A batten & batten system

Abstract

The disclosure provides a structural cavity batten made of laminated veneer lumber (LVL). The cavity batten comprises a batten member having a plurality of channels located in one or more sides of the batten member to facilitate airflow and liquid drainage to limit or prevent moisture build up within an air cavity. The batten member comprises at least one of laminated veneer lumber (LVL), plywood, ply substrate, laminated substrate and laminated timber.

Description

[0001] A BATTEN & BATTEN SYSTEM

[0002] TECHNICAL FIELD

[0003] [1] The present invention relates to building materials and construction techniques, particularly focusing on providing a batten and batten system for providing effective ventilation and moisture management within wall frame cavities and roof cavities. In particular, the disclosure relates to structural cavity battens and ventilation systems for wall and roof cavities.

[0004] BACKGROUND

[0005] [2] Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

[0006] [3] Moisture ingress and condensation within wall frame cavities pose significant challenges in construction, leading to structural deterioration, mould growth, and decreased energy efficiency.

[0007] [4] In some cases, such as in New Zealand, timber-framed homes that were not fully weather-tight have encountered numerous problems including the decay of timber framing which, in extreme cases, have made buildings structurally unsound. Some buildings have become unhealthy to live in due to moulds and spores developing within the damp timber framing. It has been estimated that the repairs and replacement costs that may have been avoided may be in excess of NZ$11.3 billion

[0008] [5] Inspired by the lessons learned from New Zealand's "Leaky Home Crisis" in which timber-framed homes, there is a growing recognition of the importance of ventilated air cavities in mitigating these issues.

[0009] [6] One existing attempt at a solution in the market includes a non-structural cavity batten product in the form of castellated battens that are finger-jointed or solid pine members having a bevelled edge and evenly spaced notches that allow moisture drainage when used in a horizontal application. This castellated batten must be attached to structural noggings (nogs) in the wall frame.

[0010] [7] Another attempt at solution is a vented cavity wall batten that is an extruded plastic non-structural member having uniform, evenly spaced openings that do not inhibit airflow within the cavity. Similar to the castellated batten, this vented cavity wall batten requires direct fixing to studs or nogs within the wall frame to be supported. [8] While these products described above can provide limited ventilation, they may have limitations in structural integrity, installation complexity, or compatibility with different framing materials.

[0011] SUMMARY OF INVENTION

[0012] [9] In an aspect, the invention provides a batten in the form of a cavity batten. The cavity batten described herein is also suitable for use as a roof batten.

[0013]

[0010] The cavity batten comprises a batten member having a plurality of channels located in one or more sides of the batten member. Preferably, the batten member may have a plurality of channels formed in up to and including four side of the batten member.

[0014]

[0011] Preferably, the cavity batten is a structural cavity batten. Additionally, or alternatively, the cavity batten is configured for structural application. Preferably, the cavity batten is configured to be directly fixed or attached to a wall frame.

[0015]

[0012] Preferably, the plurality of channels (a first plurality of channels) are formed in a single side of the batten member. Preferably, the plurality of channels are evenly spaced along a length of the batten member.

[0016]

[0013] Alternatively, the plurality of channels comprises a first plurality of channels and a second plurality of channels. Preferably, the first plurality of channels are formed in a first side of the batten member and the second plurality of channels are formed in a second side of the batten member. Preferably, the first side of the batten member is directly opposite the second side of the batten member. Preferably, the first plurality of channels are evenly spaced along a length of the batten member at first spacing intervals, and the second plurality of channels are evenly spaced along a length of the batten member at second spacing intervals. Preferably, the first spacing intervals are equal to the second spacing intervals. Alternatively, the first spacing intervals are different to the second spacing intervals. Preferably, the channels are spaced 50mm apart from edge to adjacent edge.

[0017]

[0014] In some embodiments, the channels are irregularly spaced along the length of the batten member.

[0018]

[0015] Preferably, each channel of the plurality of channels is approximately 20mm wide and 5mm deep.

[0016] Preferably, the plurality of channels may be arranged to extend longitudinally along the batten member or arranged to extend transversely across the batten member or extend diagonally across the batten member.

[0019]

[0017] Preferably, the batten member comprises an angled surface extending from the first side to the second side. Preferably, the first side of the batten member has a first width and the second side of the batten member has a second width, wherein the first width is less than the second width (i.e., the width of the first side is less than the second side). Preferably, the angled surface may be an in-use upper surface that is upwardly disposed or oriented when the cavity batten is located within a wall cavity and affixed to a frame. Preferably, a surface of the batten member opposite the angled surface is substantially flat and / or perpendicular to the first side and the second side. Alternatively, the surface of the batten member opposite the angled surface is a second angled surface such that the batten member is substantially trapezoidal.

[0020]

[0018] Preferably, in embodiments having a plurality of channels in only a single side of the batten member, the plurality of channels is located in the first side of the batten member.

[0021]

[0019] Preferably, the batten member comprises at least one of laminated veneer lumber (LVL), plywood, ply substrate, laminated substrate and laminated timber.

[0022]

[0020] Preferably, the plurality of channels extend perpendicular to a grain of the LVL, plywood or laminated timber.

[0023]

[0021] In another aspect, there is provided a method of installing a batten as described above, the method comprising: positioning a plurality of battens against a wall or roof frame; securing each batten to the wall or roof frame; aligning the plurality of channels of the battens; and connecting the batten with at least one adjacent batten to form a continuous ventilation system.

[0024]

[0022] In another aspect, there is provided a method of forming a batten for use as a cavity or roof batten, the method comprising: selecting a material from at least one of laminated veneer lumber (LVL), plywood, ply substrate, laminated timber, composite materials, or synthetic polymer; forming a batten member having a plurality of channels located in one or more sides of the batten member; applying at least one treatment to the batten member, the treatment comprising a moisture-resistant, fire-retardant, or antimicrobial treatment; and cutting the batten member to a predetermined length for use in a wall or roof cavity.

[0025] BRIEF DESCRIPTION OF THE DRAWINGS

[0026]

[0023] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0027] Figure 1 is a perspective view of a cavity batten according to an embodiment of the present invention;

[0028] Figure 2 is a side view of the cavity batten of Figure 1 ;

[0029] Figure 3 is a detail view of a portion of the cavity batten shown in Figure 2;

[0030] Figure 4 is a second side view of the cavity batten of Figure 1 ;

[0031] Figure 5 is a detail view of a portion of the cavity batten shown in Figure 4;

[0032] Figure 6 is a close-up end perspective view of the cavity batten of Figure 1 ;

[0033] Figure 7 is a close-up end perspective view of the cavity batten of Figure 1 ;

[0034] Figure 8 is a third close-up end perspective view of the cavity batten of Figure 1 ; and

[0035] Figure 9 is an end view of the cavity batten of Figure 1 .

[0036] DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0037]

[0024] Figures 1 to 9 illustrate a batten in the form of a cavity batten 1 (also referred to as ‘the batten’) configured to provide airflow and moisture drainage in a wall cavity. The cavity batten 1 comprises a batten member 2 having a plurality of channels located in one or more sides of the batten member 2.

[0038]

[0025] The batten member 2 may include a plurality of channels located in up to and including four sides. That is, pluralities of channels may be formed in one, two, three or four sides of the batten member 2.

[0039]

[0026] In embodiments having pluralities of channels formed in multiple sides, the channels may be formed in opposing sides of the batten member 2 or in directly adjacent sides of the batten member 2.

[0027] While embodiments of the batten described herein are referred to as a cavity batten, it will be understood that the batten described is also suitable for use as a roof batten.

[0040]

[0028] The cavity batten 1 is a structural cavity batten that is configured for structural application such that the cavity batten can be directly fixed or attached to a wall frame (i.e., attached directly to the studs), as opposed to a non-structural batten that must be fixed to a nogging within the wall frame. Advantageously, the structural cavity batten provides stability and support within the wall frame without the need for additional components.

[0041]

[0029] The batten member 2 may be formed from laminated veneer lumber (LVL) having a number of layers of wood veneers adhered together, which provides the structural capacity and capabilities mentioned above, and provides uniform mechanical properties. This allows the batten to be applied in a structural capacity as opposed to a non-structural capacity. Advantageously, providing a batten that has structural capacity may simplify the installation of the battens to save time and allow for simpler frame constructions while also providing airflow within the wall cavity.

[0042]

[0030] In some embodiments, instead of being formed from LVL, the batten member may be formed from plywood, a ply substrate, laminated substrate or laminated timber.

[0043]

[0031] In some embodiments, the batten member may be formed from a composite material, including at least one of engineered wood, fibre-reinforced polymer, plastic, and recycled materials.

[0044]

[0032] In some embodiments, the batten member may include one or more of a fire- resistant coating, waterproofing treatment or coating, and an anti-microbial layer or coating.

[0045]

[0033] For example, embodiments using laminated or layered materials may be sealed (using a chemical treatment or layer) to prevent moisture penetration and absorption that would otherwise damage the material.

[0046]

[0034] In the illustrated embodiment, the plurality of channels extend perpendicular to a grain of the LVL, or other material used. This orientation of the channels relative to the grain of the veneers is an important factor in the batten being suitable for structural application. This also minimises the risk of splitting or damage to the batten during installation.

[0047]

[0035] However, the channels may be arranged in ways other than perpendicularly to the grain of the material. For example, in some embodiments, for a batten installed horizontally (relative to the ground) these channels may be arranged to extend longitudinally along the batten member (i.e. , along a longitudinal axis of the batten member), In another example, the channels may be arranged transversely across the batten member (i.e., transverse or perpendicular to the longitudinal axis of the batten member) or diagonally across the batten member. Different configurations of the channels can be used for different applications and to provide different ventilation depending on the application.

[0048]

[0036] In the illustrated embodiment, the plurality of channels includes a first plurality of channels 3 and a second plurality of channels 4.

[0049]

[0037] The channels are substantially rectangular in shape but could be varied.

[0050]

[0038] The first and second plurality of channels 3,4 are located on opposite sides of the batten member 2. More particularly, the first plurality of channels 3 are formed in a first side 5 of the batten member 2 and the second plurality of channels 4 are formed in a second side 6 of the batten member 2. In an embodiment, the first side 5 of the batten member 2 is directly opposite the second side 6 of the batten member 2. In use, one side of the batten having one of the plurality of channels formed therein face outwardly from the wall frame such that the ends of the channels allow fluids, such as gases and liquids, to freely pass through to enhance airflow within the wall cavity. This will elaborated on below.

[0051]

[0039] The pluralities of channels 3,4 on both sides of the batten member 2 may be evenly spaced along a length of the batten member 2.

[0052]

[0040] The plurality of channels 3 on the first side 5 of the batten member 2 are parallel. Similarly, plurality of channels 4 on the second side 6 of the batten member 2 are parallel.

[0053]

[0041] In some embodiments, the first plurality of channels 3 are evenly or uniformly spaced along a length of the batten member 2 at first spacing intervals X1 , and the second plurality of channels 4 are evenly spaced along a length of the batten member 2 at second spacing intervals X2.

[0054]

[0042] It will be appreciated that the first spacing intervals X1 may be equal to the second spacing intervals X2. Although, in some embodiments, the channels are irregularly spaced along the length of the batten member. That is, the first spacing intervals may be different to the second spacing intervals.

[0055]

[0043] In one embodiment, the pluralities of channels are equally spaced 50mm apart from edge to adjacent edge along their respective sides of the batten and each channel of the plurality of channels is approximately 20mm wide and 5mm deep. However, the dimensions of the channels can be readily varied by a person skilled in the art according to needs.

[0056]

[0044] As can be seen in the figures, the channels of the plurality of channels 3 on the first side 5 of the batten member 2 are offset from the channels of the plurality of channels 4 on the second side 6 of the batten member 2. That is, the channels of the plurality of channels 3 on the first side 5 of the batten member 2 are not axially aligned with (or are axially offset from) the channels of the plurality of channels 4 on the second side 6 of the batten member 2. This improves the structural integrity of the batten member and minimises the risk of the batten breaking when being fixed to the wall frame or under heavy load.

[0057]

[0045] In some embodiments, the plurality of channels (e.g., the first plurality of channels) are formed in a single side of the batten member and are evenly spaced along a length of the batten member.

[0058]

[0046] The batten member 2 has a single bevelled surface (or edge) 7. The bevelled surface 7 allows the batten 1 to direct any liquids that gather on top of the batten in certain orientations towards the channels to drain away.

[0059]

[0047] In some embodiments, the batten member 2 may have one or more bevelled surfaces (or edges).

[0060]

[0048] The bevelled surface 7 includes an angled surface extending from the first side 5 to the second side 6.

[0061]

[0049] The bevelled surface 7 is provided by a first side 5 of the batten member 2 being wider than a second side 6 of the batten member 2. That is, the first side 5 of the batten member 2 has a first width W1 and the second side 6 of the batten member 2 has a second width W2, wherein the first width W1 is less than the second width W2 (i.e., the width of the first side is less than the second side). In use, the second side 6 is fixed to the wall frame to allow moisture and liquid drainage away from the wall frame.

[0062]

[0050] A surface 8 of the batten member 2 opposite the bevelled surface 7 may be substantially flat or horizontal as shown in Figure 5. That is, the surface 8 opposite the bevelled surface 7 may be perpendicular to both the first side 5 and the second side 6.

[0063]

[0051] In some embodiments that are not illustrated, the surface of the batten member opposite the angled surface is a second bevelled surface such that the batten member is substantially trapezoidal and is universally locatable within the cavity without the need for correct orientation.

[0064]

[0052] In some embodiments, the batten member may be substantially square or rectangular (i.e. , all sides horizontal and having no bevelled edges).

[0065]

[0053] It will be appreciated that in embodiments having a plurality of channels in only a single side of the batten member, the plurality of channels will be located in the lower side of the batten. Specifically, the plurality of channels is located in the first side of the batten member so as to allow any liquid that is directed toward the lower first side of the batten member can drain away via the channels located on that side of the batten.

[0066]

[0054] For installation, fixings are driven through 60mm sides of the batten to secure to the frame. These fixing methods could be nails, screws or a combination thereof. They will also be dependent on the frame substrate (e.g., steel, softwood, hardwood, engineered timber, etc.) and their mechanical and joint strength properties although this will be readily understood by the person skilled in the art.

[0067]

[0055] It will be readily understood that the shape and dimensions of the batten can be varied.

[0068]

[0056] For example, in some embodiments, the batten member has a cross-sectional shape selected from one or more of a rectangular profile, a trapezoidal profile, a triangular profile, or a rounded-edge profile. These shapes may be selected to optimise drainage and airflow within the wall or roof cavity depending on the particular application or orientation of the batten.

[0069]

[0057] In some embodiments, the plurality of channels is formed using one or more of mechanical cutting, laser etching, moulding, or extrusion. The method of forming the channels may vary depending on the material composition of the batten member and the desired manufacturing process.

[0070]

[0058] In some embodiments, the batten is configured for attachment to a frame using one or more of fasteners, nails, screws, adhesive bonding, interlocking fasteners, or an integrated clip system. The specific method of attachment may be selected based on the substrate of the wall frame and the desired ease of installation.

[0071]

[0059] In some embodiments, the batten includes integrated insulation material or thermally insulating material. The insulation material may be located within or adjacent to the batten member and configured to enhance the thermal performance of the wall or roof cavity in which the batten is installed. The integrated insulation material or thermally insulating material may be integrated within the batten member or connected to one or more surfaces of the batten member.

[0072]

[0060] In some embodiments, the batten is configured to interlock with one or more adjacent battens. The batten may be configured to interlock with an adjacent, second batten through an interlocking arrangement. The interlocking arrangement may enhance structural stability, improve ventilation by maintaining alignment of the airflow channels, or simplify installation by ensuring consistent spacing and alignment. The interlocking arrangement may comprise a tongue and groove arrangement, dovetail joint, integrated clip system, half-lap joint, lap joint, overlap joint, notched joint or corresponding male and female batten ends for battens to be interlocked.

[0073]

[0061] In some embodiments, the batten may include at least one removable portion configured to fit within a channel of the batten member. The removable portion may be configured to be retained within the channel via a friction or press fit. These removable portions allow for modification of airflow characteristics based on specific installation requirements or environmental conditions.

[0074]

[0062] In some embodiments, a method of forming the batten includes selecting a material from one or more of laminated veneer lumber (LVL), plywood, ply substrate, laminated timber, composite materials, or synthetic polymer. The selected material may be chosen based on desired structural and environmental performance characteristics.

[0075]

[0063] The method further includes forming a batten member having a plurality of channels on one or more surfaces of the batten member. These channels may be formed using mechanical cutting, laser etching, moulding, extrusion, or another suitable manufacturing process as described above.

[0076]

[0064] The method also includes applying one or more treatments to the batten member. These treatments may include a treatment for forming a moisture-resistant coating, a fire-retardant coating, and / or or an antimicrobial layer. These treatments may be applied during or after the forming of the batten member to improve its durability and performance in varying environmental conditions.

[0077]

[0065] Finally, the batten member may be cut to a predetermined length suitable for installation within a wall or roof cavity. The length may be selected to suit specific construction modules, framing layouts, or installation preferences.

[0078]

[0066] In some embodiments, a method of installing the batten includes positioning a plurality of battens against a wall or roof frame. Each batten is then secured to the frame using a suitable attachment method, such as screws, nails, or adhesives. During installation, the plurality of channels in each batten are aligned to optimise airflow and moisture drainage. The battens may be connected to one or more adjacent battens to form a continuous ventilation system within the wall or roof cavity.

[0079]

[0067] Advantages of embodiments of the invention will be described below.

[0080]

[0068] Embodiments of the invention provide a structural cavity batten configured for direct attachment to a wall frame without the need for additional supporting elements, such as noggings. This ensures stability and support within the frame.

[0081]

[0069] The use of laminated veneer lumber (LVL) provides uniform mechanical properties, allowing the batten to be applied structurally rather than merely for support, thereby simplifying installation and frame construction while promoting airflow within the wall cavity.

[0082]

[0070] The perpendicular orientation of the channels relative to the grain of the LVL enhances its suitability for structural application. Additionally, the arrangement of channels on opposite sides of the batten promotes efficient airflow within the cavity to prevent moisture and liquid build-up that can lead to mould and structural damage.

[0083]

[0071] The evenly spaced channels, along with the bevelled surface, facilitate drainage and can adapt to various orientations within the cavity.

[0084]

[0072] Furthermore, the ability to vary the shape and dimensions of the batten ensures versatility in application.

[0085]

[0073] Finally, installation is simplified, with fixings driven through the batten's sides, accommodating different frame substrates and mechanical properties. Overall, these features enhance structural integrity, simplify installation, and promote efficient airflow within wall cavities.

[0086]

[0074] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and “comprised of” is used throughout in an inclusive sense and not to the exclusion of any additional features.

[0087]

[0075] It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

[0088]

[0076] The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Claims

CLAIMS1. A batten for use as a cavity or roof batten, the batten comprising a batten member having a plurality of channels located in one or more sides of the batten member, wherein the batten member comprises at least one of laminated veneer lumber (LVL), plywood, ply substrate, laminated substrate and laminated timber.

2. The batten of claim 1 , wherein the plurality of channels are formed in up to and including four sides of the batten member.

3. The batten of claim 1 or claim 2, wherein the batten member is configured to be directly fixed or attached to a wall frame.

4. The batten of any one of claims 1-3, wherein the plurality of channels are formed in a single side of the batten member.

5. The batten of any one of claims 1 -4, wherein the plurality of channels are evenly spaced along a length of the batten member.

6. The batten of any one of claims 1 -3, wherein the plurality of channels comprises a first plurality of channels and a second plurality of channels, wherein the first plurality of channels are formed in a first side of the batten member and the second plurality of channels are formed in a second side of the batten member.

7. The batten of claim 6, wherein the first side of the batten member is directly opposite the second side of the batten member.

8. The batten of claim 6 or claim 7, wherein the first plurality of channels are evenly spaced along a length of the batten member at first spacing intervals, and the second plurality of channels are evenly spaced along a length of the batten member at second spacing intervals.

9. The batten of claim 8, wherein the first spacing intervals are equal to the second spacing intervals.

10. The batten of claim 8, wherein the first spacing intervals are different to the second spacing intervals.

11. The batten of any one of claims 1-7, wherein the plurality of channels are irregularly spaced along the length of the batten member.

12. The batten of any one of claims 1-11 , wherein the plurality of channels may be arranged to extend longitudinally along the batten member or arranged to extend transversely across the batten member or extend diagonally across the batten member.

13. The batten of any one of claims 1-12, wherein the batten member comprises an angled surface extending from the first side to the second side, wherein the first side of the batten member has a first width and the second side of the batten member has a second width, wherein the first width is less than the second width.

14. The batten of claim 13, wherein the angled surface may be an in-use upper surface that is upwardly disposed or oriented when the batten member is located within a wall cavity and affixed to a frame, and wherein a surface of the batten member opposite the angled surface is substantially flat.

15. The batten of claim 13 or claim 14, wherein the surface of the batten member opposite the angled surface is a second angled surface such that the batten member is substantially trapezoidal.

16. The batten of any one of claims 6-15 wherein when the plurality of channels is in only on a single side of the batten member, the plurality of channels is located in the first side of the batten member.

17. A batten for use as a cavity or roof batten, the batten comprising a batten member having a plurality of channels located in one or more sides of the batten member, wherein: the batten member comprises at least one of laminated veneer lumber (LVL), plywood, ply substrate, laminated substrate and laminated timber, the plurality of channels extends perpendicular to a grain of the LVL, plywood, ply substrate, laminated substrate or laminated timber, and the batten member comprises an angled surface extending from the first side to the second side, wherein the first side of the batten member has a first width and the second side of the batten member has a second width, wherein the first width is less than the second width, and wherein a surface opposite the angled surface is perpendicular to the first side and the second side.

18. The batten of any one of claims 1 to 20, wherein the batten member includes an integrated thermal insulation material.

19. The batten of any one of claims 1 to 20, wherein the batten member includes an interlocking arrangement for connecting the batten member with a second batten member.

20. A method of installing a batten as claimed in any one of claims 1 to 18, the method comprising: positioning a plurality of battens against a wall or roof frame;securing each batten to the wall or roof frame; aligning the plurality of channels of the battens; and connecting the batten with at least one adjacent batten to form a continuous ventilation system.

21. A method of forming a batten for use as a cavity or roof batten, the method comprising: selecting a material from at least one of laminated veneer lumber (LVL), plywood, ply substrate, laminated timber, composite materials, or synthetic polymer; forming a batten member having a plurality of channels located in one or more sides of the batten member; applying at least one treatment to the batten member, the treatment comprising a moisture-resistant, fire-retardant, or antimicrobial treatment; and cutting the batten member to a predetermined length for use in a wall or roof cavity.

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