CONVERTED WOOD ARTICLES, COMPOSITE WOOD PRODUCTS MADE THEREFROM AND METHOD OF MAKING SAME

Abstract: A converted wood article (10) for use in combination with other converted wood articles to form composite wood products for use in general construction such as in the construction of posts, flooring, walls and support beams.

Description: CONVERTED WOOD ARTICLES, COMPOSITE WOOD PRODUCTS MADE THEREFROM AND METHOD OF MAKING SAME FIELD The present invention relates to converted wood articles and composite wood products made therefrom for use in general construction primarily but not limited to posts, flooring, walls and support beams. BACKGROUND The depletion of old growth forest has placed increasing demand within the forest industry for alternative wood products which make better use of old growth and stagnant growth timber and which also provide for greater use of second, third and later generation trees. Several alternative wood products have emerged in an effort to address some of the needs in the industry. In this respect U.S. Patent No. 4,394,409 discloses a composite wood product formed from four elongated triangular-shaped wood pieces. The four pieces are joined to form a composite wood product having a cross-sectional outline of a parallelogram and a hollow interior. An alternative embodiment is disclosed where each wood piece has a pair of machined keys to improve yield. In U.S. Patent No. 5,299,400 there is disclosed a composite wood product formed from four log parts, each log part having a three sided cross-section forming either right angled sectors and a third curved side or a right triangle. The log parts are assembled into a composite wood product so that their right angles form the corners of a rectangle with a hollow interior which is filled with concrete or other structural enhancing material. Similar examples of this alternative wood structure appear in U.S. Reissue 35,327 and French Patent No. 962589. Other attempts to offer improved composite wood products can be found in French Patent No. 2512729 and German Patent No. 964637. While the composite wood products disclosed in the above mentioned references provide some improvements to the known art, there remains a continuing need for composite wood products providing additional resistance to shearing forces and impact forces, assembled from converted wood parts having a larger bonding surface and having a higher load bearing capacity without the preemptive need for the structural reinforcing material indicated in the prior art. Accordingly, it is an object of the invention to provide alternative converted wood articles for use in making composite wood products to fulfill the above needs in the art. SUMMARY OF THE INVENTION According to the invention there is provided a converted wood article for use with other converted wood articles to form composite wood products and characterized by having three sides, at least one of which is formed into a plurality of steps which mate with steps of another wood article. The converted wood article may have two sides which are at a right angle to one another and with steps formed on a third side. Alternatively, the converted wood article may include two sides with steps, the two sides each forming an acute angle with the third side. The converted wood article may be an elongated wood beam. The steps of a converted wood article may have substantially similar or different dimension. In one embodiment, the number of steps on a stepped side is three. In another embodiment, at least one side having steps includes corners which lie substantially along a notional straight line. In yet another embodiment, converted wood articles are joined along the stepped side of corresponding converted wood articles to form a composite wood product. The composite wood product may have at least one stepped side of at least one converted wood article oriented inversely to a side of steps of another converted wood article to which it is joined. In another embodiment, a composite wood product has four converted wood articles which are joined along stepped sides with at least two of the converted wood articles each having two stepped sides. The composite wood product may also have a rectangular cross-section. In another embodiment, four converted wood articles, each having two stepped sides, are arranged to form a composite wood product having a hollow interior space proximate the center of the cross-section of the composite wood product. A reinforcing rod or other reinforcing material may be fixed within the hollow interior space. Further included within the scope of this invention is a method of fabricating a composite wood product comprising: (a) milling and shaping wood pieces to form converted wood articles, each article having three sides with at least one side having a plurality of steps; and (b) gluing together at least two of such wood articles joined along their stepped sides to form the composite wood product. The preferred composite wood products fabricated are those described above. This method may include wood pieces selected from the group of logs, solid wood boards and laminated wood boards. This method may also include in step (a) kiln drying the wood pieces before shaping such pieces into converted wood articles so as to remove moisture from the wood pieces . BRIEF DESCRIPTION OF THE DRAWINGS The novel features believed characteristic of the invention are set forth in the appended claims . The invention itself, however, as well as other features and advantages thereof, will be best understood by reference to the detailed description which follows, read in conjunction with the accompanying drawings, wherein: Figure 1 is a perspective view of one converted wood article having two flat sides and one stepped side; Figure 2 is a cross-sectional view of a portion of the converted wood article in Figure 1; Figure 3 is a perspective view of another converted wood article having one flat side and two stepped sides; Figure 4A is a cross-sectional view of a portion of the covered wood article in Figure 3 ; Figure 4B is a cross-sectional view of a log and a converted wood article cut therefrom; Figure 5 is a perspective view of a composite wood product comprising converted wood articles; Figure 6 is a cross-sectional view of another composite wood product comprising converted wood articles; Figure 7A is a cross-sectional view of another composite wood product; Figure 7B is a cross-sectional view of another composite wood product; Figure 8 is a cross-sectional view of yet another composite wood product comprising an arrangement of converted wood articles; Figure 9 is a cross-sectional view of yet another composite wood product; Figure 10 is a perspective view of a composite wood product used in conjunction with other wood boards; Figure 11 is a cross-sectional view of another composite wood product under this invention; and Figure 12 is a flow diagram for the method of making converted wood articles and composite wood products. DETAIL DESCRIPTION WITH REFERENCE TO THE DRAWINGS Referring to Figure 1, a converted wood article 10 is formed according to the method set out below from a wood piece 11 and having steps 13 extending longitudinally along stepped side 15. Referring to Figure 2, converted wood article 10 includes flat sides 22 and 26 and stepped side 20. Sides 22 and 26 intersect at region 24 forming substantially right angle . Stepped side 20 intersects with flat side 22 and flat side 26 forming substantially right angles α' and α" , respectively. Steps 12a, 12b, and 12c form the outline of stepped side 20. Each of steps 12a, 12b, and 12c has a first edge 14 and a second edge 18 intersecting at substantially right angle corner 16. In the embodiment illustrated, steps 12a, 12b, and 12c are dimensioned and oriented such that each corner 16 substantially lies along a notional straight line 21. Referring to Figure 3 , in another converted wood article 30 is formed from elongated wood piece 31 having steps 37 on stepped side 33 and stepped side 35. Referring to Figure 4A, converted wood article 30 is shown having stepped sides 33 and 35, and flat side 42. Stepped side 33 is formed from steps 40 with each of steps 40 having edge 34 and edge 38 which intersect at substantially right angle corner 36. Stepped side 35 is similarly formed from steps 44 each having edges 46 and 50 intersecting at substantially right angle corner 48. Each of steps 40 and each of steps 44 after first steps 41 and 43 are successively offset from bisecting line 42. Accordingly, stepped sides 33 and 35 are arranged so that distances δ x , δ 3 , and δ s from bisecting line 42 and distances δ 2 , δ 4 , and δ 6 from bisecting line 42 are successively larger. In the illustrative embodiment in Figures " 1 and 2, converted wood article 10 is formed from a log with a 100 mm diameter which has been sectioned into 1 meter long segments. Converted wood article 10 has three steps on stepped side 20, each step having a height and width of approximately 15 mm. The cross-sectional length of flat sides 22 and 26 are 45 mm each. Converted wood article 30 in Figures 3 and 4A is cut from log 55 having a diameter of approximately 100 mm which has been sectioned into 1 meter lengths. Each step of stepped sides 33 and 35 has a height and width of 15 mm, so that flat side 42 has a length of approximately 90 mm. The above dimensions are illustrative of some of the typical converted wood articles contemplated in the present invention. It will be understood, however, that the length, height and width of converted wood articles and the dimensions and number of steps will vary for selected applications . The type of wood source and dimensions of the wood source will also vary. The converted wood articles in Figures 1 to 4B may be used to form a large variety of composite wood products, as indicated, by way of example, in Figures 5 to 11. Referring to Figure 5 , converted wood articles 52a and 52b are arranged to form composite wood product 52c. Stepped side 52d and 52e of wood articles 52a and 52b respectively are oriented inwardly and mate with each other so that composite wood product 52c has a rectangular cross-sectional outline. Referring to Figure 6, converted wood articles 54a and 54b are arranged to form composite wood pair 54c which in turn is attached to second composite wood pair 54d to form composite wood product 54θ. Additional composite wood pairs (not shown) may be attached to form larger composite wood products. Referring to Figure 7A, the cross-section of another composite wood product 60e is shown comprising converted wood articles 60a, 60b, 60c, and 60d which are of substantially similar dimension. Stepped sides 60f on each of converted wood articles 60a to 60d are oriented to face inwardly within composite wood product 60β so as to abut corresponding stepped sides of neighboring wood articles forming hollow rectangular interior 60h and substantially rectangular cross-sectional outline 60g. Referring to Figure 7B, composite wood product 60e is shown having reinforcing rod 60i fixed within hollow rectangular interior 60h to provide enhanced load bearing capacity. Referring to Figure 8, another composite wood product 62a is shown having rectangular cross section 62c and comprising converted wood articles 62b each having stepped sides 62d and 62β. Referring to Figure 9, yet another composite wood product 64a is shown comprising two different sets " of converted wood articles contemplated herein, namely converted wood articles 64b and converted wood articles 64c. Referring to Figure 10, composite wood product 66b is shown located between wood boards 66a and wood boards 66d which in combination form composite wood product 66g. Wood boards 66a and 66d are shown attached to sides 66β and 66f of composite wood product 66b. Referring to Figure 11, composite wood product 68a has converted wood articles 68b and converted wood articles 68c inversely arranged and joined along stepped sides 68d. As with the other composite wood products, the number of steps on any side of converted wood articles 68b and 68c will vary with the selected application. Referring to Figure 12 , one method of manufacturing the composite wood articles and composite wood products made therefrom is shown. Typically elongated wood logs are used as the initial input product to be processed. At step 70 the wood product is cut transversely into wood segments which vary in range with the desired finished or semifinished product. In one preferable embodiment, the wood segments are cut substantially into 1 meter lengths to minimize warping when kiln drying at step 78. Other segment lengths may apply depending on the drying effect of the species and the desired application. The resulting wood segments from step 70 are processed at step 72 through a doweling machine and are then each cut longitudinally into elongated wood pieces at step 74. The wood pieces undergo stickering at step 76 and are then kiln dried at step 78. Alternatively, green lumber pieces may be used, which are cut transversely into wood segments at step 70, undergo stickering at step 76 followed by kiln drying at step 78. The kiln dried wood pieces from step 78 are given a molding cut at step 84 to form converted wood articles of the type described above having either one or more stepped sides. Alternatively, kiln dried wood pieces from step 78 may be finger jointed at step 80 before undergoing the molding cut at step 84. One may also use precomposed wood products, typically laminated or solid wood boards, or wood pieces cut from solid wood boards having a wane along one or more edges in step 84 as an alternative to kiln dried wood pieces from step 78. The converted wood articles produced at step 84 may be packaged and shipped for subsequent use in assembling the composite wood products described herein. Alternatively, the converted wood articles may then undergo glue lining at step 86. Glue lining includes the application of bonding material to the surfaces of the stepped side of each converted wood article. The amount and choice of bonding material applied at step 86 to the converted wood articles may vary with the selected application of the final composite wood product. Preferably, the glue lining at step 86 includes application of bonding material to most or substantially all surfaces of each stepped side of the converted wood article. Converted wood articles are also assembled with corresponding converted wood articles in step 86 to form the composite wood products described above. Once the converted wood products have undergone glue lining and assembly at step 86 the resulting composite wood products are assembled with other corresponding wood articles and pressed at step 90. Composite wood products from step 90 are double end trimmed at step 92 and planed to final desired dimensions at step 94, resulting in semifinished or finished composite wood products. Before undergoing processing at step 90, composite wood products from step 86 which are arranged having a hollow interior, such as in Figure 7B, may first have a reinforcing rod inserted into the hollow interior at step 88 to provide additional load bearing capacity and resistance to shearing and impact forces . Wood boards may also be glued and pressed to the sides of the composite wood product at step 90. The converted wood articles described herein offer substantially improved surface area on stepped sides for the application of bonding material. The stepped side or sides on each converted wood article further allows for easy assembly with corresponding converted wood articles to form a wide range of composite wood products. The composite wood products formed from the converted wood articles provide significant improvements in resistance to shearing and impact forces and improved load bearing capacity. The composite wood products further avoid many of the complex reinforcing requirements of the prior art. In addition, the significant resistance to shearing and impact forces achieved in the composite wood products above permits the use of wood pieces from old growth and stagnant growth timber as well as younger generation timber for a much broader application of use in the lumber industry. The composite wood products are well suited for use in making flooring, paneling, support beams, and posts, and are also well suited as substitutes to the conventional use of solid wood pieces in the construction of homes and other buildings . The scope of application for smaller wood pieces provided by the converted wood articles further results in less wood waste. It will be obvious to one skilled in the art that while the converted wood articles have one or more stepped sides, the number of steps on any stepped side will vary as required by the desired composite wood product. It will be further obvious that it is not necessary for the steps on any stepped side to lie on a notional straight line. It will be further obvious that the dimensions of each step on a stepped side need not be the same. It will be further obvious that while a reinforcing rod may be inserted during assembly of composite wood products having a hollow interior, any reinforcing material may be inserted. Accordingly, while this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments as fall within the true scope of the invention.

Claims: WHAT IS CLAIMED IS: 1. A converted wood article for use with one or more other converted wood articles to form composite wood products, the converted wood article characterized by having three sides, at least one of which is formed into a plurality of steps which mate with steps of another wood article. 2. A converted wood article according to claim 1, wherein two of the sides are at a right angle to one another and steps are formed in the third side. 3. A converted wood article according to claim 1, wherein two of the sides have steps and the two sides each form an acute angle with the third side. 4. A converted wood article according to claim 1, 2, or 3, wherein the converted wood article is an elongated beam. 5. A converted wood article according to claim 1, 2, or 3, wherein each step has substantially similar dimension. 6. A converted wood article according to claim 1, 2 or 3, wherein two or more of the steps have different dimensions . 7. A converted wood article according to claim 2 , wherein the number of steps is at least three. 8. A converted wood article according to claim 3, wherein the number of steps on at least one side is at least three . 9. A converted wood article according to claim 1, 2, or 3, wherein at least one side having steps includes corners which lie substantially along a notional straight line. 10. A composite wood product comprising a plurality of converted wood articles, each converted wood article including three sides with at least one side having a plurality of steps which mate with the steps of another of said converted wood articles; and wherein the converted wood articles are joined along the stepped sides. 11. A composite wood product according to claim 10, wherein each converted wood article is an elongated beam. 12. A composite wood product according to claim 10, wherein each step of each converted wood article has substantially similar dimension to every other step. 13. A composite wood product according to claim 10, wherein at least one stepped side of one converted wood article is oriented inversely to a stepped side of another converted wood article to which it is joined. 14. A composite wood product according to claim 10, wherein four converted wood articles are joined together along stepped sides and wherein at least two of the converted wood articles each have two stepped sides . 15. A composite wood product according to claim 10, wherein four converted wood articles are joined together along stepped sides. 16. A composite wood product according to claim 10, wherein the composite wood product has a rectangular cross- sectional outline. 17. A composite wood product according to claim 16, further comprising a hollow interior space along a longitudinal direction of the composite wood product. 18. A composite wood product according to claim 17, including reinforcing material fixed to the composite wood product within the hollow interior space. 19. A composite wood product according to claim 10, wherein for each converted wood article two of the sides are at a right angle to one another and the steps are formed in a third side. 20. A composite wood product according to claim 19, wherein each converted wood article is an elongated beam. 21. A composite wood product according to claim 19, wherein each step of each converted wood article has substantially similar dimension to every other step. 22. A composite wood product according to claim 19, wherein at least one stepped side of one converted wood article is oriented inversely to a stepped side of another converted wood article to which it is joined. 23. A composite wood product according to claim 19, wherein the composite wood product has a rectangular cross- sectional outline. 24. A composite wood product according to claim 19, further comprising a hollow interior space along a longitudinal direction of the composite wood product. 25. A composite wood product according to claim 24, including reinforcing material fixed to the composite wood product within the hollow interior space. 26. A composite wood product according to claim 10, wherein for each converted wood article two of the sides have steps and the two sides each form an acute angle with a third side. 27. A composite wood product according to claim 26, wherein each converted wood article is an elongated beam. 28. A composite wood product according to claim 26, wherein each step of each converted wood article has substantially similar dimension to every other step. 29. A composite wood product according to claim 26, wherein at least one stepped side of one converted wood article is oriented inversely to a stepped side of another converted wood article to which it is joined. 30. A composite wood product according to claim 26, wherein four converted wood articles are joined together along stepped sides. 31. A composite wood product according to claim 26, wherein the composite wood product has a rectangular cross- sectional outline. 32. A composite wood product according to claim 26, further comprising a hollow interior space along a longitudinal direction of the composite wood product. 33. A composite wood product according to claim 32, including reinforcing material fixed to the composite wood product within the hollow interior space. 34. A composite wood product comprising a plurality of converted wood articles, each converted wood article comprising an elongated beam having at least three sides with two of the sides at a right angle to one another and a third side having a plurality of steps of substantially similar dimension to every other step and which mate with the steps of another of said converted wood articles; wherein the converted wood articles are joined along the stepped sides. 35. A composite wood product according to claim 34, wherein at least one stepped side of one converted wood article is oriented inversely to a stepped side of another converted wood article to which it is joined. 36. A composite wood product according to claim 34, wherein the composite wood product has a rectangular cross- sectional outline. 37. A method of fabricating a composite wood product comprising: (a) milling and shaping wood pieces to form converted wood articles, each article having three sides with at least one side having a plurality of steps; and (b) gluing together at least two of such wood articles joined along their stepped sides to form the composite wood product . 38. A method according to claim 37, wherein two of the sides of each article have steps and form acute angles with the third side. 39. A method according to claim 37, wherein the wood pieces are selected from the group of logs, solid wood boards and laminated wood boards . 40. A method according to claim 37, wherein the composite wood product has a rectangular cross-sectional outline. 41. A method according to claim 37, including in step (a) kiln drying the wood pieces before shaping such wood pieces into converted wood articles so as to remove moisture from the wood. 42. A method according to claim 37, including in step (a) cutting transversely the wood pieces to form pieces having substantially one meter lengths . 43. A method according to claim 37, wherein the composite wood product has a hollow interior space. 44. A method according to claim 43, including in step (b) inserting a reinforcing rod in the hollow interior space .

Inventors: DEITER FRANK, FRANK DEITER
Applicants: SYNERGY WOOD PROCESSING INC, SYNERGY WOOD PROCESSING INC.
Application year: 1997
Main classification: B27M3
IPC codes: B27M1, B27M3, E04C3