Patent Abstract:
A building structure comprises a post having a vertically extending longitudinal face. A plurality of horizontal logs extends from said longitudinal face and has an end face in abutment with said longitudinal face. The post having an undercut channel in said longitudinal face and extends along said post. At least one of said end faces has a recess aligned with said undercut channel, and a spline assembly extends between said post and said log to secure said log to said post. The spline assembly includes a key located in and extends between said channel and said recess and an insert in one of said undercut channel and said recess. The insert co operates with said key to facilitate relative sliding movement therebetween.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of U.S. application Ser. No. 11/892,870 filed on Aug. 28, 2007 which claims priority from U.S. Provisional Application No. 61/027,228 filed on Feb. 8, 2008 both incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates generally to wall structures and in particular to log wall structures. 
         [0003]    Log construction has been known for many decades as typified by the log cabin. For many years the logs have been notched so that at a corner, logs forming one wall of a structure can be laid on top of and at an angle alternating with logs from an intersecting wall. Although a number of materials may be used to form the “logs” used as wall members, including various types of composite materials, the wall members are typically milled from wood. The term “logs” will be used throughout this disclosure to include all types of materials that simulate a horizontal wooden log and includes different cross sections, either machined, hand-hewn or in a natural state. 
         [0004]    The assembly of buildings from logs has been performed using traditional techniques. Where hand hewn logs are used, the builder individually fits each log to ensure a proper fit. Whilst this is traditionally done at the final site of the building it has become more common to assemble the shell of the building at a convenient remote location and then disassemble the logs for transportation. The building is then reassembled at the intended site and finished. 
         [0005]    Log buildings using manufactured logs have the logs machined and cut at the factory to provide the desired floor plan. The logs are then transported to the site where the building is assembled. 
         [0006]    In either case, assembly of the building at the final site requires the relocation of skilled workmen, the provision of tools and equipment for assembly at the site and the exposure of the partially assembled structure to a potentially inclement environment. 
         [0007]    In practical use, traditional construction is usually limited to right angle corners because of the complexity of the angled notches required for non-right angle corners. More recently, posts have been introduced that can be milled with longitudinal faces at a range of desirable angles such that wall members having square-cut ends can be attached by spikes to the posts to form right-angle or non-right angle corners. 
         [0008]    To form a tight connection between the logs and the posts, split key members have been used that engage cooperating undercut recesses in the end of the log and a face of the post. In U.S. Pat. No. 6,050,033 there is disclosed a spline arrangement in which the log and post are connected by a key formed by a pair of wedges. The key is expandable and secures the log to the post. A first section of the key member is fitted into place to engage the recesses in the post and the log and then a second section of the key member is inserted and tapped into place beside the first section of the key member. The cross-sections of the split key member are wedge-shaped and tighten the joint as the second portion of the key member is tapped into place. 
         [0009]    It is necessary to ensure that the interconnecting butt joints are tight and provide an effective seal, but at the same time accommodate relative movement between logs whilst maintaining the seal. This is particularly an issue in wooden log construction because of the shrinkage of the logs as they dry. This causes the logs to settle and move vertically down. However, in some circumstances the connection of the key to both the log and the post as shown in U.S. Pat. No. 6,050,033 may inhibit such movement and as a result a gap is created between adjacent logs in the log walls. 
         [0010]    Similar considerations apply where a pair of walls intersect, such as where an internal wall meets an external wall. This may occur between the locations of the posts and a secure butt joint between the intersecting walls is required. 
         [0011]    It is an object of the present invention to obviate or mitigate the above disadvantages. 
       SUMMARY OF THE INVENTION 
       [0012]    According to one aspect of the invention, a building structure comprises a vertically extending longitudinal face, a plurality of horizontal logs extending from said longitudinal face and having an end face in abutment with the longitudinal face. An undercut channel is provided in the longitudinal face and extends along the face. At least one of the end faces has a recess aligned with the undercut channel and a spline assembly extends between the longitudinal face and the log to secure the log to the post. The spline assembly includes a key located in and extending between the undercut channel and the recess and a slide member in one of the undercut channel and the recess. The slide member co-operates with the key to facilitate relative sliding movement of the logs and the post. 
         [0013]    A further aspect of the invention provides a spline assembly to secure a log to a face of a log wall of a building. The spline assembly includes a slide member for insertion into an undercut channel in a vertical face and a key for insertion into said slide member and a recess in said log to extend between said log and inhibit separation thereof. 
         [0014]    A still further aspect of the invention provides a method of assembling a log to a vertically extending face comprising the steps of providing an undercut channel in a longitudinal face, inserting a slide member in the undercut channel providing a recess in the log, aligning the recess with the slide member undercut channel, inserting a key into the key slide to extend between the post and the log, and securing the key to the recess, whereby relative movement between the log and the post is accommodated by relative sliding movement between the key slide and the key. 
         [0015]    The face may be provided as a face of the post or as a face of an intersecting wall. 
         [0016]    A further aspect of the invention is the provision of a building having walls formed from one or more wall sections. At least one of the wall sections has a plurality of logs interconnected at opposite ends by a respective post. A spline assembly secures the posts to the logs. The wall section is secured to an adjacent wall section by spline assemblies connecting the posts of the adjacent wall sections. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    The principles of the various aspects of the invention may better be understood by reference to the accompanying illustrative drawings which depict features of examples of embodiments of the invention, and in which: 
           [0018]      FIG. 1  is a perspective view of a building. 
           [0019]      FIG. 2  is a view on the line II-II of  FIG. 1  showing components as assembled. 
           [0020]      FIG. 3  is a view similar to  FIG. 2  with the components in a expanded position. 
           [0021]      FIG. 4  is an exploded perspective view of the components shown in  FIG. 3 . 
           [0022]      FIG. 5  is a perspective view of a key member used in the embodiment of  FIGS. 1 to 4 . 
           [0023]      FIG. 6  is a rear perspective of the key member of  FIG. 5 . 
           [0024]      FIG. 7(   a )-( k ) is a schematic representation of the steps of assembling the building of  FIG. 1 . 
           [0025]      FIG. 8  is an exploded view of components used at a corner of the building of  FIG. 1 . 
           [0026]      FIG. 9  is an exploded perspective view of an alternative embodiment of the building. 
           [0027]      FIG. 10  is an enlarged view of the assembly shown in  FIG. 9 . 
           [0028]      FIG. 11  is a view in the direction of arrow XI-XI of  FIG. 10 . 
           [0029]      FIG. 12  is a exploded perspective view of a further embodiment of building structure. 
           [0030]      FIG. 13  is a plan view of  FIG. 12  in the direction of arrow XIII-XIII. 
           [0031]      FIG. 14  is a plan view similar to  FIG. 13  showing a further step in the assembly of the building. 
           [0032]      FIG. 15  is a view similar to  FIG. 14  showing a yet further step in the assembly of the building. 
           [0033]      FIG. 16  is a view similar to  FIG. 15  showing a still further step in the assembly of the building. 
           [0034]      FIG. 17  is an enlarged plan view of a component used in the building of  FIGS. 12 to 16 . 
           [0035]      FIG. 18  is a view similar to  FIG. 17  showing the component of  FIG. 17  in an expanded position. 
           [0036]      FIG. 19  is a view similar to  FIG. 17  of an alternative embodiment of the component. 
           [0037]      FIG. 20  is a view similar to  FIG. 17  of a further embodiment of the component shown in  FIG. 17 . 
           [0038]      FIG. 21  is a still further alternative embodiment of the component shown in  FIG. 17 . 
           [0039]      FIG. 22  is a view similar to  FIG. 12  showing a further step in the assembly of a building. 
           [0040]      FIG. 23  is a perspective view of a further embodiment of a building. 
           [0041]      FIG. 24  is a view on the line XXIV-XXIV of  FIG. 23 . 
           [0042]      FIG. 25  is a perspective view of a yet further embodiment of building. 
           [0043]      FIG. 26  is a view on the line XXVI-XXVI of  FIG. 25 . 
           [0044]      FIG. 27  is a schematic plan view of a building assembled from the embodiments shown in the proceeding figures. 
           [0045]      FIG. 28  is a section through an alternative embodiment of post used in the building structures in the proceeding figures. 
           [0046]      FIG. 29  is a plan view of the post of  FIG. 28  assembled into a wall structure. 
           [0047]      FIG. 30  is a plan view of a pair of wall structures utilizing the post of  FIG. 28  being connected. 
           [0048]      FIG. 31  is a plan view similar to  FIG. 29  showing a further stage in the assembly of a building structure. 
           [0049]      FIG. 32  is a plan view of the assembly of  FIG. 31  in a further stage of assemble. 
           [0050]      FIG. 33  is a section of a component used to manufacturer posts for use in the building structures shown in the proceeding embodiments. 
           [0051]      FIG. 34  is a view of the component of  FIG. 33  in a first stage of manufacturer. 
           [0052]      FIG. 35  is an end view of the components produced in  FIG. 35  in a further stage of manufacturer. 
           [0053]      FIG. 36  is a plan view of a section of wall formed using the components of  FIG. 35 . 
           [0054]      FIG. 37  is a plan view showing assembly of a pair of wall sections of  FIG. 36 . 
           [0055]      FIG. 38  is a plan view similar to  FIG. 37  of a further stage in the assembly of the wall sections. 
           [0056]      FIG. 39  is a view similar to  FIG. 38  showing a further step in the assembly of wall sections. 
           [0057]      FIG. 40  is a view similar to  FIG. 27  showing the assembly of a building using the post sections described with respect to  FIGS. 28 through 39 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0058]    The description that follows and the embodiments described therein are provided by way of illustration of examples of particular embodiments of the principles of the present invention. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the invention. In the description, like parts are marked throughout the specification and the drawings with the same respective reference numerals. The drawings are not necessarily to scale and in some instances proportions may have been exaggerated in order more clearly to depict certain features of the invention. 
         [0059]    Referring therefore to  FIG. 1 , a building  1  includes log walls  2  that intersect at a corner  6 . The log walls  2  are supported on a foundation wall  3 , that may be poured concrete or laid cement block, and have openings for windows  4 . The log walls  2  will support a roof or additional framed storey in a conventional manner. Each of the log walls  2  is formed from logs  11  that are laid horizontally one on top of the other and are secured to posts  10  to form an integral structure. The posts  10  may be located at corners  6  and at intermediate locations  7  along the log walls  2 , depending on the overall plan of the building  1 . 
         [0060]    Each of the logs  11  is machined to an uniform cross section and have complementary tongues and grooves formed on abutting upper and lower faces  13   a ,  13   b  ( FIG. 4 ). A sealant, typically in the form of a mastic tape, or foam tape is located between the tongue and groove and compressed by the log to form an effective seal. The particular form of tongue and groove forms no part of the present invention and a variety of configurations may be used, such as that shown in U.S. Pat. No. 5,020,289. 
         [0061]    It will be appreciated that the log walls  2  extend along the periphery of the building  1  and the logs  11  are cut to the required length to conform to the desired floor plan. 
         [0062]    Each of the posts  10  extends vertically the height of the log wall  2  and each post  10  has a pair of generally planar faces  12 ,  14 , that are disposed at the required included angle. Where the post  10  is located at the corner  6  of the building  1 , typically, the planar faces  12 ,  14  intersect at right angles but other included angles can be provided, as shown in  FIG. 7 . Where the posts are at intermediate locations the planar faces  12 ,  14  are oppositely directed. 
         [0063]    As can best be seen in  FIG. 2  and  FIG. 4 , which illustrates a corner  6 , each of the logs  11  has an end face  16  that extends between the upper and lower faces  13   a ,  13   b  to butt against one of the planar faces  12 ,  14  of the post  10 . The end face  16  has a part cylindrical slot  17  extending between the upper and lower faces  13   a ,  13   b  of the log  11  and intersecting the end face  16  so as to define a re-entrant recess in the end face  16 . 
         [0064]    Sealant slots  18  are provided along the length of each of the planar faces  12 ,  14  of post  10 . The sealant slots  18  are dimensioned to accept sealant materials, typically in the form of butyl or impregnated foam tapes  19  that are exposed to the end face  16  when a log  11  is butted against post  10 . 
         [0065]    Each of the planar faces  12 ,  14  has an undercut channel  20  extending along the length of the post  10 . The undercut channel  20  has a parallel sided body portion  22  which opens to an enlarged socket  24 . Inclined flanks  26  connect the body portion  22  to the enlarged socket  24 . The width of the body portion  22  corresponds to that of the opening of part cylindrical slot  17  at the end face  16 . 
         [0066]    The logs  11  are held against the respective planar face  12 ,  14  by the spline assembly generally indicated at  30  in  FIG. 4 . The spline assembly  30  includes a key  32  and a slide member, referred to as key slide  70 . The key  32  has a pair of key members  33  that are identical to one another and have a length slightly less than the corresponding height of the log  11 . For example, with a log of nominal  12 ″ height, the key  32  will typically be 10″ in length. 
         [0067]    The key members  33  are best seen in  FIGS. 5 and 6 . Each key member  33  is molded from a plastics material and has an outer shell  34  with a hollow interior  36  with reinforcing ribs  38  integrally molded with the outer shell  34 . In cross section, each of the key members  33  is similar to one half of the void formed between the part cylindrical slot  17 , undercut channel  20  and the key slide  70  so that a pair of key members  33  may be inserted within the void. 
         [0068]    Each of the key members  33  has an enlarged head  40  connected by a neck  42  to a flared shoulder  44 . The enlarged head  40  has an arcuate undersurface  46  terminating in radial step  48 . Each end of the key members  33  has a tapered terminal section  50  on the neck  42  and the flared shoulder  44  to facilitate insertion in to the key slide  70 . End walls  52  enclose the shell at each end up to a median plane  54 . A flange  56  projects outwardly from the median plane  54  at one end and extends one half the length of the key member  33 . A slot  58  having a depth slightly greater than that of the flange  56  is molded into the key member  33  in alignment with the flange  56  over the balance of the length of the key member  33 . A notch  59  is formed in each end wall  52  beside the flange  56  and slot  58  respectively. 
         [0069]    The flange  56  and slot  58  are arranged such that when two key members  33  are placed back to back, that is with the interior of the shells  34  facing one another, the flange  56  of one is received in the slot  58  of the other, so a continuous barrier is provided along the length of the key members  33 . It will be noted from  FIG. 5  that the arcuate undersurface  46  has embossments  60  molded along its length. The embossments  60  are in the form of letters in the embodiment shown that project slightly above the arcuate undersurface  46 . Similar embossments  62 ,  64  are molded on the neck  42  and above the radial step  48 . 
         [0070]    As can best be seen in  FIGS. 2 ,  4  and  8 , the slide member or key slide  70 , is provided to promote relative sliding movement between a log and the post. As shown, the key slide  70  of the spline assembly  30  is an elongate channel member arranged to be a sliding fit within the enlarged socket  24  of the undercut channel  20 . The key slide  70  generally extends the full height of the post  10  as a continuous member, although it could made from multiple shorter pieces arranged end to end, and is inserted into the enlarged socket  24  of undercut channel  20  after machining of the post  10 . The key slide  70  is dimensioned to have contact with the parallel sided body portion  22  of the undercut channel  20 , inclined flanks  26  and enlarged socket  24  in its free body state so as to be retained within the undercut channel  20  during transport of the post  10  and subsequent assembly of the log walls  2  and the post  10 . 
         [0071]    As can best be seen in  FIGS. 2 ,  3  and  8 , the key slide  70  has an outer surface that conforms substantially to the enlarged socket  24 . The key slide  70  has a base  71  with upstanding walls  72  projecting from opposite sides of the base  71 . The upstanding walls  72  project to form a throat  74  that extends into the body portion  22  with the inwardly directed surfaces of the throat  74  radiussed so as to provide a rolling contact between the junction of the neck  42  and the flared shoulder  44  of each of the key members  33  ( FIG. 3 ). The key slide  70  is of substantially uniform thickness so as to be a snug sliding fit within the enlarged socket  24  and allow the neck  42  and flared shoulder  44  of key  32  to be a sliding fit within the key slide  70 . 
         [0072]    The key slide  70  is formed of a suitable material having the requisite thermal insulation qualities, low surface friction, hardness and durability. A thermo-plastic material such as polyethylene or polypropylene is suitable. Polypropylene has a relatively low surface friction to facilitate insertion and to provide a smooth sliding surface between the key  32  and the key slide  70 . 
         [0073]    The assembly of the log walls  2  shown in  FIG. 1  is best seen with reference to the sequence represented in  FIG. 7  where the walls intersect at an obtuse angle, rather than right angle. Initially, a flashing F is secured to the foundation wall  3  and two rows of butyl tape  80  are applied toward the exterior of the building. The paper covering found on the butyl tape  80  is left in situ to allow for slight adjustment of the initial course of logs  11 . 
         [0074]    With the two rows of butyl tape  80  installed on the flashing F, the post  10  with the key slide  70  inserted in the channel  20  is placed on the foundation wall  3  and foam tape  19  inserted into each of the sealant slots  18  on one planar face  12  of the post  10  ( FIG. 7   b ). The surface of the foam tape  19  immediately adjacent the work area is revealed by removal of the paper covering, which progresses along the length of the post  10  as the log wall  2  is assembled. 
         [0075]    The initial log  11  is then placed against the post  10  with the end face  16  in abutment with the planar face  12  ( FIG. 7   c ). In this position, the part cylindrical slot  17  is aligned with the undercut channel  20 . An asphalt impregnated foam pad  82  conforming to the shape of the part cylindrical slot  17  and undercut channel  20  is inserted from the top of the log  11  ( FIG. 7   d ) and pushed down in the part cylindrical slot  17  until it reaches the top of the foundation wall  3 . 
         [0076]    To secure the log  11  to the post  10 , a key member  33  is inserted, as shown in  FIGS. 7   e  to  7   g . Prior to insertion of the key member  33  lengths of sealant tape  84 ,  86  are applied to the neck  42  directly on embossment  62  and to the enlarged head  40  directly on embossment  64  of each key member  33  ( FIG. 5 ). The sealant tape  84 ,  86 , is not initially in engagement with the parallel sided body portion  22  or the part cylindrical slot  17  during insertion and the sealant tape  84 ,  86  therefore remains in situ during insertion of the key member  33 . The sealant tape  84 ,  86  is held in situ during insertion by the inherent adhesiveness of the surface of the sealant tape  84 , 86  that is against the key member and by engagement with the embossments  62 , 64  molded on the surface of the outer shell  34 . When initially placed on the key member  33 , the sealant tape  84 ,  86  is in a compressed state as it has been removed from a roll of tape and progressively expands to its free body state. Each of the key members  33  is inserted into the key slide  70  in post  10  individually such that the flared shoulder  44  may pass through the throat  74  of the key slide  70  ( FIGS. 7   e  and  7   f ). The first of the key members  33  is inserted with the flange  56  lower most. The other of the key members  33  may then be inserted into the key slide  70  above the first key member  33  and the two key members  33  slid together axially. The flange  56  on one key member  33  is received in the slot  58  of the other key member  33  as the key members  33  slide together to form the key  32 . 
         [0077]    With the key members  33  assembled, they form the key  32  and may be pushed as a unit into the part cylindrical slot  17  ( FIG. 7   g ) until they are flush with the bottom of the grooves provided in the top surface  13   a  of the log  11 . At this time, the sealant  84 ,  86  has not expanded to its free body state, thereby avoiding contact with the walls of the part cylindrical slot  17  or parallel sided body portion  22  of the undercut channel  20 . The key members  33  and key slide  70  are dimensioned such that the key  32  may slide relatively easily along the key slide  70  and into the part cylindrical slot  17 . Typically a clearance in the order of ⅛ of an inch on the diameter is provided between the arcuate undersurface  46  and the cylindrical wall of the part cylindrical slot  17 . However, the flared shoulders  44  extend laterally into key slide  70  within the enlarged socket  24  so as to inhibit removal of the key  32 . With the key  32  correctly positioned, the key members  33  are forced apart within the part cylindrical slot  17  by insertion of a spike  88  along the length of the key member  33  ( FIG. 7   h ). The spike  88  is inserted into the notch  59  provided adjacent the flange  56  and acts as a wedge to separate the key members  33 . The enlarged head  40  is dimensioned to prevent removal from the part cylindrical slot  17  in the locked condition as seen in  FIG. 3 . The flanges  56  act as a barrier to prevent lateral movement of the spike  88  from between the key members  33  and to cause a uniform spreading of the key  32  within the part cylindrical slot  17 . The relatively small surface area of the reinforcing ribs  38  reduces the friction on the spike  88  and reduces the downward force transferred to the key members  33  by the spike  88 . The initial spreading of the key  33  members also brings the embossments  60  in to engagement with the walls of part cylindrical slot  17  to inhibit further upward or downward movement. 
         [0078]    The spike  88  separates the key members  33  within the part cylindrical slot  17  but the inner edges of the flared shoulders  44  within the key slide  70  remain in contact with one another. As can be seen from a comparison between  FIGS. 2 and 3 , spreading of the key members  33  causes a rolling action about the curved surfaces of the throat  74  of the key slide  70  so as to provide essentially an outward force that is readily resisted by the material in the post  10 , as opposed to a torque acting so as to break off the material at the  body portion  22  of the undercut channel  20 . At the same time, the sealant tape  84 ,  86  expands and is compressed against the enlarged head  40  and part cylindrical slot  17  as well as the neck  42  and undercut channel  20  to provide a continuous uniform seal within the undercut channel  20  and part cylindrical slot  17  respectively. The spreading of the key members  33  as shown in  FIG. 3  causes the log  11  to be drawn tightly against the face of the post  10  causing the foam tape  19  in sealant slots  18  to be similarly compressed to form a continuous seal. An asphalt impregnated foam pad  90  is then placed onto the top of the key  32  to ensure a proper seal between adjacent key  32  ( FIG. 7   i ). However, the reduced spreading within the key slide  70  in combination with the low friction material of the key slide  70  facilitates sliding movement of the key  32  down the key slide  70 . 
         [0079]    With the initial log in situ, a similar procedure is followed with the log on the opposite planar face  12  of the post  10  to provide the first row of logs  11  ( FIG. 7   j - 7   k ). The upper surface  13   a  of the log  11  is then prepared by applying sealant strips  87  to the sealant grooves on the upper surface  13   a  of each log  11  and the next log  11  placed in position. The key  32  is then inserted as described above and the process continues up each side of the post  10  until the full height of the log wall  2  has been attained. 
         [0080]    During assembly, the weight of each of the logs  11  is sufficient to induce sliding between the key  32  and the key slide  70  to accommodate downward vertical sliding movement of the logs  11  and compression of the sealant strips  87 . Optionally, a thru-bolt may be inserted vertically through the log walls  2  and tensioned to force the logs  11  together. As the logs dry, the weight of the logs  11  and the tension in the thru bolt if used, is sufficient to force the key  32  to slide within the key slide  70  and maintain a sealed relationship with the adjacent log  11  and the post  10 . The engagement of the embossments  60  with the part cylindrical slot  17  ensures the key  32  moves with the logs  11  and slides within the key slide  70 . 
         [0081]    Thus, the spline assembly  30  provides a relatively low friction slide member in the post  10  that permits key  32  to slide in a controlled manner within the key slide  70 . The key  32  is secured to respective ones of the logs  11  by expansion of the key members  33  so as to move with the logs  11  relative to the post  10 . In this manner, the integrity of the log walls  2  is maintained by inhibiting gaps from opening between the logs  11 . As well as maintain a seal between planar face  12  and the end face  16 . 
         [0082]    The above embodiment is described in the context of securing a vertical post  10  to logs  11  to form a corner  6 . A similar arrangement may be used where a pair of log walls intersect at a location other than where a post  10  is provided. Typically this would be where an interior log wall intersects an exterior log wall although it will be appreciated that the technique may be used to interconnect two exterior walls or two interior walls. 
         [0083]    Referring therefore to  FIGS. 9 through 11 , in which like components are identified with like reference numerals to the embodiment of  FIGS. 1 through 8  but with a suffix “a” added for clarity, an intersecting log wall  90  made from logs  11   a  is perpendicular to the length of the logs  11   a  of an exterior log wall  2   a . A vertical recess  92  is formed in the exterior log wall  2   a  extending the full height of the intersecting log wall  90 . Typically this will be the full height of the log wall  2   a , but in some applications the intersecting wall  90  may terminate at less than the full height of the exterior wall  2   a . The recess  92  has a minimum width corresponding to the width of the logs  11   a  of the intersecting wall  90  and has a depth sufficient to extend into the log  11   a  beyond any surface formations such as bevels formed on the edge of the logs  11   a.    
         [0084]    An undercut channel  20   a  is cut in the logs  11   a  at the base of the recess  92  and has a profile corresponding to that of the channel  20  formed in the post  10  described above with respect to  FIGS. 1 through 8 . Similarly, end faces  16   a  of the logs  11   a  of the interior wall  90  are formed with part cylindrical slots  17   a  that, when assembled, are aligned with the undercut channel  20   a.    
         [0085]    In the preferred embodiment, a key slide  70   a  is inserted into the enlarged socket  24   a  of the undercut channel  20   a  to receive a key  32   a . The key slide  70   a  may be inserted from the top of the wall  2   a  if space permits. However, to facilitate assembly of the intersecting wall  90  after the exterior walls  2   a  are capped with a roof or second storey, the key slide  70   a  is modified to facilitate insertion into the enlarged socket  24   a . As can be seen from  FIGS. 9 and 11 , base  71   a  has a central groove  102  that provides a living hinge at the midpoint of the base  71   a . The groove  102  permits the base  71   a  to be folded at the hinge and thereby reduce the lateral extent of the key slide  70   a  so it may pass through the body portion  22   a  of the undercut channel  20   a . Once inserted, the base  71   a  may be unfolded and force the wall  72   a  of the key slide  70   a  into the enlarged socket  24   a.    
         [0086]    With the key slide  70   a  inserted in the enlarged socket  24   a  of the undercut channel  20   a , the intersecting wall  90  may be assembled by positioning the end faces  16   a  of the logs  11   a  against the base of the recess  92 . The keys  32   a  may then be inserted to bridge the undercut channel  20   a  and part cylindrical slots  17   a  and expanded to lock the keys  32   a  in situ as described above. It will be understood that the foam tapes  19   a  may be placed in the sealant slots  18   a  in the recess  92  of the logs  11   a  and the keys  32   a  in a similar manner to that described above to ensure an air tight connection between the walls. 
         [0087]    The recess  92  may be formed in individual logs  11   a  of wall  2   a  prior to assembly or may be routed after the exterior walls  2   a  have been assembled. This latter arrangement increases the flexibility of modifying the building after its initial assembly although the routing of the recess  92 , the sealant slots  18   a  and the undercut channel  20   a  during manufacture of the logs  11   a  is to be preferred. 
         [0088]    It will also be appreciated that where the intersecting wall  90  is intended as an interior wall, maintaining a seal between adjacent logs is not as critical as where it is an exterior wall. In this case, the key slide  70   a  may be omitted allowing for the direct connection between the wall  2   a  and the wall  90  using the keys  32   a.    
         [0089]    A further application of the connection between the post  10  and logs  11  forming a wall  2  is shown in the embodiment of  FIGS. 12-17 , in which like components will be identified with like reference numerals with a suffix “b” added for clarity. 
         [0090]    In the embodiment of  FIGS. 12-17 , the connection is formed at an intermediate location  7  on the wall, as shown in  FIG. 1 . Referring therefore to  FIG. 12 , the wall  2   b  is formed by a pair of log wall sections  100  are each formed from logs  11   b  connected at each end to a post  10   b  using the key  32   b  as described above with respect to  FIGS. 1-8 . Each of the wall sections thus comprises a pair of posts  10   b  with logs  11   b  extending between them and secured thereto. The wall sections  100  may be connected end to end to one another when an extended wall  2   b  is required for the building  1 . As can be seen in  FIG. 22 , each wall section  100  is assembled with the logs  11   b  extending slightly above the post  10   b  to allow for shrinkage as the logs  11   b  dry. Where thru bolts are used they may be installed during assembly of the section  100  to enhance the integrity of the wall section. 
         [0091]    As shown in  FIG. 13  each of the posts  10   b  has a planar face  12   b  that abuts the end face  16   b  of the logs  11   b  and an oppositely directed planar face  14   b  that is designed to abut a corresponding face  14   b  of a post  10   b  of an adjacent wall section  100 . The planar face  14   b  of post  10   b  is formed with a part cylindrical slot  103  (similar to the part cylindrical slot  17   b  formed in the planar face  16   b  in log  11   b ) so that when the faces  14   b  abut, the part cylindrical slots  103  are aligned and define a waisted void  110  having a “figure of 8” cross section. 
         [0092]    To secure the posts  10   b  to one another, an elongate “figure of  8 ” shaped key  112  is inserted into the void  110 . The elongated key  112  can best be seen in  FIGS. 17 and 18 . 
         [0093]    The elongated key  112  is formed from two identical key members  113  that extend the full length of the post  10   b . Each of the key members  113  has a pair of enlarged heads  40   b  extending to either side of a waisted central portion  114  so that, in cross section, each of the key members  113  is similar to one half of the waisted void  110  formed between the abutting part cylindrical slots  103  in the posts  10   b.    
         [0094]    A pair of flanges  56   b  project outwardly from the key members  113  and a pair of slots  58   b  having a depth slightly greater than that of the flange  56   b  are molded into each of the key members  113 . As shown in  FIG. 17 , the key members  113  may be placed back to back with the flanges  56   b  of one of the key members engaging the slots  58   b  of the other of the key members. Each of the enlarged heads  40   b  is formed with a radial step  48   b . The key members  113  are preferably extruded from a plastics material and so have a uniform cross section. Alternatively, the key members may be formed from wood or plywood without flanges. 
         [0095]    To assemble the wall  2   b  from wall sections  100 , the sections  100  are placed end to end, as shown in  FIG. 12 , with the faces  14   b  of posts  10   b  in alignment. Sealant tape  19   b  is applied in the sealant slots  18   b  on the face of one of the posts  10   b  to form an effective seal as the faces  14   b  are drawn together. The key members  113  are prepared, by applying the sealant tape  86  to the enlarged head  40   b  above the radial step  48   b  and the key  112  is inserted between the posts  10   b  with the sealant tape in a compressed state. Once inserted, spikes  88   b  are inserted between the key members  113  and driven downward as shown on  FIG. 16  to separate the key members  113  and thereby spread key  112  as shown in  FIG. 18 . Whilst it is theoretically possible to insert two elongated single spikes  88   b  along the entire length of the key  112 , in practice, it is easier to insert a series of spikes  88   b  end to end. To facilitate the insertion of such spikes  88   b , each of the spikes  88   b  is formed without a head and with a countersink to receive the pointed end of a subsequent spike  88   b . Therefore, the spikes  88   b  may be inserted progressively between key members  113 , to spread the key  112  over the entire length of the post. The outer surface of the spikes  88   b  may be coated with a lubricant, such as a “wax” if required, to facilitate insertion over the entire length of the key  112 . The key members  113  may be extruded from a relatively low friction material. The spreading of the key  112  causes the posts  10   b  to be drawn toward one another and abut along the opposed faces  14   b.    
         [0096]    It will be appreciated that it is not necessary to form the key members  113  as a single component and shorter lengths of key member  113  may be stacked in the void  110  without jeopardizing the integrity of the connection between the posts  10   b . However, the insertion of multiple spikes  88   b  suggests that a continuous key members  113  is to be preferred. 
         [0097]    With the wall sections  100  aligned and connected to one another, as shown in  FIG. 22 , the rigidity of the exterior wall  2   b  is increased by placement of straps  120  across the posts  10   b . The steel straps  120  extend along the upper surface of the logs  11   b  and are secured by nails or screws to the logs  11   b  to inhibit a hinging action about a vertical axis at the posts  10   b . Clearance is provided between the strap  120  and the upper end of the posts  10   b , to facilitate log wall shrinkage and settlement. A foam pad  125  is placed between the strap and the post  10   b  to inhibit air movement over the top of the post. 
         [0098]    The strap  120  may also provide a support for additional structural members, such as a joist or rafter. A yoke  122  attached to strap  120  may be dimensioned to receive standard section lumber and provides a nailing point to secure the structural member. The yoke  122  is maintained in alignment with the upper surface of the logs  11   b  as they shrink by virtue of the strap  120 . 
         [0099]    Alternative embodiments of the key  112  are shown in  FIGS. 19 ,  20  and  21 . In the embodiment of  FIG. 19 , each of the key members  113  has a pair of flanges  56   b  to one side of the waisted central portion  114  and a pair of grooves  58   b  to the other side. This still permits the key members  113  to be placed back to back and to constrain the spikes  88   b.    
         [0100]    In the embodiment of  FIG. 20 , the end face of the body is offset with projecting flanges  115  that serve to define an air cavity between the post  10   b  and the key member  113 . This enhances the insulative properties to reduce heat transfer across the posts  10   b.    
         [0101]    Similarly, in the embodiment of  FIG. 21 , the key members  113  are formed to provide a void between them when assembled to provide a further air cavity in the key  112 . 
         [0102]    In some buildings, it is necessary to integrate conventional frame construction with log construction. The connection system described above can be adapted for these circumstances, as illustrated in  FIGS. 23 to 26 . 
         [0103]    Referring firstly to the embodiment of  FIGS. 23 and 24 , in which like reference numerals will denote like components with a suffix V added for clarity, a wall section  100   c , formed by posts  10   c  and logs  11   c , is connected to a framed wall section  200  of conventional construction and having a top plate  202  and studs  204 ,  206  and a post  10   a . It will of course be appreciated that the framed wall section  200  includes the additional components normally associated with frame construction, such as a bottom plate, lintels and the like. 
         [0104]    The end stud  204  is nailed to a post  10   c , that has a part cylindrical slot  17   c  along the face  14   c . The posts  10   c  of the wall section  100   c  and framed wall section  200  are aligned with the respective faces  14   c  in abutment and a key  112   c  inserted to connect the wall section  100   c  to wall section  200 . 
         [0105]    In the embodiment of  FIGS. 25 and 26 , an elongated keyspline  32   d  and keyslide  70   d  is used to connect a framed wall section  200   d  to a post  10   d . The wall section  100   d  has a recess  92   d  corresponding in width to the width of the post  10   d . An undercut channel  20   d  is formed in each of the base of recess  92   d  and a part cylindrical slot  17   d  formed in the post  10   d . A key  32   d  is inserted and spread to secure the wall sections  100   d ,  200   d , to one another. 
         [0106]    If required, a post  10  may be secured to the wall section  100  as shown in  FIGS. 25 and 26  to stiffen the wall along its length. In this case, a stud wall  200  would not be utilised so as to minimise the protrusion in to the room. 
         [0107]    It will be seen from the above that embodiments are provided to form a corner between a post and two walls, to connect walls that intersect between posts and to connect walls end to end. 
         [0108]    The arrangement of connections between the post and logs may be integrated into a single building as illustrated schematically in  FIG. 27  to permit a panelised construction technique to be used. In this arrangement, a corner unit indicated at  300  consists of a post  10  with logs  11  connected to its oppositely directed faces  12 ,  14 . The logs  11  extend to and are secured at opposite ends to a face of the posts  10   b  that is directed toward the post  10  in the manner shown in  FIGS. 1-4  so that the unit  300  defines a panelised corner unit. The intermediate wall indicated at  302  is formed by a wall section  100  constructed as shown in  FIG. 12 to 16  and has a pair of posts  10   b  with a logs  11   b  extending between opposed faces. The post  10   b  of the wall section  100  is joined to the post  10   b  of the corner unit  300  using the formations in the form of recesses  17  and keys  112  to form an integral exterior wall  2 . A further corner unit  300  is connected at the opposite end of the wall section  100 . The exterior periphery of the building shown in  FIG. 27  may thus be built from four corner units  300  and a pair of wall sections  100 , which may be either log or frame construction. 
         [0109]    An interior wall  304  may be joined to the exterior wall section  100  using the connection as shown in  FIGS. 9 through 11 . A further connection in the exterior wall is made at the post  10  connecting the two corner units  300  using a connection similar to that shown in either  FIGS. 9 through 12  or  FIGS. 13 through 18 . 
         [0110]    It will be seen that the arrangement of self contained wall units permits a panelised building to be assembled from previously constructed wall units each of which utilizes formations in the posts and a key to connect logs to posts or post to post or log walls to log walls or framed walls to log wall. In each case, provision is made for proper sealing between the keys and the logs to maintain the integrity of the walls and where key slides are used, relative movement between the logs is facilitated. 
         [0111]    A further embodiment particularly suitable for providing a panelized construction technique is shown in  FIGS. 28 through 40 , although it will be appreciated that the components illustrated in these figures may be utilized in the construction of a non-panelized building as illustrated for example, in  FIG. 7 . 
         [0112]    Referring to  FIG. 28 , the post  10   d  is formed from laminations of different lumber for stability and economy of manufacturer. As shown in  FIG. 28  outer laminations  400  are machined from a premium quality wood, such as a white pine or cedar, and the balance of the laminations  402  are machined from a lower premium wood, such as construction grade spruce/pine/fur. The faces  12   d ,  14   d  extend between the laminations  400  and have formations machined in them to provide the re-entrant part cylindrical recess  17   d  in the face  14   d  and the undercut channel  20   d  in the face  12   d . The face  14   d  is also machined to have an upstanding tongue  404  to one side of the recess  17   d  and a complimentary groove  406  to the opposite side. Sealant grooves  408 ,  410  are provided adjacent the tongue  404  and groove  406  respectively. The sealant grooves  412  are also provided on the face  12   d  to either side of the channel  20 . 
         [0113]    The post  10   d  is secured to logs  11   d  by a spline assembly  30   d  as shown in  FIG. 29 . A key slide  70   d  is inserted into the channel  20   d  and the key  32  inserted after placement of the end face  16   d  of each of the logs  11   d  against the face  12   d . The key  32   d  is expanded by means of the spike  88   d  as described above to secure the logs  11   d  to the post  10   d . A post  10   d  may be connected at opposite ends of the log  11   d  such that the logs  11   d  and posts  10   d  form a self contained wall unit  100   d.    
         [0114]    To facilitate transportation of the units  100 , the lower most log  11   d  is secured to the posts  10   d  by screws driven through the post and into the log. This inhibits the relative movement between the lowermost post and log while still permitting such movement with the balance of the logs. 
         [0115]    Where tie bolts are used, as described above, they are inserted and provide convenient locations to permit hoisting of the wall units during transportation and assembly. 
         [0116]    To assemble a pair of wall units  100   d , the units are oriented such that the faces  14   d  are opposed. In this position, as can be seen in  FIG. 30 , the tongue  404  of one post  10   d  is aligned with the groove  406  of the opposed posts  10   d  and the recesses  17  are aligned. Sealing strips are located in the grooves  408 ,  410  and the post  10   d  brought into abutment as shown in  FIG. 31 . 
         [0117]    With the post  10   d  abutting, an elongate “figure of  8 ” shape key  112   d  is inserted to bridge the aligned recesses  17   d . Any suitable form of key  112  may be used, such as one of the embodiments shown in  FIGS. 17-21  and preferably is similar to that shown in  FIG. 14  or  15  with notches for the spikes  88 . The key  112   d  can then be expanded using spikes  88  as described above with respect to  FIG. 12 to 15 . The key  112   d  may be either a single continuous extrusion extending the full length of the post  10   d  or may be individual shorter lengths of key, again as described above with respect to  FIGS. 12 through 15 . 
         [0118]    With the key  112   d  expanded as shown in  FIG. 32  a secure connection is made between the wall sections  100 . The engagement of tongue  404  and groove  406  locates the posts  10   b  in a lateral direction as well as providing a more tortuous path to inhibit air infiltration. The seals located in the grooves  408 ,  410  also enhance the air lightness of the connection between the walls. 
         [0119]    It will be noted from  FIG. 32  that with the posts  10   d  secured to one another, the outer laminations  400  cover the joint between the posts and thereby provide a continuous pleasing appearance to the exterior surface of the post. 
         [0120]    The manufacturer and use of the posts  10   e  used at the corners  6  may also be enhanced to facilitate the panelized construction of the building. As shown in  FIG. 33 , a post  10   c  is formed with undercut channels  20   e  on opposite faces. The post  10   e  is again laminated from exterior laminations  400   e  and internal laminations  402   e  as described above with respect to  FIG. 28 . Sealant grooves  412  are machined into the faces  12   e ,  14   e  to accommodate sealing strips upon further assembly. 
         [0121]    The post  10   e  is then slit into two components  510  along a separation plane inclined at 45 degrees to the median plane of the post. The inclination of the cut will vary depending upon the included angle of the corner to be formed, but for a 90 degree corner, the 45 degree cut is required. After cutting, two corner posts  510  are formed that are identical in section. Inversion of one component end over end provides two components that when assembled with the cut faces in abutment, define a 90 degree corner post, as described below. A different angle of cut will of course provide a different inclined angle. As shown in  FIG. 35 , each has a part cylindrical re-entrant recess  17   e  machined along its cut face. This recess  17   e  may be machined using a cannon ball router bit with the recess  17   e  located at the mid point of the cut face  512 . The corner post components  510  can be connected at opposite ends of logs  11   e  as shown in  FIG. 36  using spline assemblies  30   e  installed as described above. The logs  11   e  and the post components  510  form a wall unit  100   e  that can be assembled with like wall units to form a corner. Again, the lowermost log is secured to the post component with screws to inhibit sliding movement and the tie bars used as hoist points. 
         [0122]    To form a corner  6 , as shown in  FIG. 37 , a pair of wall units  100  each having a corner component  510  at one end are brought into alignment such that the cut faces  512  abut. Sealant grooves are machined into the cut face to receive sealant strips and are offset from adjacent strips so as to provide four separate seal locations along the cut face  512 . With the corner units in abutment as shown in  FIG. 38 , a key  112   e  is inserted to bridge the aligned recesses  17   e  and connect the sections  100   c  at right angles to one another. Thereafter, spikes  88   e  may be inserted into the key  112   e  to expand the key and secure the corner components  510  into a unitary post  10   e  at a corner. 
         [0123]    It will be noted with respect to  FIGS. 37 through 39  that the exterior laminations  400  extend around both exposed surfaces of the corner and thereby enhance the aesthetics. At the same time, it will be appreciated that the wall units  100  may be made as linear units for ease of transportation and subsequently assembled at corners by the insertion of the spikes  100 . 
         [0124]    With the arrangement shown in  FIGS. 28 through 39 , it is apparent that a panelized structure may be assembled readily as shown schematically in  FIG. 40 . Each of the wall units is formed by a pair of posts  10  connected by logs  11  which extend between the faces of the posts directed toward one another. The formations provided on the other face facilitates connection to an adjacent post through the “figure of eight keys  112 .” The wall units  100  are therefore flat self contained units that are readily transported and assembled into the required configuration at the site.

Technology Classification (CPC): 4