Patent Application
20160222657
The present invention relates to wood laminate panels, a system of two or more laminate panels joined permanently together, a method of making the panels and a method of fabrication of objects with the panels.
Curved wood products are used in a number of applications from small degree curves in furniture to full cylindrical shapes as drum kits to solid wood pieces banded together into staves or barrels. As far back as 1950, the US Forest Service investigated different methods of producing curved veneer products. However, of the few curved wood products commonly in manufacturing today, most are steam bent solid wood products and none are longer than an individual sheet of veneer, these still have the ability to produce a system at multiple panels in large and varied number of shapes.
In accordance with one aspect of the present invention, there is provided a wood laminate panel comprising an elongated body having a longitudinal axis and extending a length thereof, the body having an arcuate cross-section in a plane substantially perpendicular to the longitudinal axis defined by: a first and second spaced apart curved surfaces, the first surface being concave and the second surface being convex, first and second spaced apart edge surfaces interconnecting longitudinal ends of the first and second curved surfaces; wherein the first and the second spaced apart surface edges extend along the length of the elongated body and each include an attachment joint, the attachment joint of the first spaced apart surface edge having a shape that is complementary to that of a second spaced apart edge surface of a second wood laminate panel such that the wood laminate panel is permanently bonded with the second laminate panel through an engagement of adjacent complementary edge surfaces and such that the first and second spaced apart curved surfaces extend continuously from the attachment joint.
In accordance with another aspect of the wood laminate panel herein described, the first and second spaced apart surface edges include at least one male profile and a complementary female profile respectively adapted to fit one into the other and jointable with the adjacent identical laminate panel.
In accordance with yet another aspect of the wood laminate panel herein described, the least one male profile and the complementary female profile are a finger joint comprising two male profiles and at least two female profiles.
In accordance with still another aspect of the wood laminate panel herein described, the arcuate cross-section is semi-circular.
In accordance with yet still another aspect of the wood laminate panel herein described, the semi-circular cross-section has an arc-length of less than or equal to 180°.
In accordance with a further aspect of the wood laminate panel herein described, the arc-length is selected from the group consisting of 45°, 90°, 120°, and 180°.
In accordance with yet a further aspect of the wood laminate panel herein described, the arc-length is 120°.
In accordance with still a further aspect of the wood laminate panel herein described, the length of the panel is 8 feet.
In accordance with another aspect of the invention, there is provided a system of wood laminate products, the system comprising at least a first and a second wood laminate panel, the first and the second wood laminate panel each comprising first and second spaced apart curved surfaces, each of the first and second spaced apart curved surfaces having an axial edge surface including an attachment joint that is complementary with the attachment joint of the other wood laminate panel, wherein the attachment joint permanently bonding the first and the second wood laminate panel together through an engagement of the axial edge surfaces and extending the first and second spaced apart curved surfaces.
In accordance with another aspect of the invention, there is provided the system herein described wherein the wood laminate panel has a semi-circular cross-section with an arc-length of less than or equal to 180°.
In accordance with another aspect of the invention, there is provided the system herein described wherein the wood laminate panel has an arc-length of selected from the group consisting of 45°, 90°, 120°, and 180°.
In accordance with another aspect of the invention, there is provided the system herein described further comprising a third wood laminate panel, wherein the first and the second and the third wood laminate panel each panel has the arc-length of 120°, and are joined to produce a cylindrical cross-section.
In accordance with another aspect of the invention, there is provided the system herein described wherein the first and the second wood laminate panels are attached to produce an S cross-section.
In accordance with another aspect of the present invention, there is provided a method of producing an axially jointable edge surface wood laminate panel comprising providing a plurality of softwood veneer sheets; preparing the veneer sheets in a cross-ply arrangement; providing an adhesive; applying the adhesive to at least three of the veneer sheets; aligning the at least three veneer sheets to produce a multilayer adhered flat panel; pressing the multilayered adhered flat panel into or with an arcuate form to produce a semi-cylindrical panel having two axial edge surfaces; and profiling the two axial edge surfaces of the semi-cylindrical panel along length of the at least three veneer sheets to produce the jointable wood laminate panel comprising complementary axially jointable edge surfaces.
In accordance with yet still a further aspect of the method herein described, the profiling of the two axial edge surfaces include at least one male profile and a complementary female profile respectively adapted to fit one into the other and jointable with the adjacent identical laminate panel.
In accordance with one embodiment of the method herein described, the least one male profile and the complementary female profile are a finger joint comprising two male profiles and at least two female profiles.
In accordance with another embodiment of the method herein described, the softwood veneer sheets have a thickness ⅛″.
In accordance with yet another embodiment of the method herein described, the softwood is selected from the group consisting of hemlock, amabilis fir, Douglas fir, SPF and combinations thereof.
In accordance with yet another aspect of the present invention, there is provided a method of producing a wood laminate object comprising the steps of: providing a plurality wood laminate panels herein described each having an axial length; and permanently jointing a first axial edge surface of a first panel to a second axial edge surface of a second panel.
In accordance with still another embodiment of the method herein described, jointing the first axial edge surface to the second axial edge surface is with an axial offset of at least 20% of the length of the panel.
In accordance with yet still another embodiment of the method herein described, the panels have an arc length of 120°.
In accordance with a further embodiment of the method herein described, further comprising permanently jointing the first and the second panels together to produce an arc length of 240°.
In accordance with yet a further embodiment of the method herein described, wherein permanently jointing a third axial edge surface of a third panel to a non-jointed first and second axial edge surface with an axial offset of at least 20% of the length.
In accordance with still a further embodiment of the method herein described, further comprising permanently jointing the first and the second panels together to produce an S-shaped cross section.
In accordance with yet still a further embodiment of the method herein described, further comprising permanently jointing a third axial edge surface of a third panel to a non-jointed first axial edge surface and a fourth axial edge surface of a fourth panel to a non-jointed second axial edge surface to producing a tear drop shaped cross-sectional member.
The present describes wood laminate panels that have permanently and/or irreversibly jointable edge surfaces, and a system produced by the joined the wood laminate panels The wood laminate panels are made at a plurality of veneer sheets stacked and glued together with an adhesive.
Permanently jointable edge surfaces are defined herein as joint surfaces that fit one into another and mesh strongly permanently and without the further application of adhesive. The edge surfaces are also complementary with other edge surfaces of other wood laminate panels of the present invention. The permanently jointable edge surfaces may take many forms. In a preferred embodiment the jointable edge/axial surfaces are complementary, male and female finger joints that are continuous along the length of the axial edge.
The jointable edge/axial surfaces are profiled to be complementary.
Complementary is used to define the profile of the axial edge surfaces, and means that the edge surfaces are shaped to join on a wood edge surface into the other. In one embodiment, a male profile member(s) is permanently jointable with the female profile member(s) of the axial edge surfaces. The profile is made in alignment with the veneer sheets/layers not perpendicular to the sheets/layers.
The word jointing is used similarly and is defined a producing a permanent joint between the panels of the present invention.
The system of the present invention once permanently joined extends the surfaces of the wood panels in a continuous manner, such that the arcuate surfaces despite the attachment joint have a continuous surface shape on both sides of the attachment joint.
Turning to , along the an imaginary axis 2 of the cylinder of the body 5 having an arcuate cross-section 12. In a preferred embodiment the arcuate panel is semi-circular in cross-section although other cross-sectional shapes can be envisaged. The present application describes a wood laminate arcuate panel 5, produced in a repeatable manner, and affording the possibility of producing a wide range of useful objects including plywood laminate arcuate panel sections that in a preferred embodiment may have circular in cross-section.
The panels 5 described herein, can be joined to make a system of panels thereby producing objects of different shapes having an almost indeterminate length, as well as varied durability and strength, from these relatively simple panels 5.
The laminate has a plurality of veneer layers/sheets 7 held together by layers of adhesive. Some aspects of the panel 5 include: 1) a plurality of layers 7 of pressed softwood veneer, that in a preferred embodiment have an semi-circular/semi-cylindrical cross-section having an arc length 22 of 120°.
The semi-cylindrical curved panels 5 are in a preferred embodiment 8 feet in axial length, , with effective (inner diameter) 14 inch diameter (or a 7 inch radius, r1). The veneer layers 7 are laminated/held together using an inert adhesive that in a preferred embodiment is a polyurethane with low sodium/potassium salt levels that requires no heat to set the adhesive. The plurality of veneer layers 7 with adhesive have an arcuate thickness, t, that in a preferred embodiment is semi-circular/sem-cylindrical.
Two axial edge surfaces 14 are spaced apart and at opposite ends of the curved surfaces and have substantially the thickness t, and substantially the length, , of the body/panel 10/5. Axial edge surfaces 14 comprise joints 24a, 24b, such as finger jointed edge surfaces that are complementary with one another and adapted to fit into a complement edge surface of an second identical panel described herein.
In a preferred embodiment, the joints 24a, and 24b on the axial edge surface 14 comprise at least one male profile joint 24a adapted to fit into a complementary female joint 24b. As the wood laminate panels of the present invention are made in a repeatable manner the female joints 24b of a second panel 5 are compatible with the male joints 24a of the first panel. With this compatibility, where a second, third, fourth, fifth etc. wood laminate panel have compatible joints, assembly of these curved panels into a multipanel system of cylinders and other shapes is possible. Once again these axial edge surface joints 24a/24b join together permanently without any further adhesive having to be applied. The joints have a profile that is substantially aligned with the veneer layers of the laminate panel.
The panel 5 also has an arcuate cross-section 12 of thickness, t, defined by a first arced curve 16 (often considered the inner convex curve) with first/inner opposite ends, and a second arced curve 18 often considered the outer concave curve, having two second/outer opposite ends. The opposite ends of the inner and outer arced curves 16/18 terminate at the axial edge surfaces 14. As will be seen the inner curve 16 and the outer curve 18 may be interchangeable when producing various objects with the semi-cylindrical panels 5 as described herein, with curve 16 becoming the outer curve and curve 18 becoming the inner curve.
In a preferred embodiment the curves are semi-cylindrical. The inner curve 16 having a radius, r1 and the outer curve 18 having a radius r2. The radius r1 being less than r2.
The wood laminate arcuate panel 5 generally includes from 3 to 12 veneer layers 7 interspersed between 2 to 11 adhesive layers, with 4 to 8 veneer layers 7 being particularly preferred. Each veneer layer having a thickness from ⅛″-¼″. Between each veneer layer 7 there is an adhesive layer that may be a polyurethane adhesive.
The elongated body 10 includes a first/inner concave surface 26 produced by the intersection of the first/inner arced curve 16 with the axial length . Similarly, the second/outer convex surface 28 is generated by the intersection of the second/outer arced curve 18 with the axial length
.
The arc length 22 of r1, and r2 may be any lengths up to and including 180°. The preferred arced length are 45°, 60°, 90°, 120° and 135°. Particularly preferred arc lengths are 90° and 120°, with 120° being most preferred.
The elongated panels 5 of the present application are particularly well suited for use as culverts buried in roads to allow for the passage of water through the road network rather than damming it on one side. Resource roads have a high degree of variation in lifespan, depending on perceived utility of the road—some are installed for the long term as arteries, while others are more temporary capillaries servicing areas for short periods.
Culverts range in length, diameter and in-situ longevity based on site conditions and materials for culverts are selected accordingly. Culverts were once commonly made of wood (box culverts), but are now predominantly made of corrugated steel or high density polyethylene because of ease of installation, standard availability and long term performance. Box culverts made of wood were commonly used in the early days of resource road building and performed well over time, but were generally custom built using available materials at the time and not re-usable.
However, several issues arise when installing culverts made of plastic or steel. On one hand, steel and plastic are designed to last many years in ground contact, often much longer than the lifespan of the road and have an associated high cost—approximately $300 for a 20 foot section at 14″ diameter. The road contractor is paying for an unnecessarily long life. The anticipated retail selling price for the bio-degradable culvert described herein is $225 for the same section or 25% lower in price for the product only.
The other issue with plastic and steel culverts is the need to remove all foreign materials from a resource road upon deactivation. In this case, the cost of removing plastic or steel culverts presents a significant cost, including heavy equipment and culvert transport trucks, in addition to the cost of carefully removing the culvert for re-use elsewhere, a process in which attrition occurs. The cost of removing culverts is believed to be at least equivalent to the product cost or at least $300 per culvert. Therefore, combining the cost advantage of the bio-degradable culvert and the foregone removal cost, the bio-degradable culvert is equivalent to a 60% savings.
Finally, both HDPE and steel culverts are known to deteriorate over time, such that the HDPE becomes brittle and the steel culvert corrodes, in both case depositing foreign materials into the natural environment.
The market for culverts in the production and maintenance of BC forest roads is worth millions of dollars annually. Estimates suggest over 2000 km of new roads are constructed annually, requiring at least five culverts per kilometer. In addition, there are also more than 35,000 kms of maintained forest resource roads. If only considering non-fish bearing streams on new roads, the market is worth approximately $14 million per year. When adding non-permanent resource roads for the growing oil and gas and pipeline sectors in BC, Alberta, the market could be many times larger.
An important components of the wood laminate panel 5 described herein, are softwood veneers commercially available of ⅛″ and ¼″ thicknesses and in a variety of species—hemlock, amabilis fir, Douglas fir, SPF. Polyurethane adhesive is applied on one face of the veneer as it is laid into the curved-steel mold in a press. The number of layers of veneer is specific to the application, durability requirement and loading, but for prototyping purposes, the present inventors have built 5 ply cylinders at 14″ diameter.
. Therefore in a preferred embodiment of the axial edge surface the male profile and the complementary female profile are a finger joint comprising two male profiles members and two complementary female profile members that are permanently jointable. As can be seen, the profile of the finger joints is in substantial alignment with the veneer sheets of the laminate panel, not perpendicular the veneer sheets.
The uniqueness of culverts made of the wood laminate semi-cylindrical panel described herein is 1) the method by which final assembly culvert is made, 2) its end-use flexibility and 3) its bio-degradability.
1) The curved, finger jointed pieces are assembled in an offset manner to allow for repeating and no butt joints. The finger joint allows the product to slide together into a cylinder that requires force applied equally in all directions from the inside to separate the pieces from one another—the benefit of cylindrical strength, with the repeatable manufacturing of pressing in 120° segments. Assembling the pieces in this manner also allows for custom lengths. The target is generally 20 foot lengths, but adjustments can be made on site to extend the culvert if necessary.
2) The repeatability of the 120° curved base unit allows for culverts to be any length assembled and also offer the opportunity to assemble on site to adjust to terrain conditions—i.e. 12 curved pieces can be transported as shells in a pick-up truck and assembled into a culvert on site from 1-4 units in length.
3) The wood culverts are made of natural wood and a small component by weight of resin, an inert polyurethane spread at 14 g/sqft or a bio-based resin. If left in service, the culvert is engineered to slowly bio-degrade over time, depending on soil conditions, from 3-10 years. No other culvert currently manufactured bio-degrades, thereby substantially reducing the road decommissioning costs.
The present invention also provides a method of producing differently shape culvert systems. There is a push in resource road management to have culverts without bottoms, as illustrated in
The present invention also provides a method 40 of
The panels 68 are removed from the forms and their axial edge surfaces 14 are profiled into complementary joints to produce the wood laminate semi-cylindrical panels 5, that can be permanently axially jointed into a wide variety of shapes that will be described herein, including axially connecting 120° arc length panels producing novel or unconventional shapes to support the flow of water under roadways.
The first and the second panels may be jointed to produce either a system having a greater circular arc length or a S-shape cross-section seen in
The method 80 may continue, with a repeating step 90, where steps 82, 84 and 86 can be repeated as often as required. For example, in a further step 84, a third panel is jointed to the as of yet non-jointed, second axial edge of the second panel once again with offset of at least 20% of the axial length of the second panel. The second (non-jointed) axial edge surfaces of the first panel and the third panel are also jointed. This type of construction (if the arc length of the panels 5 is 120°) produces a circular cross-section or tube where no butt-joints between sections of axially jointed panels 5 are aligned. This jointing construction can continue to be repeated to produce a length of circular cross section of virtually indefinite length. If non-120° arc length sections of the panels 5 (i.e. 45°, 90°, and 180°) are used various other closed tubular shapes may be produced.
The method can be easily extended to produce a wood laminate system having a tear drop cross section, obtained by jointing a first and second panel into a 240° semi-cylindrical shape and then permanently jointing a third axial edge surface of a third panel to a non-jointed first axial edge surface and a fourth axial edge surface of a fourth panel to a non-jointed second axial edge surface thereby producing a tear drop shaped cross-sectional member. The skilled person would understand that by repeating and adapting this procedure the various tear drops shapes found in
The joint produced by this method is particularly strong and no additional adhesive or glue is required to keep the axial joints together permanently. The axial joints produced by this method are virtually impossible to undo when jointed completely. The butt joints between different plates may include the application 88 of an adhesive in a preferred embodiment. With this simple method of joining axial edge surfaces a very large number variously shaped objects 92 can be produced. The method of claim 16, further comprising permanently jointing the first and the second panels together to produce an arc length of 240°.
The present wood laminate semi-cylindrical panels also relates to a system of combining curved plywood shells to further their utility and create new products such as:
Curved formwork (
A lightweight deck, or sandwich panel, (
A wall system (
Columns (
Curved ductwork (
Culverts (
The wood laminate semi-cylindrical panels 5 described herein have the following advantages 1) final system assembly, 2) end-use flexibility and 3) natural/green.
The scope of the claims set forth here should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
| Number | Date | Country | |
|---|---|---|---|
| 62109952 | Jan 2015 | US |
