Patent Document

This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 09/781,511 filed Feb. 9, 2001 now U.S. Pat. No. 6,450,235. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a slat and method for constructing slats which is efficient, warp resistant, saving of natural resources, and longer slat of natural materials without warping, to enable the construction of a high quality, consistent louver product of any practical dimension. 
     BACKGROUND OF THE INVENTION 
     Slats are utilized in a variety of window coverings, including Venetian blinds, and vertical blinds. Slats have in the past been constructed of thin metal from rolls, curved along the path of their shorter dimension to produce a break through stiffness, holding stiff unless stressed. More recent slats include relatively thicker structures whose stiffness is similar to that of a ruler. Modern materials have enabled the construction of slats having a wide variety of strength and size, and other attributes associated with the materials from which they were constructed. 
     Slats constructed of such synthetic material have a main disadvantage of cost, both through raw material scarcity and processing time. Carbon based materials can require pressure based formation as well as consideration relating to sizing shrinkage and other dimensional accommodation. 
     Natural materials, especially wood, are uneven and tend to warp. Warping in long slats is especially pronounced during periods of humidity change. Formation in one humidity environment followed by installation in a different humidity environment will typically result in twisting, bending, and general un-evenness. Further, the effects may occur at different locations along the length of the slats, and such effects cannot typically be defensed against by treating or sealing, as most materials are permeable to moisture. Selection of lengths of wood of even grain creates an even more severe materials problem as the reject rate for material rises and the costs rise further. 
     Furthermore, in the construction of wood slats, there occurs a consistent level of waste based upon statistical differences between the lengths of raw material and the lengths and processing requirements for the individual slat sizes. This waste is extremely significant and contributes to the overall cost for natural slats. Where waste material has a longitudinal (with the grain, for example) size which is less than the minimum length slat, it is disposed of as scrap or refuse. Such scrap is significant in the slat production process and not only drives up cost, but results in a wasting of natural resources by causing more natural resources than are absolutely needed for the slats as being spent. 
     Utilization of absolute small sized scrap has been had by further costly processing as by making of press board and composites which are dependent upon costly processing, and do not lend themselves to use with slats since the bending strength must extend over a long length, much like a ruler or yardstick. There is a further waste in such scrap as utilization in press board requires further cutting and chipping and further destroys the structural integrity of the material structure present. Beyond press board, the only other value of such small scrap is the thermal value on burning. 
     SUMMARY OF THE INVENTION 
     The structures and process for producing the structures of the invention enable extensive and efficient use of block scrap for slat manufacturing. The techniques employed advantageously accomplish two goals simultaneously. The technique enables scrap, such as block scrap, to be formed into longer effective lengths. Such longer effective lengths can then be cutably formed into slats of various sizes. The joinder of the block scrap is by deeply extending, finite interlock length finger joints which, once the material is cutably formed into slats, remain as relatively shallow (the thickness of the slat) and finite interlock length finger joints. The joints have the added benefit that they statistically “break up” any grain differences which would otherwise create warp, and enable long lengths of slat to be employed from several shorter lengths of scrap. The utilization of multiple sets of finger joints virtually completely eliminates the tendency to warp, and provides additional strength against twist forces. Further, as an added economic benefit above and beyond the benefits already mentioned, the technique not only enables waste normally occurring in slat manufacture to be saved, but actually encourages the manufacture of a superior quality product by encouraging lower cost scrap to be used as the primary resource in the manufacturing process. In other words, longer lengths of higher priced wood can be used elsewhere in products where grain structure and uninterrupted length is necessary, and thus drive down the costs in those industries, while at the same time enabling slat construction almost exclusively from scrap. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention, its configuration, construction, and operation will be best further described in the following detailed description, taken in conjunction with the accompanying drawings in which: 
     FIG. 1 illustrates a perspective view of a short length of board rectangular board facing round saw having a particular shape, at a point of moving past a saw blade having a shape to form a locking shape at the end of the board; 
     FIG. 2 is a perspective view of two short lengths of board turned so that the locking shapes oppose each other, one board being rotated so that the interlocking shapes will be complementary for a fully engaged fit; 
     FIG. 3 is a perspective view looking down upon the boards of FIG. 2 as fused together to form a joined board and orientated so that a finger pattern is directed upwardly, and illustrating a slat being cutably removed from the bottom; 
     FIG. 4 is a perspective view of a slat seen in FIG. 3 undergoing attachment of a decorative layer on its major upper and lower sides, such as paint or paper or other material, possibly utilizing an application of a glue layer, and optional glue and cover layer where the wood is discolored; 
     FIG. 5 is a perspective view of the slat seen in FIG.  4  and split into two zones illustrating the application of a glaze layer in one zone and showing the application of a side surface paint layer, either singly or with a stack of such slats; 
     FIG. 6 is a perspective view of the slat seen in FIG.  5  and split into two zones illustrating the application of a buffing or touch finish and a punching operation in one zone, and illustrating a finished appearance, including an aperture, in the other zone; 
     FIG. 7 is an end view of an oval shaped slat; 
     FIG. 8 is an end view of a slat having double curvature; 
     FIG. 9 is an end view of a slat having uneven curvature and rounded edges; 
     FIG. 10 illustrates a perspective view of three boards being joined together as by gluing and the like; 
     FIG. 11 illustrates the utilization of the three board set with the finger pattern formed as seen in FIGS. 1-9 in conjunction with a two-board set, and along with subsequent slat formation by cutting; 
     FIG. 12 illustrates a four sided wrapped version of the slat with wrapping occurring about the top, right side, bottom and left side, with a precision knife shown trimming the wrapping to evenness; 
     FIG. 13 illustrates a sectional end view of the slat being squentially wrapped which may occur at the same distance along the length of the slat or over different lengths; and 
     FIG. 14 illustrates an end view of a slat having an oval cross section. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The description and operation of the shutter system of the invention will begun to be best described with reference to FIG. 1 which illustrates a perspective view of a short length of generally rectangular board  21 . Explanation of the orientation of the formed shapes and subsequent slat producing cutting operations will need to take account of the orientation of matching shapes in the wood, as well as cutting orientation. 
     As such, the board  21  is seen to have a first end  23  and a second end  25 . The board  21  has a height  27  and a width  29 . Height  27  extends between a first surface  31  and an oppositely disposed second surface  33 . Width  29  extends between a third surface  35  and an oppositely disposed second surface  37 . The first end  23  will be shown to be processed, but the second end  25  can also be processed such that a series of such relatively short boards  21  can have ends formed for matching together. 
     A rotating saw head  41  is seen as having an overall saw shape  43  as an overall bellows shape having, when viewed from the side, a series of alternating triangular radial extensions or protrusions  45  separated by a series of alternating triangular radial depressions  47 . The ideal depth of each triangular protrusion from tip to base (such base forming the tip of the space between each triangular projection) is approximately ten to fifteen, and preferably eleven to thirteen millimeters in depth. The width of the triangular projection at its base (and so the tip separation of the triangular extensions at their tips is from about two to six millimeters and preferably about four millimeters apart. This triangular “finger” shape, then, has an ideal ratio of height to width of about twelve or thirteen to four, or about 2.75:1 to about 3.25:1. This ratio and the absolute dimensions may change for different sized slats, especially to form the requisite contact area, but the above ratios and surface extents have been found to work well. 
     The overall length of slat producible utilizing the steps and structures shown can include slat lengths of even longer than ten feet. Slat widths can vary from as narrow as several millimeters to more than 10 centimeters. The same force withstanding limitations in a natural slat made from a single length of material is applicable to the slat made from multiple boards. Thus, the multiple board technique herein can be used to make any slat which would otherwise be made from a continuous length of natural or man made materials. 
     Note that the pattern of protrusions  45  separated by a series of alternating triangular radial depressions  47  ends at one end of the rotating head  41 , with a relatively larger width depression  49  at one end and a relatively larger width protrusion  51  at the other end. The pattern of protrusions  45  and depressions  47 , if they terminated at the center of either, would leave a resulting end protrusion on the board  21  having a half width tip which would be subject to bending, breaking and shattering, either by unintended touching during processing or even by further surfacing operation on the board  21  even where two ends  27  of boards  21  are joined and affixed to each other. In other words, it would leave simply too sharp of an edge and which may result from further destruction in further processing, or in breaking off, result in a gap or depression in the wood. The overall saw shape  43  is meant to give a shape which enables the fitting of first ends  23  which are complementary to each other, rather than a mirror image of each other. 
     Referring to FIG. 2, a perspective of two short lengths of board  21 , including a board  55  and a board  57 , this designation used only to tell them apart, with the resulting board end shapes  61  at their respective first ends  23  are seen adjacent each other. Resulting board end shapes  61 , taking board  57  as an example, each include a linear series of wood protrusions  63 , alternating between a linear series of wood depressions  65  which each extend between first surfaces  31  and second surfaces  33  of board  57 . Board  55  has complementary set of protrusions  63 , also alternating between the linear series of wood depressions  65 . The board  57 , for example has a relatively thicker end protrusion  67 , corresponding to formation by relatively larger width depression  49 , adjacent surface  35 . The board  57  also has a relatively thicker width depression  69 , corresponding to formation by relatively larger width protrusion  51 , adjacent surface  37 . 
     Note also that board  55 , for example, has a relatively thicker end protrusion  67 , corresponding to formation by relatively larger width depression  49 , adjacent its surface  35 , and a relatively thicker width depression  69 , corresponding to formation by relatively larger width protrusion  51 , adjacent surface  37 . However, note the positioning of board  55 , in that it is rotated 180 degrees about its central axis and is seen such that surface  35  of board  55  is most closely adjacent surface  37  of board  57 . This 180 degree rotation of one board, say board  55 , with respect to the other board  57  is so that the surfaces  61  are now fully complementary and may be brought together to a snug fit, with significant surface area. 
     Where the height and width of the boards are one square unit, and where the contribution of the relatively thicker protrusion  67 /depression  69  are ignored, each regular protrusion of 4 millimeter base, 2 millimeter half base and a 12.5 millimeter height, by trigonometry produces a linear extent of two times the square root of the sum of the latter two amounts squared, or about 25.31 additional linear extent for each base width. For a base of 4 millimeters, a 10 millimeter wide length has a linear contact length of about 63.3 millimeters. This is a contact surface area of 6.33:1.0, since the contact in the other direction is directly proportional to the height, or distance in the direction parallel to the general extent of the protrusions  63  and depression  67 . Thus, this amount of increased contact, and this geometry of interlocking connection has been found to equal or exceed the strength needed to form a relatively longer slat from relatively shorter pieces. 
     In the process as set forth, it will be shown that the blocks  55  and  57  may be joined at a time when they are have a distance between surfaces  31  and  33  of sufficient dimension to form several slats, especially where each operation forming board end shapes  61  may follow more efficiently. Further, to maintain the finger orientation, the generalized plane of the board shapes  61  is perpendicular to the plane of the slats which will be formed from the boards  55  and  57 , and also, more specifically, the plane formed in a direction along the lengths of the linear series of wood protrusions  63 , and linear series of wood depressions  65  will also be perpendicular to the plane of the resulting slats. 
     Taken from the perspective of board  57 , for example, the slats will be formed having surfaces parallel with surfaces  31  and  33 . Any slat whose major surfaces were parallel to the surfaces  35  and  37 , or to the extent of the linear series of wood protrusions  63 , and linear series of wood depressions  65  would be weak because (1) there would be joinder force only in proportion to the slat thickness which is not desired, and (2) would have a bending force applied tending to directly separate any surfaces of the board end shapes  61  rather than taking advantage of the finger geometry, where major bending forces would tend to move the fingers laterally among each other rather than to promote an angled separation. 
     The view of FIG. 2 is looking in perspective into the board end shapes  61  which will be angularly displaced as they are brought together to bring the opposing end shapes  61  into interlocking contact with each other. A glue applicator  81  is seen in schematic over the boards  55  and  57  as administering droplets of glue  83  as may be appropriate to join the first ends  23  of the boards  55  and  57 . Glue  83  may be applied in any manner, including spraying or by providing an amount to be squeezed out when the ends  23  of the boards  55  and  57  are brought together. Further techniques may involve the use of hot glue, solvent glue, setting glue, and the like. Further, pressure may be placed on the boards  55  and  57  against each other during and after the glue  83  application process in order to accelerate the surface process and enhance the holding strength and interfit of the boards  55  and  57 . Once the glue is dried or set, the joined boards  55  and  57  may have their second ends  25  processed with the rotating saw head  51  as shown in FIGS. 1 and 2, for adding further lengths together. In some cases, this may be repeated several times to accomplish two goals simultaneously. A given length of formed slat can then utilize much smaller amounts of scrap, and a given length of formed slat will have the effect of the natural differences in wood grain, the tendency of its lengths to warp, to be further truncated, and linearity matched. 
     Referring to FIG. 3, a perspective view looking down upon the interlocking boards  55  and  57  seen in FIG. 2, and especially the top portion, shows the effective formation of a new board in terms of its overall shape. Upon first formation of the structure, especially the upper structure seen in FIG. 2, it may be advantageous to sand the major surfaces, such as surfaces  33 ,  31 , and the planar interfaces between surfaces  35 - 37  on either of their two sides. Sanding while the structure of FIG. 3 is in a block shape may be more convenient in eliminating any mismatch, on any side, especially at the interface. Further, where boards  55  and  57  would be sanded in any event, sanding of the completed structure of FIG. 3 may facilitate handling and eliminate further sanding where desired, such as side edges of formed slats, etc. 
     A section of the interlocking boards  55  and  57  of FIG. 3 have been segregated as a slat  91 . For orientational purposes, the slat  91  has a first surface  93  and a second surface  95  which is oppositely disposed with respect to surface  93  and indicated by a curved under arrow. As seen in FIG. 3, surface  93  is a cut surface, formed by cutting away from boards  55  and  57 . This surface may be sanded smooth, but it is not necessary to produce the type of surface purity where surface  93  is to be later covered with a material which would overlay, hide, cover or redistribute glue or filler which would otherwise be used to affix such covering material. 
     Surfaces  93  and  95  are the largest surfaces of the slat  91  and are typically the upper and lower surfaces, the slat  93  being considered as a flat structure. Slat  91  has a first side surface  97  and a second side surface  99  not immediately viewable from the perspective of FIG.  3  and shown with a hook arrow indicating the surface opposite to first side surface  97 . Slat  91  has a first end surface  101  and a second end surface  103  not immediately viewable from the perspective of FIG.  3  and shown with a hook arrow indicating the surface opposite to first end surface  101 . 
     The direction in which each of the slats  91  is cut forms a reproduction of the zig-zag pattern seen between surfaces  33  at the top of the boards  55  and  57  of FIG.  3 . The “fingers” formed by the linear series of wood protrusions  63  and linear series of wood depressions  65  extend across the width of the slat  91 , between side surfaces  97  and  99 , as they cross the surfaces  93  and  95 . The linear lengths of the outermost protruding edges linear series of wood protrusions  63  extend internally, within the slat  91 , between the first surface  93  and second surface  95 . The linear extent of the linear series of wood protrusions  63  will thus always be perpendicular to the main extent of the upper and lower surfaces  93  and  95 . The finger pattern seen on the top of the slat  91 , and indeed between the surfaces  33  of boards  55  and  57  is hereinafter referred to as finger pattern  109 . 
     A side separation line  111  is seen between the joined tip end of the relatively thicker end protrusion  67  and relatively thicker width depression  69 , and carries on into the slat  91  after it is separated by cutting from the two joined boards  55  and  57 . 
     Referring to FIG. 4, an exploded perspective view illustrates further processing as applied to the slat  91 . The slat  91  shown has four finger patterns  109  merely to illustrate that many are possible. In general, the slat  91 , made up of wood from both joined boards  55  and  57 , and indeed may be made from other joined boards, the merely two joined boards  55  and  57  being the simplest example. Ideally the wood grain and color will be compatible, but it may not be compatible. In many cases, in the natural state of slat  91  as it appears just after cutting, the finger pattern  109  is not even recognizable. This is especially so if the glue  83  is fairly colorless. 
     FIG. 4 illustrates that just above and below the slat  91 , a layer of glue or contact adhesive can be applied, and seen as layer  115  and  117 . This layer may be and is preferably extremely thin and may be applied by spray or the like, even in a pattern which may give less than full statistical coverage of the surfaces  93  and  95 . A layer of pattern paper  121  is seen to sandwich the glue layer  115  between pattern paper  121  and surface  93  of the slat  91 . The term “paper” is used to indicate a paper-like dimension, but the actual material of choice may be paper, plastic, sheeting, or any other dimension or area of material whose primary purpose is the application of a pattern onto the slat  91 . Other examples may include peel and stick applique, or even sequential painting where the pattern is laid down similar to silk screened t-shirt manufacture, sequentially with each portion of the pattern being added at different times. Thus the term “paper” is not limited to paper cellulose products. Selection is made such that the glue layers  115  and  117  do not react with, especially from a color change standpoint, the layers  121  and  123 . 
     Similarly, a layer of pattern paper  123  is seen to sandwich the glue layer  117  between pattern paper  123  and surface  95  of the slat  91 . The pattern paper may be available, for example, in rolls  125  and may be applied by machine. Where many slats  91  are to be produced at one time, a device is easily formed which may apply the glue layers  115  and  117  by rolling, spraying and the like, followed by rolled application of pattern paper  121  and  123  from matching rolls  125 . In this manner, the appropriate amount of glue and the appropriate amount of pressure may be applied to the pattern paper  121  and  123  as it is applied to the slat  91 . 
     Pattern paper  121  has an upper surface  127  facing away from the slat  91  containing a pattern. The pattern may be a wood grain, a solid color, a decorative pattern or any other design which can be expressed on paper or any layered surface, even by painting, for but one example. 
     Where paper or other unfinished material is used as the layers  121  and  123 , subsequent glazing to a slick washable surface finish is desirable. The order of subsequent steps, and in particular any glazing step will depend in large part the materials chosen for the layers  121  and  123  and in use with some of the other processing steps. 
     As indicated before, it is preferable for the wood tones to be even, and especially where the color, patterns or thickness of the layers  121  and  123  are such as to transmit light and dark patterns which may occur on the surfaces  93  and  95  through the layers  121  and  123 . However, where this does occur, and where patchy or splotchy wood discoloration may show through, an optional glue layer  131  along with an optional covering layer  133 , perhaps white, is seen to one side of and fittable underneath the layer  115  and atop the surface  93 . Interposition of these wood color evening layers  131  and  133  should be accomplished with due consideration of the color and pattern on the layers  121  and  123 . In some cases, extreme discoloration of the wood may be covered by relatively thicker layers  121  and  123 . Materials and wood quality will control whether or not layers  121  and  123  are even needed. 
     Referring to FIG. 5, an operation is shown as occurring to a fully formed slat  91 , and which may have been formed of two to many individual lengths of board  55 ,  57 , etc. Prior to the processing seen in FIG. 5, the slat  91  will simply consist of a piece of wood having an upper layer  121  and a lower layer  123  glued onto it. The side edges of the paper, as they meet the first and second side surfaces  97  and  99 , are closely adhered to the surface of slat  91  at their edge of termination. Some glue may fill the gap and prevent micrometer upward protrusion of the paper. To the extent that the glue fails to completely even up the surface  127  with the adjacent bare wood, one of either or both of glazing or side painting will effectively complete this evening. 
     Considering side painting, the right half of FIG. 5 illustrates paint applicators  135  applying a spray of paint  137  to the first side surface  97 , and not shown, but also to the second side surface  99 . Paint may be applied to individual slats  91 , or it may be applied to a stack of slats  91 . Where stacking, shown at the right side end of FIG. 5, is accomplished, the sandwiching pressure on the slats  91  can prevent sprayed paint from entering spaced between the surfaces  127 . Other methods for applying the paint  137  may be by rolling, brushing, and the like. The color of paint  137  selected should blend as much as possible with the color or pattern on the surface  127 . Because the first and second side surfaces are of such limited surface area, the effect of a solid color of paint, compared to a wood grain pattern on the pattern paper  121  and  123  will be minimum. The effect of the solid side colors will be non-noticeable or give the impression that the sides of natural wood were simply painted a solid color. Where paint is used as the paper  121  and  123 , the pattern may be combined with side painting to create a completely four dimensional pattern. Thus where application of the paper  121  and  123  layers is omitted, the painting step of FIG. 5 can be used to simply create a finished slat  91  with paint, sometimes in one step. Further, as micro paint control is known, such paint could be accomplished with a color bar, where the slat simply passes through an area which “draws” the desired pattern onto the slat  91 . Other combinations are possible. 
     At the other end of FIG. 5, a set of nozzles  141  are shown applying a glaze material  143  to the upper surface  127  of the pattern paper  121  covered slat  91 . Where the glaze is to be applied to both the upper surface  127  and painted first and second sides  97  and  99 , the glazing may occur after the painting of the painted first and second sides  97  and  99 . Conversely, some glaze material may create better adherence of the paint for the painted first and second sides  97  and  99 , and thus, especially where the paint is high gloss, the glazing may occur first. Typically the glaze may preferably be a semi-gloss as to avoid high mirror type reflectivity when the slats are in a general parallel position within a blind set. The glaze material  143  should facilitate wiped cleaning of the surface of the slat  91  and should exhibit good wear characteristics under conditions of repeated cleanings over its lifetime. 
     Referring to FIG. 6, a perspective illustration of a slat undergoing further processing is seen. On the right hand side, a punching device  151  forces a punch ram  153  through the slat  91  to expel a wafer  155 . Also, a buffing pad  157  on a shaft  159  provides a smoothing effect and removes any small glaze or paint buildups and gives the resulting finished slat  91  a high quality finish. On the left side of FIG. 6, the finished slat  91  includes an optional slot  161  to accommodate the through-slat suspension string if there is one. In some cases slats can be fixed and angularly operated without the need for openings such as slot  161 , and in such cases other hardware or appurtenances may be attached to the slat  91 . At the left side of FIG. 161, upper surface  127  shows a wood grain pattern which was previously painted upon pattern paper  121  and  123 . Again, any pattern is possible, and the wood grain is but one example. 
     The shape of slat shown herein has thus far been a rectangular shape and such illustrations have been rectangular to simplify an explanation of the method involved. However, other shapes are possible, especially due to new cutting techniques as well as the ability of band saws to be guided to form different cutting shapes. Referring to FIG. 7, an end view of an oval shaped slat  171  is shown and may be formed by independent processing or by starting with a board  55  having patterns, for example on surfaces  35  and  37 , for example. 
     Referring to FIG. 8, an end view of a slat  175  having double curvature is seen, and may be formed by a curved saw blade, for example. Similarly, referring to FIG. 9, an end view of a slat  177  is seen as having an uneven curvature and rounded edges. Any combination of slat shapes are possible, either through advanced cutting or through further processing, cutting bending and shaping after an individual slat  91 ,  171 ,  175 , or  177  or other has been formed. 
     The description previously has been deliberately simplified to illustrate the formation of the interlocking sets of wood protrusions  63  and wood depressions  65  which form the finger pattern  109 . One simplification was in beginning the process with a single, solid, although abbreviated length of board. The starting material need not have been a solid piece of material. 
     FIG. 10 illustrates a perspective view of a grouping  181  of three boards  183 ,  185  and  187  shown having glue  83  applied there between, and movement together being joined together as by gluing and the like, into a single block of material. Now ideally, the interface boundaries shown as  191  and  193 , which start out as being the areas between the boards  183 ,  185  and  187 , and which will be narrow and filled with glue, will not extend across the final slat  91  laterally with respect to the major axis of its length so as to weaken it. Other orientations, such as would place an interface boundary in a general parallel relationship to a finished slats first and second surfaces  93  and  95 , taken with respect to FIG. 3, are not favored unless it can be assured that the glue  83  will be strong enough not to delaminate or weak enough that its parallel position would impair further processing, such as buffing, sanding, and the like. Where such a super strong glue is available, an interface boundary  191  and  193  may be allowed to approach a parallel orientation with first and second surfaces  93  and  95 . Further, orientations for the interface boundaries  191  and  193  shown in FIG. 10 may also differ from their generally vertical and parallel relationship to a slanted and non-parallel relationship, and even a horizontal relationship, if such a glue  83  with good strong properties were to be used. However, assuming that such a glue is not available, the generally vertically oriented interface boundaries  191  and  193  will give the strongest relationship against the most severely expected stresses and strains which slat  92  is expected to encounter. 
     FIG. 11 illustrates the utilization of the three board set  181  with the finger pattern  109  formed as seen in FIGS. 1-9, to form a finger pattern  109  due to the interlocking protrusions  63  and depressions  65 , to form, in conjunction with a two-board set  195 , an integrated board  197 . Integrated board  197  is one of many, and is used to illustrate that it may be preferable that the board sets,  181  and  195  for example, not have interface boundaries  191  and  193  which would align with an interface boundary  197  seen between boards  201  and  203  of board set  195 . A slat  205  is shown as produced by cutting the bottom of the integrated board  197  to produce a slat  205  having the finger pattern  109  and separation  111 , as well as shallow interface boundaries  191 ,  193 , and  199 . The major stress on the slat  205  is likely to be against the middle, roughly the position where the finger pattern  109  is seen and against ends  207  and  209 . As such, any interface boundaries  191 ,  193 , and  199  will neither detract from nor add to the strength against this sort of bending. For a given strength of glue  83 , orientations of the interface boundaries  191 ,  193 , and  199  which deviate from being vertically perpendicular to an upper surface of the slat  205  may tend toward weakening slat  205  with respect to the aforementioned stress orientation. Again, this is not to say that other orientations for the interface boundaries  191 ,  193 , and  199  are not possible, and may depend upon the combination of glue  83  and wood materials used. Again, a single elongate slat may have several finger patterns  109  and may have sections made from one, two, three or more boards  183 , and which may extend through sections having one lateral section  211 , to two, to three, and then back to two. It is desired that the thicknesses of the boards  183 ,  185  and  187  be such that the interface boundaries  191 ,  193 , and  199  not come into alignment at the area of finger patterns  109 , so that the finger pattern area  109  may be an area of further urging together of the different board areas. 
     Referring to FIG. 12, a slat  91 , as before, has a first surface  93 , second surface  95 , first side surface  97  and second side surface  99 . Also as before, finger pattern  109  occurs periodically along the slat  91 &#39;s length. In this instance, the slat  91  will have all four sides wrapped with a length of full width applied covering  225  which may be made of pattern paper. The pattern paper has a width which is at least as wide as the width of the first surface  93 , second surface  95 , first side surface  97  and second side surface  99  combined. Where the finishing is to be a cutting operation, the width will ideally be wide enough to support any cutting operations of a machine or manual cutting which facilitates a good finish. For example, even by hand, it may be preferable to pull any excess width of pattern paper taught in order to avoid cutting blade drift. Where cutting is done by machine, the machine may be able to continuously grasp the excess width and apply taught pressure in order to produce a cleaner cut. In FIG. 12, a blade  227 , which is a schematically shown blade, is seen proceeding along the length of the slat  91  along a fully wrapped section  231 . The blade  227  is shown at an angle which is about forty five degrees with respect to first surface  93  and second side surface  99 . This technique, using the added upper dimension of the starting edge of the applied covering  225  to set the level of cut, will insure that the remaining, opposing side edges after cutting will be as evenly matched into an enclosing parameter as possible. 
     Another alternative for the cutting and finishing would be a fine grinding action upon the edge of the overlap which would tend to form a micro-blend of the of the remaining, opposing side edges after grinding. 
     Another technique is to use a glue which is matched to the color of the applied covering  225  in order to provide a micro-filler between the two remaining, opposing side edges after cutting. With this technique, a micro-gap would be deliberately created, but in which the filler glue could be pressed to the surface to provide a closest possible joinder of the of the remaining, opposing side edges after grinding. It would in effect be a pattern matching space. 
     All three techniques and more can be combined with carefully calculated pattern matching, such as a print pattern, where the visual match across the gap of the remaining opposing side edges after cutting is so powerful that it dominates any such small gap remaining. Still other techniques may be combined including further roller pressing of the applied covering  225 . Where a small gap is created, and it is known that for certain types of glue at certain temperatures and conditions that further pressing of the fully wrapped section  231  will cause the of the remaining, opposing side edges to move toward each other a predetermined amount, such pressing technique can be used to close the small gap to a sharp right angle. Other techniques for cutting the applied covering  225  can be employed. 
     The manner of supplying the applied covering  225  and its manner of application to the slat  91  can also be widely varied. Where the applied covering  225  is supplied in roll form as was shown in FIG. 4, although in a single roll rather than two rolls and in a much wider format, it can be applied to the slat in a batch type process or a continuous type process. 
     In a continuous type process, the applied covering  225  is applied linearly utilizing a wrapping guide which adjusts the angle of wrap and application about each of the surfaces as both the applied covering  225  and the slat  91  move linearly in the same direction. A guide can be used to sequentially apply the applied covering  225  to the slat  91  as they both proceed forward. The sequential application is used to smooth and press one surface just before the next adjacent surface meets the applied covering  225 . With this process, application and pressing can be carefully controlled. Glue can be applied as by spraying as seen in FIG. 5, for example, or by rollers or the like. Where the applied covering  225  is applied as a roll, provision can be made to cut between adjacent slats  91  and the like. 
     In the alternative, the applied covering  225  may be applied by a batch process, where the applied covering  225  is applied in one individual step to a given length of slat  91  in a “wrapping” sequence. In FIG. 13, an end sectional view illustrates this wrapping, but also illustrates the above guide sequential application of the applied covering  225 . In FIG. 13, the dashed line format is used to indicate the portion of the applied covering  225  which is away from the slat  91  as another portion is applied. 
     For example, in a first step, for example, a width  235  of applied covering  225  is applied to a first (upper with respect to FIG. 13) surface  93  with a not yet applied width  237  shown in dashed line format. In the next step, the not yet applied width  237  is folded down to apply a width  239  of applied covering  225  to cover a first side surface  97  with a not yet applied width  241  shown in dashed line format. In the next step, the not yet applied width  241  is folded across to apply a width  243  of applied covering  225  to cover a second surface  95  with a not yet applied width  245  shown in dashed line format. Finally, In the last application step, the not yet applied width  245  is folded (up with respect to the orientation of FIG. 13) to apply a width  247  of applied covering  225  to cover a second side surface  99  with an optional excess width  249  shown in dashed line format awaiting further treatment to cut or remove it from the now four sided covered slat  91 . A tangential line of cut or removal is seen as a dashed line  251 , and typically occurs at the point where any excess width of applied covering  225  is to be cut away. 
     Referring to FIG. 14, an illustration that other shapes of slat  91  can be covered in the same way as was the case for slat  91 . An oval slat  255  has a continuous coating of applied covering  253  and illustrates an option extension of the excess in dashed line format as excess  257  as the width of the applied covering  225 , such as pattern paper, extending beyond the point at which the first side edge of the pattern paper was first applied. Glue  143 , as in FIG. 5, can be applied to assist attachement of any applied covering. Again, the excess  257  is not necessary depending upon the type of application desired, but is illustrated to show how the technique could occur. Without the optional excess  257  applied covering  253  can also be a continuous hollow annular cylinder. 
     Another technique illustratable with respect to all of the Figures, and especially FIGS. 13 and 14 would be the provision of an applied covering  253  as a single piece of annularly cylindrical shrink wrap. In this method, the slat, such as oval slat  255  is inserted into a prepared hollow annularly cylindrical sleeve  253  and then treated to have the sleeve  253  shrink to fit tightly about the slat  255 . One method is by heat shrinking. This type of production is more batch processed in that each slat  255  section must be inserted before the sleeve  253  can be shrunk. A separated sleeve  253  is shown adjacent the oval slat  255 . 
     While the present invention has been described in terms of a system and method for forming slats from lengths and collective widths of various shapes of relatively shorter, relatively less narrow pieces of material and for shifting the economics of slat making towards a more efficient use of scrap and for freeing longer lengths of wood stocks for other uses, one skilled in the art will realize that the structure and techniques of the present invention can be applied to many structures, including any structure or technique where joinder with enhanced contact structures and where joinder with interlocking finger structures can be utilized, where lateral joinder of different materials may be enhanced and where structures like finger grooves or protrusions and depressions can be advantageously used to interrupt differences in natural wood extents. 
     Although the invention has been derived with reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. Therefore, included within the patent warranted hereon are all such changes and modifications as may reasonably and properly be included within the scope of this contribution to the art.

Technology Category: b