Patent Application
20100021677
This invention relates to the coating of lengths of wood in a material such as plastic.
Many industries use materials which over time, perish or become otherwise unsuitable for continued use. One such industry is the wine industry which uses posts made of wood such as timber to provide a support structure to support the vines producing the grapes for the wine.
Over time, these posts may begin to perish and/or are damaged by machines which are used to pick the grapes from the vines. In such cases, the posts must be replaced with new posts. This can be a relatively expensive exercise as material such as timber can be costly.
In order to minimise the degradation of the timber, the timber is often treated with materials such as arsenic and creosote. These substances make the timber more resilient to the environment however, are toxic. This can cause serious problems to the environment if the chemical leaches into the ground and surrounding region. Furthermore, the use of such chemicals complicates the storage and/or disposal of damaged posts. In particular, damaged posts must be stored on a concrete or otherwise impermeable surface rather than on the ground to prevent the chemicals from leaching into the ground.
Even more seriously, the disposal of these damaged posts is complicated because burying of the posts results in a potential contamination hazard to the environment surrounding the burial site, while burning of the posts results in toxic fumes being produced and released into the atmosphere. Neither solution is acceptable and in fact, in some cases, is against regulatory requirements.
Alternative materials which are more resilient to the environment, such as plastics, have been used in an attempt to replace the chemically-treated wooden posts. While this addresses one of the problems, the plastic material is susceptible to other forms of environmental attack, particularly from exposure to sunlight. This can cause the plastic to degrade and weaken, causing the post to become deformed and less suitable for use as a support mechanism.
Accordingly, it is an object of the present invention to provide a method and product which can address some of the problems discussed above.
According to a first aspect of the present invention, there is provided a method of coating a length of wood having a first end and a second end, in a coating, the method including:
Preferably, the method further includes completely coating the length of wood and at least a portion of the end caps with the coating such that the length of wood is entirely covered by the coating and the first and second end caps.
Preferably, the coating is plastic.
Preferably, the plastic is polyethylene.
Preferably, the plastic is UV-resistant.
Optionally, the length of wood is a post.
Alternatively, the length of wood is a plank.
According to a second aspect of the present invention, there is provided a method of coating a length of wood having a first end and a second end, in a coating, the method including:
Preferably, the method further includes cutting through each of the first and second spacers to separate the length of wood from the first length of wood and the further length of wood.
Preferably, the step of coating results in covering the entire length of wood, including at least a portion of each of the spacers, such that the length of wood is entirely covered by the coating and the first and second spacers.
Optionally, the length of wood is a post.
Alternatively, the length of wood is a plank.
According to a third aspect of the present invention, there is provided a coated length of wood produced according to the method of the first aspect of the present invention.
According to a fourth aspect of the present invention, there is provided a coated length of wood produced according to the method of the second aspect of the present invention.
According to a fifth aspect of the present invention, there is provided a machine for coating a length of wood, the machine including:
Preferably the machine further includes means for disposing a first spacer between the first length of wood and the length of wood, and the second spacer between the length of wood and the further length of wood.
Preferably, the means for detecting the location of the first spacer and the second spacer includes means for detecting an irregularity in the surface of the coated first length of wood, the length of wood and the further length of wood.
According to a sixth aspect of the present invention, there is provided a coated length of wood made by the machine of the fifth aspect of the present invention.
According to a seventh aspect of the present invention, there is provided a coated length of wood including:
Preferably, the coating is a plastic.
Preferably, the plastic is polyethylene.
Preferably, the coating is UV resistant.
Preferably, the end caps are of the same material as the coating.
A preferred embodiment of the invention will now be described with reference to the following Figures in which:
FIG. 1—shows a coated length of wood according to an aspect of the present invention;
FIG. 2—shows a cross-sectional view of the coated length of wood of
FIGS. 3A to 3C—show a perspective view, a side view and a plan view of an end cap used in one aspect of the present invention;
FIGS. 4A to 4C—show a perspective view, a side view and a plan view of an alternative end cap according to one aspect of the present invention;
FIG. 5—shows an alternative coated length of wood according to an aspect of the present invention;
FIG. 6—shows a modified end cap of
FIG. 7—shows a modified end cap of
FIG. 8—shows a cross-sectional view of a coated length of wood using the end cap illustrated in
FIG. 9—shows an example arrangement of equipment used to produce a post of the present invention;
FIGS. 10A to 10C—show the spacer used in the present invention;
FIG. 11—shows a close-up of the spacer between two posts;
FIG. 12—shows the arrangement of
FIG. 13—shows a post resulting from a method of the present invention;
FIGS. 14A to 14C—show an alternative of the spacer of
FIG. 15A to 15C—show a further alternative to the spacer of
As can be seen, the length of wood is completely sealed in the plastic coating, including the ends. According to one aspect of the present invention, the ends of the post 40 are provided with end caps 31 and 33. These end caps are applied to the ends of the length of wood 20, and then the plastic coating 110 is applied to cover both the length of wood and at least the join between the end of the post and the end caps 31, 33. In this way, a post or other length of wood is able to be completely sealed if desired.
The plastics material may be any suitable material, including polyethylene, polyvinylchloride, polypropylene, an ethyl-vinyl chloride polymer or ABI-resin. The material used will preferably be UV resistant (eg black polyethylene) so as to minimise degradation once in use due to exposure to sunlight. If the plastic used is not black in colour, UV stabilisers could be added, however, this would add to the cost of the process.
Again, while a plastics material is preferred, any other suitable material may be used.
End cap 31 is a disc made of the same plastic in which the post 20 is to be coated. End cap 33 is identical to end cap 31. Of course, materials different to the coating material may be used to make end caps 31 and 33, however, there are specific advantages in having the materials the same, as will be described in more detail below.
It will be understood that end caps 31 and 33 will be able to be made in any suitable configuration to suit the length of wood being coated.
Looking at end cap 31 in
A similar arrangement will be produced if the length of wood is a plank or other-shaped length of wood, rather than a cylindrical post.
The aspect of the invention described above can be applied to individual lengths of wood. According to another aspect of the present invention however, the invention can be applied to a plurality of lengths of wood. According to this aspect of the invention, a production line can be provided to automate the process of coating multiple lengths of wood.
As post 20 is fed into the end of extruder 12, a spacer 30 is located at the end of post 20 and the post/spacer is inserted completely into extruder 12. A second post 20′ is then fed into extruder 12 directly behind post 20, sandwiching spacer 30 therebetween. A further spacer 30′ is then placed behind post 20′ and so on and so forth.
Preferably, the spacer 30 is attached to the end of post 20. This may be done by any suitable means. For example, the spacer 30 could be secured to post 20 by a suitable adhesive which is automatically applied just prior to placing spacer 30 onto the end of post 20. Alternatively, the surface of the ends of spacer 30 may have projections which can pierce the end of post 20 upon being pushed hard against the end of post 20, or spacer 30 may be secured by way of a nail using a conventional automatic nail gun. It will be appreciated that the securing of spacer 30 to post 20 need not be a strong one, but is preferred to maintain a reasonable connection between post 20 and spacer 30 until they are sealed together by the plastics material.
Spacers 30′ are stored in a magazine arrangement as are posts 20′.
The line of post 20, spacer 30, post 20′, spacer 30′ etc is then fed further into extruder 12, such that it passes by cross head 13, which extrudes a plastic material, so as to coat the line with a plastics material as would be understood by the person skilled in the art.
The plastics material is stored in container 11 and extruded therefrom at cross-head 13.
The plastics material may be any suitable material, including polyethylene, polyvinylchloride, polypropylene, an ethyl-vinyl chloride polymer or ABI-resin. The material used will preferably be UV resistant (eg black polyethylene) so as to minimise degradation once in use due to exposure to sunlight. If the plastic used is not black in colour, UV stabilisers could be added, however, this would add to the cost of the process.
Again, while a plastics material is preferred, any other suitable material may be used.
The material of spacer 30 is preferably the same as the plastic used to coat the posts, so that upon itself being coated, the spacer and coating will melt on the surface and fuse together, providing a strong bond and completely seal the post 20 and surrounding spacers 30 and 30′.
The plastics material in container 11 is heated to a temperature of about 210 degrees Celsius before being extruded to coat the posts. Spacers 30, 30′ may also be pre-heated to facilitate the bonding of the two plastics.
As the line passes cross-head 13 and is coated with the plastic, there results a continuous line of coated posts 20, 20′ and spacers 30, 30′. This is seen in
As will be discussed further below, while line 21 is essentially continuous, its surface exhibits an irregularity at the point where the spacers are, to enable the identification of their location within line 21.
The plastics coating will be applied at a thickness appropriate to the application as will be understood by the person skilled in the art, but will preferably be at least 3 mm in thickness. 5 mm has been found to be ideal for the present application.
Line 21 then proceeds to be cooled (eg in a bath or shower of water) to ensure that the line 21 is sufficiently cool to allow cutting (see further below) in to individual encapsulated poles.
The plastics coating will in fact also shrink as it cools, further ensuring a tight seal around post 20 and spacers 30, 30′.
Turning now to
The surface of spacer 30 may be ribbed or textured to provide a greater surface area and thereby greater bonding between the spacer and the plastics coating, if required.
It is also possible for spacer 30 to be different sizes and in particular, different lengths. This can be useful if posts 20 are of different lengths and spacers of different lengths may then be used to compensate for length irregularities to provide for encapsulated posts of more uniform length.
In use, spacer 30 is placed at one end of post 20, and a further post 20′, will then be placed against the other end of spacer 30 as described above and shown in more detail in
After coating with the plastics material, there results a continuous line 21 of post and spacer, encapsulated by the plastic 110, as can be seen in
The reason for irregularity 22 is to allow the position on spacer 30 within line 21 to be determined. This is because the line 21 must then be cut to separate the different posts 20, 20′ from each other.
Referring again to
Of course the identifying means could also be provided by any other suitable means such as a laser arrangement which is aimed at a detector on the other side of line 21, which is blocked by the regular surface of line 21 but allowed to pass through momentarily as irregularity 22 passes by.
Alternatively, identifying means 14 may be a metal detector which may detect the presence of a nail if nails are used as a securing means as discussed above.
Upon detecting the presence of irregularity 22, a signal is sent to cutting mechanism 15 to cut through spacer 30 to separate pole 20 from its previous and subsequent poles 20′.
The resulting product is a plastics encapsulated post 40 (see
A further embodiment of the spacer 30 of
Due to the method of the present invention, the ends of post 20 are also sealed due to the presence of the end caps 21, 33, to provide a completely sealed construction.
While in most applications, it is preferred that a complete seal is provided (for example if the wood post 20 has been treated with toxic materials, or if the encapsulated post is to be used in a harsh environment), it should be understood that apertures or the like could be provided, and that the coating need not be complete to provide a seal.
Post 20 may be a new piece of wood which is being used to provide a strengthening member for plastic coating 110 to provide a composite post 40. Alternatively, post 20 may be a recycled material but need not necessarily have been pre-treated with toxic chemicals.
It will however be appreciated that the maximum benefit of the invention is provided when using recycled wood which has been pre-treated with toxic chemicals, in which, case, plastic coating 110 completely encapsulates post 20 and end caps 31 and 33 to prevent the leaching of the chemicals into the environment.
It will also be appreciated that the plastic material 10 may also be from recycled material, further improving the efficiency of the method of the present invention.
It will also be appreciated that the post 40 can be produced individually by placing end caps 31 and 33 directly onto post 20 and moulding or otherwise coating the entire construction. It will be understood however, the method described above provides for a convenient way of mass-producing completely sealed posts, which would be otherwise extremely difficult to do.
The present invention provides many advantages to both the user of the invention as well as the end consumer. For example, the invention allows the end consumer (for example a vineyard) to dispose of its toxic waste in the form of damaged treated wooden posts, as well as perhaps expired plastic products which may form the basis of plastic casing 110.
Vineyards use large amounts of poly irrigation pipe (LDPE—Low Density Polyethylene) in designing and constructing the irrigation of their vines. A typical amount of plastic used every year by a vineyard is in the order of 40 tonnes. It is also estimated that the Australian wine industry replaces approximately five hundred thousand treated timber posts per year.
The end consumer will also benefit from being able to purchase the processed product to provide posts at a potentially lower rate than existing wooden treated posts. The sealed composite post 40 also relieves the user of the burden of dealing with potentially toxic material in storage, handling, use and disposal.
The user of the invention benefits by being able to source the raw materials from the end consumer, who would conceivably be happy to provide these materials free of charge, and provide the user of the invention with an income from reselling the processed posts back to the end consumer or other end consumers.
While the above has been described with reference to a particular application, it will be understood that the invention is equally applicable to other areas. For example, any product which uses pre-treated wood or other material may benefit from the present invention, for example sleepers and garden edging products.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2005901494 | Mar 2005 | AU | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/AU2006/000413 | 3/29/2006 | WO | 00 | 6/15/2009 |
