Boards, kit and methods for construction of prefabricated structures

Abstract

Precut and pre-machined boards, a kit, and methods for constructing prefabricated structures are described. Each board includes at least one grooved notch for in a top or a bottom of the board for forming a cross lap joint. Two such boards can be joined together by interlocking the respective grooved notches forming a cross lap joint. Each grooved notch includes a first shoulder and a second shoulder extending perpendicularly from a cheek. A first groove is disposed on a first side of the board adjacent to the first shoulder and a second groove is disposed on a second side of the board adjacent to the second shoulder. The grooves ensure secure interlocking of the boards at the cross lap joint without requiring glue or fasteners. The grooves also cover gaps in joint inhibiting wind, water and light from penetrating the joint.

1 . A board for constructing prefabricated structures, the board comprising:
 a first grooved notch having a first depth in a top of the board and a second grooved notch having a second depth different than the first depth, in a bottom of the board, for forming cross lap joints, each grooved notch comprising:
 a first shoulder and a second shoulder extending perpendicularly from a cheek; 
 a first groove disposed on a first side of the board adjacent to the first shoulder; and 
 a second groove disposed on a second side of the board adjacent to the second shoulder. 
   
     
     
         2 . The board of  claim 1 , wherein the first groove is cut to a first size and the second groove is cut to a second size different from the first size. 
     
     
         3 . The board of  claim 1 , wherein each groove comprises:
 an inner surface orthogonal to the shoulders; and   an outer surface orthogonal to the inner surface and parallel to the shoulders.   
     
     
         4 . The board of  claim 1 , further comprising:
 at least one tongue on the top of the board.   
     
     
         5 . The board of  claim 1 , further comprising:
 at least one groove on the bottom of the board.   
     
     
         6 . The board of  claim 1 , wherein the board is made of timber. 
     
     
         7 . The board of  claim 1 , wherein each grooved notch is orthogonal to a long axis of the board. 
     
     
         8 . The board of  claim 1 , wherein each grooved notch is adjacent to an end of the board. 
     
     
         9 . A kit for constructing a prefabricated structure, the kit comprising:
 a plurality of boards, one or more of the boards comprising:
 a first grooved notch having a first depth in a top of the board and a second grooved notch having a second depth different from the first depth, in a bottom of the board, for forming cross lap joints, each grooved notch comprising:
 a first shoulder and a second shoulder extending perpendicularly from a cheek; 
 a first groove disposed on a first side of the board adjacent to the first shoulder; and 
 a second groove disposed on a second side of the board adjacent to the second shoulder. 
 
   
     
     
         10 . The kit of  claim 9 , wherein the first groove is cut to a first size and the second groove is cut to a second size different from the first size. 
     
     
         11 . A board for constructing prefabricated structures, the board comprising:
 at least one grooved notch in a top and/or a bottom of the board, for forming cross lap joints, each grooved notch comprising:
 a first shoulder and a second shoulder extending perpendicularly from a cheek; 
 a first groove cut to a first size on a first side of the board adjacent to the first shoulder; and 
 a second groove cut to a second size, different than the first size, on a second side of the board adjacent to the second shoulder. 
   
     
     
         12 . The board of  claim 11 , wherein each groove comprises:
 an inner surface orthogonal to the shoulders; and   an outer surface orthogonal to the inner surface and parallel to the shoulders.   
     
     
         13 . The board of  claim 11 , further comprising:
 at least one tongue on the top of the board.   
     
     
         14 . The board of  claim 11 , further comprising:
 at least one groove on the bottom of the board.   
     
     
         15 . The board of  claim 11 , wherein the board is made of timber. 
     
     
         16 . The board of  claim 11 , wherein each grooved notch is orthogonal to a long axis of the board. 
     
     
         17 . The board of  claim 11 , wherein each grooved notch is adjacent to an end of the board.