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US20060054267A1 - Value extraction from harvested trees and related laminates and processes - Google Patents

Value extraction from harvested trees and related laminates and processes Download PDF

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Publication number
US20060054267A1
US20060054267A1 US11/223,208 US22320805A US2006054267A1 US 20060054267 A1 US20060054267 A1 US 20060054267A1 US 22320805 A US22320805 A US 22320805A US 2006054267 A1 US2006054267 A1 US 2006054267A1
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US
United States
Prior art keywords
boards
sticks
length
log
transverse
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/223,208
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English (en)
Inventor
Warwick Bosson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
WOOD ENGINEERING TECHNOLOGY Ltd
Original Assignee
WOOD ENGINEERING TECHNOLOGY Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from NZ524672A external-priority patent/NZ524672A/en
Application filed by WOOD ENGINEERING TECHNOLOGY Ltd filed Critical WOOD ENGINEERING TECHNOLOGY Ltd
Assigned to WOOD ENGINEERING TECHNOLOGY LIMITED reassignment WOOD ENGINEERING TECHNOLOGY LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BOSSON, WARWICK
Publication of US20060054267A1 publication Critical patent/US20060054267A1/en
Priority to US12/153,277 priority Critical patent/US8088494B2/en
Priority to US13/317,857 priority patent/US8420222B2/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/13—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board all layers being exclusively wood
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/12—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces of wood, e.g. with reinforcements, with tensioning members
    • E04C3/122—Laminated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27M—WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
    • B27M1/00—Working of wood not provided for in subclasses B27B - B27L, e.g. by stretching
    • B27M1/08—Working of wood not provided for in subclasses B27B - B27L, e.g. by stretching by multi-step processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27M—WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
    • B27M3/00—Manufacture or reconditioning of specific semi-finished or finished articles
    • B27M3/0013—Manufacture or reconditioning of specific semi-finished or finished articles of composite or compound articles
    • B27M3/006—Manufacture or reconditioning of specific semi-finished or finished articles of composite or compound articles characterised by oblong elements connected both laterally and at their ends
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1059—Splitting sheet lamina in plane intermediate of faces
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1062—Prior to assembly
    • Y10T156/1075—Prior to assembly of plural laminae from single stock and assembling to each other or to additional lamina
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/2457—Parallel ribs and/or grooves
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31989—Of wood

Definitions

  • the present invention relates to value extraction from tree stem materials (without any reduction to discrete fibre form) (i.e. from tree stem lengths) so as to provide engineered structural products and/or appearance products (e.g. laminates) which, especially when from lower valued material and/or lower valued logs of a tree stem, will represent lumber value enhancement.
  • Weyerhaeuser Company PCT/US98/11566 discloses composite lumber products based on sweep avoiding slat production from flitches derived from round logs.
  • MacMillan Bloedel Limited in NZ 241289 (also referring Holman U.S. Pat. No. 4,255,477 in respect of panel or strand lumber products and U.S. Pat. Nos. 4,610,913 and 4,751,131 of Barnes in respect of the use of longer wafers in higher strength lumber product production) discloses composite wood products of improved strength where cutting avoids surface and internal damage to the veneer, wafers and strands.
  • Weyerhaeuser Company PCT/US97/15250 discloses engineered structural wood products and related methods reliant on different rectangular board orientations in the resultant laminated product.
  • U.S. Pat. No. 5,500,070 (Traben et al) discloses knife cutting of thin boards for the purpose of manufacturing multilayered laminated products.
  • the present invention as an object or an alternate object addresses issues of waste reduction during the production of dimensional lumber and in so doing preferably improves usage of feedstock for the purpose of value enhancement.
  • the present invention has as one or one alternative object a method of producing laminated elongate products and to related products, practices and procedures reliant on a performance advantage over mere random assembly.
  • the present invention has as one or an alternative object an overall process capable of better using logs or part of tree stems (and particularly those of conifers such as Radiata Pine, Loblolly Pine, Douglas Fir, Spruce, etc.) which might otherwise only be suitable for chipping or non structural or non appearance lumber.
  • Another or an alternative object therefore is the conversion of low grade wood into high grade products preferably at an efficient yield from trees.
  • the process envisages the breaking of a log into small (preferably rectangular) sections, grading these sections (preferably once dry) and assembling these in accordance with the invention into an improved product.
  • the process of the present invention breaks down logs into specific component parts (i.e. thin boards) (e.g. hereinafter “sticks”) to provide a large population of parts (i.e. many parts from many logs) exhibiting a wide range of properties strength/stiffness/appearance which at the discretion of the processor (preferably with (a) end jointing and/or (b) determination and/or assessment) are streamed to produce a high proportion of superior laminates as products from a small proportion of superior strength or appearance parts.
  • specific component parts i.e. thin boards
  • sticks e.g. hereinafter “sticks”
  • stick refers to thin boards whether trimmed for length or otherwise trimmed to reduce distortions and/or blemishes.
  • board includes but preferably means rectangular or square sectioned boards. Such boards of any length (usually between 0.5 m to 2.4 m in length) may post drying require some trimming to a dimensional lumber width.
  • engineered in respect of product or boards means or includes fabricated and/or laminated.
  • sections or “small sections” means or includes preferably smaller rectangular sections preferably of lamina thickness.
  • stem or “stems” refers to any trunk and/or branch.
  • drying involves any suitable process whereby “green” wood is brought to a state of dryness (e.g. 200% to ⁇ 12% w/w).
  • splitting includes a process typified by that of Linck disclosed at its website www.linck-hvt.com or in any of its patents referred to herein.
  • customer in respect of length, width or any other dimension or appearance means that required by a wholesaler, retailer or end user whether to be cut further or not.
  • grade/assessing is any machine, optical or manual procedure to determine structural and/or strength and/or stiffness and/or appearance characteristics.
  • Reference to “streaming”, etc. means streaming into at least two streams (e.g. preferably from 4 to 8 but can be more or less).
  • the invention is a laminate of laminae (e.g as engineered structural and/or appearance lumber preferably made to length), each lamina having been derived from a feedstock comprising a population of logs (single or multigrade), each cross-section of each lamina being uniform at least insofar as depth and representing a maximum of one twentieth of the log cross-section for structural products or each lamina having a thickness not greater than one fifteenth of SED for wide appearance lamina, and arranged with a profiled array of their properties in the laminate.
  • laminae e.g as engineered structural and/or appearance lumber preferably made to length
  • each lamina having been derived from a feedstock comprising a population of logs (single or multigrade)
  • each cross-section of each lamina being uniform at least insofar as depth and representing a maximum of one twentieth of the log cross-section for structural products or each lamina having a thickness not greater than one fifteenth of SED for wide appearance lamina
  • each lamina represents a maximum of one thirtieth of the log cross-section.
  • Preferably breakdown from logs is in a pattern to minimise spike knots.
  • the total breakdown is or has been to effect, as far as is practical, a maximising of the spread of properties amongst laminae [“sticks”].
  • each stick is or has been from a minimum number of growth years as is practical.
  • the laminate has been made to specification.
  • the profiling has been with respect to strength and/or stiffness [e.g by reference to Modulus of Elasticity [MOE] or other measure or assessment].
  • MOE Modulus of Elasticity
  • the profiling has been with respect to appearance thereby to maximise the external appearance especially on one side.
  • the laminate preferably has been prepared by reliance upon variation of structural properties within a tree stem and between stems in a forest resource such as, in the case of engineered structural timber, the logs have been broken down into at least 20 [preferably 30 or more] thin boards or sticks per log preferably to ensure a mean structural performance between 10 and 20% higher than milled lumber, and/or having a lowest structural property (90% confidence) of approximately twice that of milled lumber, and/or having a very low or zero incidence of critical defects.
  • the invention is a method of producing engineered “structural” lumber which comprises or includes the steps of
  • the sticks are of uniform laminar thickness.
  • a minimum of 30 sticks per log cross-section are obtained to expose a broad range of properties.
  • each stick or stick sequence is from 0.5 to 2.4 metres. Whilst the length can be 1.2 to 2.4 metres, preferably the length of each stick is from 0.5 to 1.2 metres.
  • the invention consists in a method of producing an engineered “appearance” lumber which comprises or includes the steps of
  • sticks are derived with a uniform laminar thickness.
  • each stick has a maximum thickness one fifteenth ( 1/15) or less of the small end diameter of the log(s).
  • each stick is from 0.5 to 2.4 metres. Whilst it can be preferably the length of each stick is from 0.5 to 1.2 metres.
  • the sticks derived from a population of logs and hence the laminae incorporated into the corresponding population of laminates would be of uniform thickness with the thickness preferably being chosen prior to breakdown of the logs. Such thickness preferably would be not less than 4 mm and not greater than 17 mm.
  • the aforesaid range ensures a thickness can be chosen that is amenable to the production and processing of sticks, while ensuring an adequate number of sticks can be produced to reveal the spread of properties and ensure a laminate will comprise at least 3 laminae for an appearance product and preferably at least 4 laminae for a structural product.
  • the chosen thickness would normally be between 6 mm and 11 mm.
  • Preferably breakdown from logs is in a pattern to minimise spike knots.
  • the total breakdown is or has been to effect, as far as is practical, a maximising of the spread of properties amongst lamina [“sticks”].
  • each stick is or has been from a minimum number of growth years as is practical.
  • the sticks derived from a population of logs and hence the laminae incorporated into the corresponding population of laminates would be of uniform thickness with the thickness preferably being chosen prior to breakdown of the logs. Such thickness preferably would be not less than 4 mm and not greater than 17 mm.
  • the aforesaid range ensures a thickness can be chosen that is amenable to the production and processing of sticks, while ensuring an adequate number of sticks can be produced to reveal the spread of properties and ensure a laminate will comprise at least 3 laminae for an appearance product and preferably at least 4 laminae for a structural product.
  • the chosen thickness would normally be between 6 mm and 11 mm.
  • the invention consists in a method of producing an engineered “appearance” lumber which comprises or includes the steps of
  • the sticks are derived with a uniform laminar thickness.
  • each stick has a maximum thickness one fifteenth ( 1/15) or less of the small end diameter of the log(s).
  • each stick is from 0.5 to 2.4 metres.
  • each stick is from 1.2 to 2.4 metres.
  • each stick is from 0.5 to 1.2 metres.
  • the sticks and/or endwise joined sticks have been cut to a customer length prior to lamination.
  • Preferably better appearance boards are to the outside of the transverse section of the main faces of the laminated product.
  • the present invention consists in a method of producing engineered “structural” lumber which comprises or includes the steps of
  • the sticks and/or endwise joined sticks have been cut to a customer length prior to lamination.
  • Preferably higher strength and/or stiffness sticks are to the outside of the transverse section of the laminated product.
  • the present invention consists in a method of producing an engineered “appearance” lumber which comprises or includes the steps of
  • the sticks have been cut to a customer length prior to lamination.
  • Preferably better appearance boards are to the outside of the transverse section of the main faces of the laminated product.
  • the present invention consists in a method of producing dimensional lumber reliant upon a breakdown of the source wood to boards and the subsequent use of such boards with knowledge of their individual gradings (preferably after drying) for streaming and/or placement in a laminate structure.
  • Preferably breakdown from logs is in a pattern to minimise spike knots.
  • the total breakdown is or has been to effect, as far as is practical, a maximising of the spread of properties amongst laminae [“sticks”].
  • the sticks derived from a population of logs and hence the laminae incorporated into the corresponding population of laminates would be of uniform thickness with the thickness preferably being chosen prior to breakdown of the logs. Such thickness preferably would be not less than 4 mm and not greater than 17 mm.
  • the aforesaid range ensures a thickness can be chosen that is amenable to the production and processing of sticks, while ensuring an adequate number of sticks can be produced to reveal the spread of properties and ensure a laminate will comprise at least 3 laminae for an appearance product and preferably at least 4 laminae for a structural product.
  • the chosen thickness would normally be between 6 mm and 11 mm.
  • the present invention consists in a method of deriving an elongate laminate product from a tree or logs thereof, said method comprising or including
  • the present invention consists in an elongate engineered timber product having a laminated transverse substantially rectangular or square cross section transverse to the longitudinal axis,
  • the present invention consists in an elongate engineered timber product having a laminated transverse substantially rectangular or square cross section transverse to the longitudinal axis,
  • the present invention consists in an elongate engineered timber product made to length L and having a laminated transverse substantially rectangular or square cross section transverse to the longitudinal axis,
  • the present invention consists in an elongate engineered timber product made to length L and having a laminated transverse substantially rectangular or square cross section transverse to the longitudinal axis,
  • the present invention consists in elongate engineered timber products
  • the present invention consists in an elongate engineered timber product of length L having a laminated transverse substantially rectangular or square cross section transverse to the longitudinal axis,
  • the sticks derived from a population of logs and hence the laminae incorporated into the corresponding population of laminates would be of uniform thickness with the thickness preferably being chosen prior to breakdown of the logs. Such thickness preferably would be not less than 4 mm and not greater than 17 mm.
  • the aforesaid range ensures a thickness can be chosen that is amenable to the production and processing of sticks, while ensuring an adequate number of sticks can be produced to reveal the spread of properties and ensure a laminate will comprise at least 3 laminae for an appearance product and preferably at least 4 laminae for a structural product.
  • the chosen thickness would normally be between 6 mm and 11 mm.
  • the logs are derived from debarked tree stems or debarked longer log lengths.
  • the logs are at least primarily in the range of from 0.5 m to 2.4 m in length.
  • the logs may include primarily or may include a good percentage of higher tree stem regions.
  • profiling is performed so as to assist by the provision of at least one datum flat and one datum edge to facilitate breakdown.
  • the optional profiling is to provide at least one datum flat and edge to facilitate breakdown by either
  • the profiling is such as to provide a contour of the log periphery which best provides boards or billets reducible to boards by a splitting process with boards of greater transverse section symmetrically cut from the log.
  • the profiling can include the provision of four flats for the purpose of subsequent breakdown and, if desired, rebates to ensure an ensuing splitting process can provide at least primarily boards of rectangular section and/or square section.
  • At least some initial longitudinal breakdown by sawing can occur and this may include the profiling steps and/or some initial billet provision for subsequent further longitudinal breakdown by preferably a splitting procedure.
  • the splitting procedure involves the still “green” wood being heated to facilitate splitting, (e.g. by any of the processes herein described (e.g. bath, steam chamber, or other non drying heating process)).
  • any of the processes herein described e.g. bath, steam chamber, or other non drying heating process
  • the characteristics of the boards is determined wholly or primarily post drying.
  • the determination of the characteristics of the boards can follow or precede, or both, trimming of at least one transverse dimension of at least some of the boards.
  • Preferably boards of a suitable appearance may be selected by inspection and/or scanning as “appearance” boards whilst preferably boards (whether appearance boards or otherwise) may be assessed by inspecting and/or scanning and/or grading for strength and/or stiffness.
  • the endwise finger jointing of at least some of the dried boards is to provide a feedstock of boards at least as great as a desired customer length or multiple of desired customer length (such as 2.4 m in length or greater) even if there may be a subsequent cutting step at the time of or post or during lamination.
  • the method just described provides streams of dimensional appearance and/or structural timber.
  • the present invention consists in a method of deriving an elongate laminate product from a tree, said method comprising or including
  • the optional profiling is to provide at least one datum flat and edge to facilitate breakdown by either
  • the profiling is such as to provide a contour of the log periphery which best provides boards or billets reducible to boards by a splitting process with boards of greater transverse section symmetrically cut from the log.
  • the present invention consists in a method of value extraction from tree stem timber so as to provide engineered structural products and/or appearance products, which when from lower valued material and/or lower valued logs of a tree stem, will represent lumber value enhancement reliant upon a method of deriving elongate laminate products by a method of the present invention.
  • the invention is an elongate dimensional structural and/or appearance timber product, the product being a laminate of at least primarily sliced boards of previously determined characteristics (i.e. as a board post board creation) thereby having allowed selective positioning of such boards in the laminate to allow use of boards of different characteristics yet still provide the desired (i) structural, (ii) appearance or (iii) both (i) and (ii) outcome.
  • At least one of the boards has been finger jointed prior to lamination to provide the required length.
  • each of the boards has had its characteristics determined post drying, etc.
  • the outcome is (i) or (iii).
  • the separation of characteristics is in a spaced minor axis sense for structural requirements.
  • the present invention consists in a method of producing such a timber product, which method includes at least
  • Preferably breakdown from logs is in a pattern to minimise spike knots.
  • the total breakdown is or has been to effect, as far as is practical, a maximising of the spread of properties amongst lamina [“sticks”].
  • each stick is or has been from a minimum number of growth years as is practical.
  • the present invention consists in a panel or panels formed by or during performance of a method as aforesaid.
  • the invention is a laminate, engineered structural lumber or engineered appearance lumber made by a method of the present invention.
  • the invention consists in a laminate of laminae of uniform rectangular cross-sections or depths and lengths arranged randomly in the laminate, such laminae having been derived from a feedstock comprising a population of logs (single or multigrade) wherein the population of laminae comprises all of the laminae that can be derived from the population of logs (exclusive only of laminae that are not of acceptable rectangular cross-section and/or length), and where each cross-section of each lamina represents a maximum of one twentieth (preferably a maximum of one thirtieth) of the log cross-section, or the thickness of each lamina represents a maximum of one fifteenth of the small end log diameter.
  • At least some of the laminae result from streaming of endwise joined parts thereof.
  • the sticks derived from a population of logs and hence the laminae incorporated into the corresponding population of laminates would be of uniform thickness with the thickness preferably being chosen prior to breakdown of the logs. Such thickness preferably would be not less than 4 mm and not greater than 17 mm.
  • the aforesaid range ensures a thickness can be chosen that is amenable to the production and processing of sticks, while ensuring an adequate number of sticks can be produced to reveal the spread of properties and ensure a laminate will comprise at least 3 laminae for an appearance product and preferably at least 4 laminae for a structural product.
  • the chosen thickness would normally be between 6 mm and 11 mm.
  • the invention consists in a laminate of laminae of uniform rectangular cross-sections or depths and lengths arranged randomly or otherwise in the laminate, such laminae having been derived from a feedstock comprising a population of logs (single or multigrade) wherein the population of laminae comprises all of the laminae that can be derived from the population of logs (exclusive only of laminae or material for laminae that are not of acceptable rectangular cross-section and/or length), and where each cross-section of each lamina represents a maximum of one twentieth of the log cross-section, or the thickness of each lamina represents a maximum of one fifteenth of the small end log diameter.
  • each lamina represents a maximum of one thirtieth of the log cross-section.
  • the process preferably employs slicing and/or fine band saw technology for the bulk of its breakdown into sections.
  • short logs can be used or created from logs with excessive bend or taper.
  • the value of the process is driven more by its ability to use low value logs than by maximising yield, however the process is preferably able to keep yields above acceptable minima.
  • the process can add value to any log—including butt logs.
  • the process targets low value (i.e. low cost) logs only because it is expected they will produce the highest margin.
  • the present invention in its preferred forms is also based upon the contention that there is sufficient high strength board extraction derivable from low value upper log forming regions of a tree, and from shorts provided an effective process of high yield and not involving any mandatory substantial encroachment into materials extracted from high value lower most logs of the tree is available, yet still allowing such encroachment as and when wanted.
  • the present invention in another aspect also recognises a capability of cutting upper regions, (e.g. optionally beyond those of the butt log and perhaps or preferably above the second log) into short lengths [in order to counter the influence of taper, sweep, curvature, etc.], thereafter machining with minimal sawing smaller diameter logs than those of a butt log and shorter in length (e.g. 0.5 m to 2.4 m) into boards, drying such boards, matching boards after the drying procedure, edge trimming if required to a required transverse dimension, endwise joining by finger jointing at least to a customer required length, thereafter
  • Sectioning options are a trade off between yield and technical risk/process complexity. There are at least two sectioning options contemplated. The sectioning option is independent of the targeted output (structural or appearance).
  • the process can produce three outputs by employing three process scenarios.
  • post drying characteristic assessment/grading in some forms where less dry or green boards can correlate in characteristics to the dry or more dry boards such assessment/grading can occur earlier in the process but only post board creation.
  • FIG. 1 shows a flow diagram of one process in accordance with the present invention having the capability of streaming components after the drying and inspection steps and preferably prior to finger jointing of individual boards, one stream being to produce laminates to act as beams, studs or the like reliant upon lamination planes normal to the greatest dimension of the board, e.g. forms such as those that by choice of appropriate materials, web space, stronger timber boards, and those which preferably have at least one appearance face where the lamination is parallel to the greater transverse dimension of each board and said at least one appearance face,
  • FIG. 2A shows a first option for breakdown of logs of similar dimension where any machining other than splitting and profiling is kept to a minimum (it being appreciated that rebates can be machined in by cutting, milling, routing or the like to allow better location relative to splitting apparatus),
  • FIG. 2B shows by a mixture of heavy lines and less heavy lines respectively saw cuts and splitting during a breakdown
  • FIG. 3A shows a wooden billet such as that provided centrally of the breakdown option of FIG. 2B showing wooden billet location relative to a locating side bar to oppose side forces from the acute angle slicing geometry
  • FIG. 3B shows the section of AA of FIG. 3B
  • FIG. 3C shows the end elevation BB
  • FIGS. 4A and 4B shows side elevation and end view respectively of a slicing pattern for a short logs to minimise drying deformation by cutting boards symmetrically about the log centre line
  • FIG. 4C shows in side elevation and FIG. 4D an end view showing how progressive slicing can provide boards of the required timber thickness
  • FIG. 5 shows a plan view of one arrangement whereby after pre-heating the logs can be introduced to a profiling and slicing process that may include the slicing machine and profiling machine in series, such apparatus being appropriate for the option shown by reference to FIG. 2A ,
  • FIG. 6 shows apparatus from above adapted after heating the logs to provide a standard slicing process, such slicing process following a breakdown of the logs as detailed in FIG. 2B ,
  • FIG. 7A is a similar view to that of FIG. 2B but showing how the heavy line saw cuts can provide a number of rectangular sections or square sections perhaps of a multiple of 46 mm (or any green pre-dressed finished dimension required by the customer) with the larger sections concentric with the log centre,
  • FIG. 7B showing sections with at least one side of a relatively large dimension which can be sent to wide slicer and FIG. 7C showing a number of square or rectangular sections of a small which can be sent to a smaller slicer
  • FIG. 8 shows how the sliced boards can be prepared for drying whilst being restrained to ensure the dry boards exit the dryer more or less straight, the typical process being to stack in several batches of like length and weight before charging to a batch dryer, but other drying process and/or a continuous drying process can be used,
  • FIG. 9 shows an optional visual or camera scan for appearance critical features and streaming according to these features
  • FIG. 10 shows the edge dressing or optional (for structural) combined edge dressing and slitting (by guillotining or fine sawing) operation
  • FIG. 11 shows an optional density test or stiffness test for structural properties and streaming according to these features
  • FIG. 12 shows a finger jointing process
  • FIG. 13A is an end view of a panel formed by edge gluing of panels post finger jointing whilst FIG. 13B is a partial plan view of such a panel as shown in FIG. 13A showing the finger joints spaced along the length, such a panel being adapted for slitting parallel to the edge joints to a desired customer board width prior to lamination,
  • FIG. 13C shows such a panel slitting to provide constant width boards from a panel as shown in FIG. 13A and FIG. 13D with the broken lines parallel to the edge joints shows the lines of guillotining into constant width boards,
  • FIGS. 14A and 14B showing how boards produced from the guillotine cutting as described with respect to FIG. 13D can be face to face glue laminated to provide a product preferably but not necessarily with one at least appearance face on a face that is parallel to the lamination plane and which is a face of greater transverse dimension,
  • FIG. 15 shows another lamination option [not usually requiring panel formation as described with reference to FIGS. 13A through 13D nor the consequent slitting provided they are provided more or less to the desired width of board by the breakdown system albeit they may require some edge dressing to customer width], such boards being laminated with lamination planes normal to the planes of greater board transverse dimension,
  • FIG. 16 shows how for a laminate as shown in FIG. 15 each board shown is positioned so as to maximise greater strength away from the centre of the laminate, thereby, by following the principles of an “I” beam, using lesser strength boards as web spacers for the higher strength boards thereby better to resist deflection of the beam in a plane normal to the lamination planes,
  • FIG. 17 shows how for the arrangement as shown in FIG. 14A there is preferably a high grade layer on one side, a lower grade layer centrally and a medium grade layer on the reverse face,
  • FIG. 18 shows by relationship to a tapering tree stem how gross value by a process of the present invention can deviate from the structural and appearance lines of a conventional saw mill, the line marked “C” being that of conventional sawing and the line marked “I” being that of the invention,
  • FIGS. 19A to 19 C show a process from beginning to end in accordance with preferred options of the present invention, there being shown an optional departure from the manufacture of purely structural engineered timber where, as might be in demand from time to time, appearance engineered timber is required,
  • FIGS. 19A to 19 C nevertheless show how in the preferred form of the present invention with a view to enhancing efficiencies the feedstock is of single forest or multiple forest derived single and/or multi grade logs,
  • FIG. 20 graphically shows representative MOE distributions of “clear sawn lumber” verses “thin boards inclusive of defects” from low grade logs (as published by NZFRI and our testing respectively), along with an inserted table of expected structural grade outputs of sawn lumber from similar logs (published by NZFRI).
  • FIG. 21 shows the cumulative distribution of MOE for the thin boards from FIG. 20 .
  • FIG. 22 shows how multiple sticks or thin boards formed and end jointed in accordance with the present invention can be profiled within a laminate, the darker shade boards being those of greater strength and/or stiffness (i.e. MOE) and those of lighter shade being those of less strength and/or stiffness (i.e. MOE),
  • FIG. 23 shows the expected MOE distribution in our final assembled product e.g. as in FIG. 22 .
  • FIG. 24 is an overlay of FIG. 23 and FIG. 20 clearly showing expected increase in MOE (e.g. as an indicator of stiffness or strength or both).
  • Another area of wastage is the general convergence or taper of a tree stem thus leading to waste where flitches or boards of constant breadth and constant thicknesses are to be formed. Still other wastage arises from the to be expected sweep, crook, bow, cup, twist and other distortions of tree stems and/or logs (particularly lower value higher logs) cut therefrom.
  • Another area of wastage is a lack of value recovery from upper logs owing to the lower value properties being traditionally ascribed to upper logs of a tree stem, to the dimensions and to wood defects thereof.
  • the present invention makes use of some of the aforementioned technologies including the knife cutting procedures typified by Linck in some of their aforementioned patent specifications.
  • the present invention recognising, as an example only, the situation of the New Zealand Timber Industry and taking account of the value proposition whilst keeping yields (i.e. by reducing waste) within acceptable limits has been prompted by the situation as follows;
  • the procedure of the present invention by emphasis upon board formation (e.g. from short length defect reducing still green or substantially green logs from the lower value upper regions of the tree stem), the subsequent drying thereof and inspection (preferably thereafter) can minimise wastage by ensuring direction (e.g. by machine grading and/or visual inspection) of appropriate materials to appropriate feed streams for ensuring use as components where required in dimensional structural or appearance timber laminate assemblies.
  • a preferred process for making customer dimensioned structural laminate materials and customer dimensions appearance faced materials preferably involves the following steps:
  • any suitable conventional dry timber adhesive system can be used.
  • Adhesives for end joining and/or finger joining include any waterproof glues or others used in any of the prior art laminate structures herein discussed.
  • a particularly preferred adhesive is a resorcinol based adhesive as currently used in LVL type products.
  • Table 1 shows typical yields from conventional saw milling. TABLE 1 Typical Yield Conventional Saw Mill No 1 No 2 Box Engineering Framing Framing Grade Bds Log type Proportion of output by grade Butt 7% 38% 25% 25% 5% No 2 Log 4% 21% 32% 37% 6% No 3 Log 1% 16% 34% 43% 6% No 4 Log 0% 4% 21% 58% 17%
  • the present invention provides a significant advantage in value extraction where in Table 2 hereafter stated are the yields from the processes, option 1 being an almost exclusive splitting breakdown of logs as detailed in FIG. 2A whilst option 2 is the hybrid breakdown system (sawing and splitting) detailed by reference to FIG. 2B .
  • option 1 With such acceptable level yields particularly those of option 1 since a value enhanced product is also being provided there is a great prospect of value enhancement of harvested materials particularly when it can be seen that lesser quality feedstock materials can be utilised almost completely. Even option 2 provides more than acceptable yields and whilst providing the same enhanced value products can provide advantages of the kind shown by FIG. 15 .
  • a preferred process according to the present invention at least for structural lumber, however opts away from panel forming as a precursor to final stick or thin board width determination. Instead it opts for structural timber for taking the sticks to the final customer wanted width and thereafter laminating with appropriate strength and/or stiffness characteristics throughout the structure reliant upon the principles previously stated.
  • FIG. 1 shows a flow diagram of one process in accordance with the present invention having the capability of streaming components after the drying and inspection steps and preferably prior to finger jointing of individual boards, one stream being to produce laminates to act as beams, studs or the like reliant upon lamination planes normal to the greatest dimension of the board, e.g. forms such as those that by choice of appropriate materials, web space, stronger timber boards, and those which preferably have at least one appearance face where the lamination is parallel to the greater transverse dimension of each board and said at least one appearance face.
  • Breakdown is preferably but not necessarily as follows:
  • Cutting to length whether lamina or laminate is by sawing (e.g. circular sawing).
  • FIG. 2A shows a first option for breakdown of logs of similar dimension where any machining other than splitting and profiling is kept to a minimum (it being appreciated that rebates can be machined in by cutting, milling, routing or the like to allow better location relative to splitting apparatus).
  • FIG. 2B shows by a mixture of heavy lines and less heavy lines respectively saw cuts and splitting during a breakdown.
  • FIG. 3A shows a wooden billet such as that provided centrally of the breakdown option of FIG. 2B showing wooden billet location relative to a locating side bar to oppose side forces from the acute angle slicing geometry.
  • FIGS. 4A and 4B shows side elevation and end view respectively of a slicing pattern for a short logs to minimise drying deformation by cutting boards symmetrically about the log centre line.
  • FIG. 4C shows in side elevation and FIG. 4D an end view showing how progressive slicing can provide boards of the required timber thickness.
  • FIG. 5 shows a plan view of one arrangement whereby after pre-heating the logs can be introduced to a profiling and slicing process that may include the slicing machine and profiling machine in series, such apparatus being appropriate for the option shown by reference to FIG. 2A .
  • FIG. 6 shows apparatus from above adapted after heating the logs to provide a standard slicing process, such slicing process following a breakdown of the logs as detailed in FIG. 2B .
  • FIG. 7A is a similar view to that of FIG. 2B but showing how the heavy line saw cuts can provide a number of rectangular sections or square sections perhaps of a multiple of 46 mm (or any green pre-dressed finished dimension required by the customer) with the larger sections concentric with the log centre.
  • FIG. 7B showing sections with at least one side of a relatively large dimension which can be sent to wide slicer and FIG. 7C showing a number of square or rectangular sections of a small which can be sent to a smaller slicer.
  • FIG. 8 shows how the sliced boards can be prepared for drying whilst being restrained to ensure the dry boards exit the dryer more or less straight, the typical process being to stack in several batches of like length and weight before charging to a batch dryer, but other drying process and/or a continuous drying process can be used.
  • FIG. 9 shows an optional visual or camera scan for appearance critical features and streaming according to these features.
  • FIG. 10 shows the edge dressing or optional (for structural) combined edge dressing and slitting (by guillotining or fine sawing) operation.
  • FIG. 11 shows an optional density test or stiffness test for structural properties and streaming according to these features.
  • FIG. 12 shows a finger jointing process
  • FIG. 13A is an end view of a panel formed by edge gluing of panels post finger jointing whilst FIG. 13B is a partial plan view of such a panel as shown in FIG. 13A showing the finger joints spaced along the length, such a panel being adapted for slitting parallel to the edge joints to a desired customer board width prior to lamination.
  • FIG. 13C shows such a panel slitting to provide constant width boards from a panel as shown in FIG. 13A and FIG. 13D with the broken lines parallel to the edge joints shows the lines of guillotining into constant width boards.
  • FIGS. 14A and 14B showing how boards produced from the guillotine cutting as described with respect to FIG. 13D can be face to face glue laminated to provide a product preferably but not necessarily with one at least appearance face on a face that is parallel to the lamination plane and which is a face of greater transverse dimension.
  • FIG. 15 shows another lamination option [not usually requiring panel formation as described with reference to FIGS. 13A through 13D nor the consequent slitting provided they are provided more or less to the desired width of board by the breakdown system albeit they may require some edge dressing to customer width], such boards being laminated with lamination planes normal to the planes of greater board transverse dimension.
  • FIG. 16 shows how for a laminate as shown in FIG. 15 each board shown is positioned so as to maximise greater strength away from the centre of the laminate, thereby, by following the principles of an “I” beam, using lesser strength boards as web spacers for the higher strength boards thereby better to resist deflection of the beam in a plane normal to the lamination planes.
  • FIG. 17 shows how for the arrangement as shown in FIG. 14A there is preferably a high grade layer on one side, a lower grade layer centrally and a medium grade layer on the reverse face.
  • FIG. 18 shows by relationship to a tapering tree stem how gross value by a process of the present invention can deviate from the structural and appearance lines of a conventional saw mill, the line marked “C” being that of conventional sawing and the line marked “I” being that of the invention.
  • FIG. 19A the full textual content of which is incorporated herein
  • a run of forest single grade logs, a run of forest multiple grade logs, multiple forest single grade logs and/or multiple forest multi grade logs can be used even if of a short length or deliberately so cut.
  • thin boards at laminar thickness can be produced for drying by any appropriate means such as those disclosed in FIG. 19B , whereupon by a variety of different procedures, each board of a desired width can be streamed as to strength and/or stiffness or other structural properties prior to end-joining by any suitable procedure e.g. butt, scarf, finger, etc whereupon thereafter, if desired, and preferably prior to lamination, they are cut to a customer length. Thereafter lamination by any suitable profiling procedure is adopted optionally with other machine intervention.
  • FIG. 19C deals with certain options in that respect.
  • FIGS. 19B and C Also shown in FIGS. 19B and C is an option for mixed mode plants scanning for appearance properties with appropriate edge dressing to production width prior to end-joining with like boards. Thereafter if desired the panel forming by edge joining and cutting to various production widths can follow thereby allowing formation by lamination to a desired appearance product form.
  • FIG. 20 graphically shows representative MOE distributions of “clear sawn lumber” verses “thin boards inclusive of defects” from low grade logs (as published by NZFRI and our testing respectively), along with an inserted table of expected structural grade outputs of sawn lumber from similar logs (published by NZFRI).
  • FIG. 21 shows the cumulative distribution of MOE for thin boards
  • FIG. 22 shows how by way of example how multiple sticks or thin boards formed and end jointed in accordance with the present invention can be profiled with the darker shade boards being those of greater strength and/or stiffness and those of lighter shade being those of less strength and/or stiffness.
  • FIG. 23 shows the expected MOE distribution in our final assembled product e.g. as in FIG. 22 .
  • FIG. 24 is an overlay of FIG. 23 and FIG. 20 clearly showing expected increase in MOE (e.g. as an indicator of stiffness or strength or both).

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US11/223,208 2003-03-10 2005-09-12 Value extraction from harvested trees and related laminates and processes Abandoned US20060054267A1 (en)

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CN1764535A (zh) 2006-04-26
SI1601530T1 (sl) 2012-08-31
CA2762927A1 (en) 2004-09-23
AU2004220169A1 (en) 2004-09-23
CL2009001784A1 (es) 2010-02-05
ZA200506995B (en) 2007-02-28
AR043532A1 (es) 2005-08-03
DK1601530T3 (da) 2012-07-16
EP1601530A1 (en) 2005-12-07
AU2010201066A2 (en) 2011-09-01
PT1601530E (pt) 2012-07-24
NZ584801A (en) 2011-12-22
US20090000730A1 (en) 2009-01-01
EP1601530A4 (en) 2008-11-05
ATE555899T1 (de) 2012-05-15
ES2385480T3 (es) 2012-07-25
US8420222B2 (en) 2013-04-16
US20120077011A1 (en) 2012-03-29
KR20050107512A (ko) 2005-11-11
AU2010201066A1 (en) 2010-04-08
US8088494B2 (en) 2012-01-03
CN1764535B (zh) 2012-11-21
WO2004080713A1 (en) 2004-09-23
EP1601530B1 (en) 2012-05-02
KR101193050B1 (ko) 2012-10-23
PL1601530T3 (pl) 2012-10-31
CA2518524A1 (en) 2004-09-23
CL2004000476A1 (es) 2005-05-20
KR101252373B1 (ko) 2013-04-08
KR20110054078A (ko) 2011-05-24
JP2011046201A (ja) 2011-03-10
CY1113186T1 (el) 2016-04-13
BRPI0408253A (pt) 2006-03-01
KR20120024993A (ko) 2012-03-14
AU2004220169B2 (en) 2011-02-03
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JP2006521229A (ja) 2006-09-21
CN102886943A (zh) 2013-01-23

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