Abstract:
The heat storage capacity of natural cellulosic products is increased by injecting nucleating products and/or heat storing material into unfilled cells thereby increasing the amount of material that can undergo phase change for transferring latent heat.

Description:
FIELD OF THE INVENTION 
     The present invention relates to fibrous and cellulosic materials and, in particular, to natural and man-made wood products treated to improve sensible and latent heat characteristics. 
     BACKGROUND OF THE INVENTION 
     When North America was first settled, the eastern coast was forested with long-leaf, “heart pine” trees. Their wood is characterized by narrow growth rings and high cellular resinous content. In additional to structural value in construction, it was appreciated that these woods also possessed excellent heat retention properties and they were commonly employed as panel, floor and ceiling materials around the fireplace rooms, such as dens, living rooms, and dining rooms where they functioned to provide comfortable, non-insulated living spaces. Moreover, homes built entirely of such woods were regarded as more livable than homes built with other species. The preferred usage of these old growth trees continued into the late nineteenth century when the lumber supplies became depleted, and second and third growth pine became the material of choice. 
     While the newer woods were structurally adequate, they did not possess the apparent thermal advantage of the heart pine. They did not have either the compact ring structure or the inherent resin content, and accordingly needed to be supplemented with the available insulating materials and techniques of the time. 
     The advantages of the heart pine structures are many. The latent heat storing capability allowed heat retention without corresponding increases in surface temperature, thereby allowing dissipation during non-heating periods when the fireplaces, stoves, and furnaces were out. The thermal advantages also were enjoyed during summer months when the cool nights reduced the temperature structure for energy transfer as the temperature rose during the day. 
     Notwithstanding the above erosion of performance, structures built of solid wood are inherently energy efficient. With the continuing interest in log-type homes, reminiscent of earlier times, it would be advantageous to restore as well the unique thermal performances of the old growth trees. 
     Accordingly, it is an object of the present invention to provide a method for improving the energy retention and release properties of cellulosic and fibrous materials. 
     SUMMARY OF THE INVENTION 
     The foregoing objects are accomplished by treating available wood materials to increase their latent heat storage capabilities through introducing phase change agents and/or additives. In one aspect, nucleating agents are introduced that promote internal phase changes. In another aspect, supplemental resinous content is added thereby overcoming the deficiencies in new growth wood wherein the resin channels are not completely filled prior to harvest. In both, the modified material exhibits improved thermal release characteristics approaching the performance of the old growth woods. 
     In one aspect of the invention there is provided a method for treating wood to increase latent heat transfer capabilities by absorbing into the cellular structure of the wood an effective amount of a nucleating agent for promoting increased crystallization of the resin content in the wood. The nucleating agents are selected from the group comprising borax, boron, borosilicates, zeolites, metallic salts and sulfates. The process can be further enhanced by removing excess moisture from said wood prior to the absorbing, which may be conducted at least partially under vacuum conditions and the absorbing promoted under vacuum conditions and high pressure conditions. Supplemental resin compatible materials may also be absorbed into said wood to occupied unfilled cellular space naturally occurring and/or occasioned by removing of moisture. The materials are selected from resins, waxes, salts, salt-hydrates and cross-linked polymers. In another aspect of the invention the heat characteristics of a natural wood products having a heart area of normal resin content and a sapwood area having resin canal structure of reduced resin content are improved by infusing supplemental resin compatible materials into said resin canal structure to provide a resin content approaching said normal resin content of said heart area. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The above and other features and advantages of the invention will become apparent upon reading the following written description taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is a schematic view of a process for treating wood product according to the invention. 
         FIGS. 2A and 2B  are schematic views of resin canals in coniferous wood with and without the processing of the present invention; 
         FIGS. 3A and 3B  are schematic views of resin canals showing normal crystallization in unprocessed wood and crystallization of wood processed in accordance with the invention; 
         FIGS. 4A and 4B  are schematic views showing the effect of adding resin to sapwood cells of young growth timber; 
         FIGS. 5A and 5B  are graphs showing the effect of surface temperature versus time for wood products samples with and without treatment with the nucleating agents of the invention; and 
         FIGS. 6A and 6B  are graphs showing the effect of surface temperature versus time for other wood products with and without treatment with the nucleating agents of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention provides thermally enhanced wood products treated or altered to improve heat storage capacity and/or change the heat retention and release properties. Referring to  FIG. 2A , natural unprocessed wood  10  is characterized by resin canals  12  that are in whole or in part filed with resin  14 . As described below and as shown in  FIG. 2B , nucleating agents  16  are inserted into the resin canals  12  and cause a phase change in response to temperature fluctuations resulting in improved latent heat properties and increase the release or absorption of thermal energy. Such core structure is typical of resinous wood. As shown in  FIG. 3A , the resin canals  12  normally undergo progressive crystallization in a peripheral zone  20  inwardly of the canal wall  22 . As shown in  FIG. 3B , the nucleating agents  16  are effective to propagate the crystallization both inwardly and outwardly to greatly increase the phase change material (PCM) volume thereby increasing the latent thermal potential of the material. 
     The latent thermal potential of resinous wood can also be enhanced by increasing the resin content, thereby reintroducing many of the thermal advantages afforded by the heart pine type woods. Referring to  FIG. 4A , a typical second or subsequent growth pine or like wood  40  is characterized by small heart area  42 , rich in resin content, surrounded by a sapwood area  44  having a lesser or deficient resin content. Referring to  FIG. 4B , the present invention provides a process for introducing a resinous content throughout the sapwood area to provide an enhanced thermal zone  46  having thermal characteristic of the heart area. 
     Both of the foregoing are applicable to a wide variety of woods and fibrous materials including new growth pines, plantation-grown pines, hardwoods, straw, and bamboo. 
     Referring to  FIG. 1 , there is illustrated a process for improving the thermal capacitance or wood products. Therein a main pressure vessel  50  having an interior cavity  52  that is accessible by end doors  54  for introducing and removing wood products  56  as rough cut lumber. The vessel  50  is connected by line  58  including a control valve  60  to a three-way selector valve  62  for allowing selective connection with a vacuum source  64  by line  65  or a pressure source  66  by line  67 . 
     A liquid resin source  70  is connected to the vessel  50  by supply line  72  including control valve  74 . A nucleating agent source  80  is connected to the vessel  50  by supply line  82  including control valve  84 . Vent line  90  including vent valve  92  communicates with the cavity  52  for atmospheric venting thereof. A drain line  94  including drain valve  96  communicates with the cavity for removing liquid and/or solid contents therefrom. 
     For purposes hereinafter described, a secondary vessel  100  may be fluidly connected with the vessel  50  by auxiliary line  102  including control valve  104 . The secondary vessel  100  includes a cavity  106  accessible by end doors  108  for loading and removing a wood load  110  therefrom. The cavity  106  is vented to atmosphere by vent line  112  including vent valve  114 . A drain line  116  including drain valve  118  communicates with the cavity  106  for removing liquid and/or solid contents therefrom. 
     The vessels  50  and  106  are capable of handling high pressure conditions of about 100 psi and above and withstanding low vacuum conditions of about 28 in Hg or below. As required by the environment or processed materials, the vessels may be jacketed or insulated for achieving and maintaining desired processing conditions. The sources  70  and  80  as well as associated lines and components may also be appropriately temperature controlled. Injectable materials in the resin source  70 , in particular, are preferred in the liquid state, thus requiring elevated temperature control. The nucleating agents in the source  80  are preferably in solution, also requiring temperature control. 
     Suitable resins for the process include natural and synthetic resins, waxes, salts, salt-hydrates or cross linked polymers, or solutions thereof. Suitable nucleating agents include zeolites, borax, borate, boron, borosilicates, metallic salts or sulfate. 
     The process is initiated using timbers and lumber and removing the free-cell water through air drying, kiln drying, vacuum drying, dehumidification, desiccant drying, microwave heating, steam conditioning or the like. The drying may take place entirely or partially exterior of the pressure vessel  50 . Alternatively, the drying may be performed, totally or partially, in the pressure vessel  50 . Thereat, the material charge of wood product  56  is loaded into the cavity  52  through door  54  and the valves  62 ,  60  opened to connect to the vacuum source  64 . The cavity  52  is evacuated to a high vacuum of about 28 in Hg or greater for a sufficient time to remove the free-cell water to appropriate levels based on the desired subsequent processing. Generally about 40 minutes or less is preferable depending on the density and saturation of the material charge. Thereafter, the valves  62 ,  60  are closed, the vacuum source  64  disabled and the valve  74  is opened to inject the liquids from source  70  and during the course thereof raising the pressure to atmospheric, at which time or based on requirements therebefore the valve  74  is closed. Next the pressure source  66  is enabled, the valve  62  conditioned to pressurize the cavity to a pressure of about 150 psi for an extended period, up to about 3 hours, sufficient to get the maximum resin content absorbed into the product. The amount of liquid resin introduced in this step will be dependent on the starting resin content of the load, which may vary considerably based on source. 
     Concurrently with injection, the valve  84  is opened to inject the nucleating agents are introduced from the source  80  through line  82  into the cavity  52 . In the event the agents are not in a solution form compatible with the injectables, the nucleating agents may be introduced in a secondary evacuation followed by pressurization, which may be entirely sequential after the injection sequence or a sequential evacuation and a common pressurization. Without resin treatment, about 0.2 to 1.0 pounds of nucleating agents per cubic foot of load may be required. If the load has been resin treated, additional nucleating agents in the range of about 0.5 to 2.0 pound per cubic foot of load should be sufficient. Depending on the selected nucleating agent, the step may be conducted exterior of the vessel through infusion by immersion or osmosis. 
     Following treatment, the lumber may be dried for usage, artificially or ambiently. In the event of weeping of the resin content from the material, the excess may be hardened through subsequent conventional processing to polymerize, cross link or harden the same. 
     In a variation of the above process, a secondary material load may be placed in vessel  100  and co-evacuated with primary vessel  50  through line  102 . For a secondary material load high in resin content, the released resin vapor will be drawing into cavity  52  thus supplanting or reducing the amount of resin necessary treat the load  56 . The resulting product in vessel  100 , free of water and resins, is a light empty cell product much like balsa wood, useful for insulation. 
     It will be appreciated that foregoing provides thermally enhanced characteristic for a varied wood sources. Young rapid growth trees having a marked resin deficiency will have the characteristics of the old growth wood as shown in  FIG. 4B . Adding the nucleating agents will provide a phase change matrix increasing the thermal capacitance improving the latent heat capabilities of structures based on or incorporating the treated wood. By maximizing the use of such materials in construction in substitution for conventional source, the energy efficiency of the buildings can be greatly increased. 
     The foregoing advantages are shown by examples depicted in the graphs of  FIGS. 5 and 6 . Wood product samples measuring 5.75 in. by 5.75 in. by 12 in. and having a heart diameter of 1.69 were for the example of  FIG. 5 . The sample of  FIG. 5A  was unprocessed and the sample of  FIG. 5B  was infused with 0.15 lbs. of borax. It will be noted that the unprocessed sample had a latent heat period, i.e. the constant surface temperature period of 72° F. for 10 minutes whereas the treated sample had a latent heat period of 20 minutes, or a 100% increase. The samples of  FIG. 6  had a heart diameter of 5.75 in. and similar nucleating treatment. The unprocessed sample had a latent heat period of 20 minutes whereas the treated sample had a corresponding period of 40, once again about double the untreated condition. Both clearly establish the improved latent heat capabilities achieved in one aspect of the invention. 
     Having thus described a presently preferred embodiment of the present invention, it will now be appreciated that the objects of the invention have been fully achieved, and it will be understood by those skilled in the art that many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the sprit and scope of the present invention. The disclosures and description herein are intended to be illustrative and are not in any sense limiting of the invention, which is defined solely in accordance with the following claims.