, and 23 described an example prefabricated timber building panel 300 comprising multiple insulation blocks 310. The prefabricated timber building panel 300 may be used in the timber building module production system 1000, described above.

Figures 22a and 22b show perspective views of an insulation block 310 for the prefabricated timber building panels 300. The insulation block 310 may comprise a plant-based material, for example, hemp or a hemp composite material (e.g., hemp shiv). In other examples, the insulation block 310 may comprise any other material with insulating properties, for example, fibreglass, wool, cork, or other materials known in the art. The insulating block 310 may comprise heat and/or sound insulating properties. As shown in Figure 22b, the insulation block 310 may comprise a width of 500mm and a length of 500mm, and a depth of 270mm, however, it would be understood that the dimensions of the insulation block 310 may vary as dependent on the dimensions of the respective prefabricated timber building panels 300.

The insulation block 310 may comprise two sides, a first side 310a and a second side 310b. As shown in Figure 20b, the first side 310a and the second side 310b of the insulation block 310 may be joined to one another to form an insulation block 310. The first side 310a and the second side 310b of the insulation block 310 may be joined to one another by an adhesive, dowels, or any other suitable means known in the art. In other examples, the sides 310a, 310b of the insulation block 310 are formed integrally with one another. Each side 310a, 310b of the insulation block 310 may be cuboidal with a series of protrusions 312 extending perpendicularly from a first surface 316a of the insulation block 310. For example, each side 310a, 310b of the insulation block 310 may comprise six protrusions (shown in Figure 20a in a 3x2 arrangement). It would be understood that first side 310a and second side 310b of the insulation block 310 may comprise any number of protrusions 312 and in any arrangement. In other examples, the insulation block 310 may not be cuboidal, and may comprise a three-dimensional triangular, hexagonal, or spherical profile. Similarly, the protrusions 312 may be cuboidal, or any other profile. The protrusions 312 comprise a first type 312a of protrusion 312 and a second type 312b of protrusion 312b. As shown in Figure 22a, the first type 312a of protrusion 312 may comprise four protrusions, and be disposed in the corners of the first surface 316a of the insulation block 310. Whereas, as further shown in Figure 20a, the second type 312b of protrusion 312 may comprise two protrusions, the second type 312b of protrusions 312 disposed between the first types 312a of protrusion 312, along at least two opposing edges of the first surface 316a. The depth and length of the second type 312b of protrusion 312 may be equal to the first type 312a of protrusion 312. However, the width of the second type 312b of protrusion 312 may be greater than the first type 312a of protrusion 312. The second surface 316b may be planar, and comprise no protrusions. In other examples, the second surface 316b comprises further protrusions, or surface features to interact with the prefabricated timber building panel 300, in use.

As shown in Figure 22b, the first side 310a and second side 310b of the insulation block 310 may be joined to one another. The first side 310a and the second side 310b of the insulation block 310 may be joined such that the protrusions 312 of the first side 310a abut the protrusions 312 of the second side 310b. Joining the first side 310a and the second side 310b of the insulation block 310 results in a number of channels 314 being formed in the insulation block 310. Along a first set of opposing edges 318a of the insulation block 310, a first channel 314a may be formed between two adjacent protrusions 312 of the second type 312b. Further, along second opposing edges 318b of the insulation block 310, two second channels 312b may be formed between a protrusion 312 of the first type 312a and a protrusion 312 of the second type 312b. In some examples, the insulation block 310 may be configured such that only one set of edges 318 comprise channels 314. As described below, services such as wiring, plumbing, or ventilation may be disposed in the channels 314 that are formed in the insulation blocks 310.

Figure 23 shows a perspective view of a prefabricated timber building panel 300 comprising multiple insulation blocks 310. As shown in Figure 23, the prefabricated timber building panel 300 comprises a number of exposed studs 320 that extend over the height of the prefabricated timber building panel 300 between horizontal members 324, the horizontal members 324 extending over width of the prefabricated timber building panel 300. Said studs 320 of the prefabricated timber building panel 300 run substantially parallel to one another, and are spaced from one another such that a gap 322 is formed between each stud 320. The gap 322 between the studs 320 is sufficiently wide such that a number of insulation blocks 310 may be disposed in the gaps 322. The insulation blocks 310 may be disposed in the gaps 322 of the prefabricated timber building panels 300 by firstly disposing a first side 310a of the insulation block 310 in the gap 322, and subsequently joining a second side 310b of the insulation block 310 (as shown in Figure 23). Alternatively, a complete insulation block 310, comprising both the first side 310a and the second side 310b may be disposed directly in the gap 322 (as also shown in Figure 23). The insulation blocks 310 may be disposed in the gaps 322 over the height of the prefabricated timber building panel 300 such that the insulation blocks 310 abut each other (i.e., no gaps or cavities are formed between the adjacent insulation blocks 310). The insulation blocks 310 may be disposed in the gaps 322 of the prefabricated timber building panels 300 at the fitting station 700 of the timber building module production system 1000. The insulation blocks 310 may be disposed in the gaps 322 such that the insulation blocks 310 rest on boarding attached to a side 304 of the prefabricated timber building panel 300. The insulation blocks may be joined to the boarding of the of the prefabricated timber building panels 300 (for example, using adhesives), and in other examples, the insulation blocks 300 are not joined to the boarding of the prefabricated timber building panels 300.

Once the insulation blocks 310, or at least parts thereof, have been disposed in the gaps 322 of the prefabricated timber building panels 300, services such as wiring, plumbing, or ventilation may be disposed in the channels 314 that are formed in the insulation blocks (as described in relation to Figures 22a and 22b). In some examples, services may be disposed in the first channels 314a of the insulation blocks 310, enabling the services to run at least part of the width of the prefabricated timber building panels 300. Alternatively, services may be disposed in the second channels 314b of the insulation blocks, enabling the services to run at least part of the length of the prefabricated timber building panels 300. In further examples, the services may be disposed in a combination of the first channels 314a and the second channels 314b, enabling the services to run at least part of both the width and length of the prefabricated timber building panels 300. Where complete insulation blocks 310 have been disposed in the gaps 322, services may be thread through the channels 314 of the insulation blocks 310. Where only the first side 310a of an insulation block 310 has been disposed in the gaps 322, services may be laid in the channels 314 of the first side 310a of the insulation block 310, and subsequently, the second side 310b of the insulation block 310 may be joined to the first side 310a of the insulation block 310. In some examples, following disposing services within the insulation blocks 310 of the prefabricated timber building panels 300, further boarding may be affixed to the timber building panels 300, as to cover the insulation blocks 310 and exposed studs 320.

Figures 24a and 24b show perspective views of a plurality of interlocking construction blocks 902 for constructing a building element 900, for example a wall. The construction blocks 902 are those described in GB patent application GB2200056.6, which is incorporated herein by reference. The construction blocks 902 may be plant-based construction blocks. That is, the construction blocks 902 may comprise a plant-derived material, for example, hemp or a hemp composite material (e.g., hemp shiv). In other examples, the construction blocks 902 are made of any other known construction material, for example, concrete. Each construction block 902a-d is substantially identical and has a recess 912 configured to interlock with interlocking portions 908 of two further construction blocks 902 to form a building element 900. In particular, as shown in Figure 24a, a first construction block 902a has a recess 912 configured to interlock with interlocking portions 908b, 908c of second and third construction blocks 902b, 902c. In the same manner, the second construction block 902b has a recess 912b configured to interlock with interlocking portions 908a, 908d of the first construction block 902a and a fourth construction block 902d. As shown in Figure 24b, in this way, a plurality of construction blocks 902 can be interlocked together in a generally horizontal direction to form a course, or layer, of a building element 900.

As shown in Figure 24a, the construction blocks 902 overlap each other in the horizontal direction such that the interlocking portions 908 can engage each other. This creates a front portion (or front skin) formed of construction blocks 902a and 902d as illustrated, and a rear portion (or rear skin) formed of construction blocks 902b and 902c as illustrated. The interlocking between the front and rear portions provides a structurally rigid building element 900. As also shown in Figure 24a, the front portion and the rear portion may be offset in a vertical direction. Accordingly, when a further course of construction blocks 902 are positioned on top of construction blocks 902b and 902c, there is interlocking between courses (i.e., layers) of construction blocks 902 in a vertical direction (i.e., between layered courses) as well as in a horizontal direction (i.e., in the same course). Such vertical and horizontal interlocking between courses further improves the structural rigidity of the building element 900. This arrangement is possible due to the profile of the recess 912a and interlocking portions 908, and in particular how the recess 912 and interlocking portions 908 have a uniform profile extending between the top face and the bottom face of the construction block 902 allowing any degree of vertical overlap. This is particularly advantageous when the construction blocks 902 comprise a plant-based construction block because though the construction blocks 902 have a relatively low strength and hardness individually, the interlocking arrangement provides a structurally rigid building element 900.

Figures 25a and 25b show perspective views of a horizontal prefabricated timber building panel 300 (as described in relation to Figures 1 to 23b) adjoined to a building element 900 (as described in relation to Figures 24a and 24b), the building element 900 comprising a plurality of construction blocks 902, 904, 906. The prefabricated timber building panel 300 may be produced by the timber building module system 1000 (for example, produced by the panel production station 500 of the timber building module system 1000), as described above.

In the example shown in Figures 25a and 25b, the prefabricated timber building panel 300 is a floor panel of a building, and the building element 900 is an exterior wall of a building. In other examples, the prefabricated timber building panel 300 may be a roof panel of a building, and/or the building element 900 may be an interior wall of a building. As shown in at least Figure 25a, the prefabricated timber building panel 300 comprises a number of joists 320 that extend over a width of the prefabricated timber building panel 300, between horizontal members 324, the horizontal members 325 extending over a length of the prefabricated timber building panels 300. The joists 320 may be joined to the horizontal members 324 using fixing members 328, for examples, nails, clamps, or any other fixing means known in the art. As shown in Figure 25a, the horizontal members 324 comprise a number of recesses 330 along the length of the horizontal members 324 of the prefabricated timber building panel 300. The recesses 330 of the horizontal members 324 are configured to interlock with interlocking portions 908 of the construction blocks 902 of the building element 900, such that the prefabricated timber building panel 300 may be adjoined to the construction blocks 902 of the building element 900.

The construction blocks 902 may form an outer skin of the building element 900 (i.e., the side of an external wall facing towards an exterior of a building), whereas the horizontal members may form part of the inner skin of the building element 900 (i.e., the side of an external wall facing towards an interior of a building). As shown in Figure 25b, when adjoined to the construction blocks 902 of the building element 900, the prefabricated timber building panel 300 may be supported on the inner skin of the building element 900 by further construction blocks 904, 906. The further construction blocks 904, 906 comprise a number of recesses, the recesses similarly configured to interlock with interlocking portions 908 of the construction blocks 902 of the building element 900. Where the course height of the horizontal member 324 is not equal to the course height of the standard-height inner skin construction blocks 904, reduced-height inner skin construction blocks 906 may be disposed adjacent (i.e., below and optionally above) the horizontal members 324, such that the combined course height of the horizontal members 324 and reduced-height inner skin construction blocks 906 is equal to the course height of the standard-height inner skin construction blocks 904. As also shown in Figure 25a, the inner skin and the outer skin of the building element 900 may be offset in a vertical direction. Accordingly, when a further course of construction blocks 902, 904, 906 is positioned on top of construction blocks 902. 904, 906, there is interlocking between courses of construction blocks 902, 904, 906 in a vertical direction (i.e., between layered courses) as well as in a horizontal direction (i.e., in the same course).

In further embodiments, the prefabricated timber building panel 300 may be a vertical prefabricated timber building panel 300, for example, an internal or external wall panel of a building. The prefabricated timber building panel 300 may comprises a number of studs 320 that extend over the height of the prefabricated timber building panel 300 between horizontal members 324, the horizontal members 324 extending over the width of the prefabricated timber building panel 300. The studs 320 and/or horizontal members 324 of the prefabricated timber building panel 300 may comprise a number of recesses, the recesses configured to interlock with interlocking portions 908 of the construction blocks 902 of the building element 900. In such examples, the prefabricated timber building panels 900 may form the inner skin of the wall of the building, and the construction blocks 902 of the building element 900 may form the outer skin(s) of the wall of the building. Where the wall is an internal wall the prefabricated timber building panel 300 may be adjoined to two sets of building elements 900 on either face of the prefabricated timber building panel 300.

Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to,” and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics, or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.