THERMALLY MODIFIED WOOD PRODUCTS AND PROCESSES

BACKGROUND

Board and batten siding or cladding is a classic exterior cladding style renowned for its rustic aesthetic. The design features alternating wide boards and narrow vertical battens. The wide boards form the primary surface and are typically installed vertically, while the battens cover the scams between the boards, enhancing both visual appeal and weather resistance. This siding style has a rich history, often associated with traditional and rural structures, contributing to a timeless and charming appearance. Materials for board and batten siding vary but commonly include wood, fiber cement, and engineered wood. The alternating pattern of boards and battens creates a textured facade, adding interest to buildings such as barns and cottages.

While board and batten siding offers a charming and classic aesthetic, there are some inefficiencies associated with its installation such as a labor-intensive installation that requires experience in the proper installation of board and batten siding. Each board and batten piece needs to be individually placed and secured, which can be time-consuming compared to other siding methods that come in larger, pre-made panels. There are also maintenance requirements with traditional wood board and batten siding. While aesthetically pleasing, traditional wood is susceptible to weathering, rot, and insect damage. Regular sealing is often necessary to protect the wood and ensure the longevity of the siding. This maintenance can be a drawback for homeowners seeking low-maintenance exteriors. Moreover, the seams between the boards can potentially be vulnerable to water ingress if not properly sealed during installation. This can lead to issues such as rot and mold over time.

The combination of wooden siding and insulated panels or insulated layers have been a popular choice for homeowners seeking a harmonious blend of aesthetic appeal and enhanced energy efficiency. This type of arrangement provides the timeless beauty of wood with an additional layer of insulation, such as foam board, rolled insulation, or sprayed foam insulation. The insulation significantly improves the siding or cladding's thermal performance, contributing to increased energy efficiency and a more comfortable living environment. Wooden siding offers the warmth and charm of natural wood while the insulation addresses concerns related to heat loss and energy consumption. Beyond its visual appeal, this arrangement helps create a well-insulated building envelope, potentially reducing heating and cooling costs. Homeowners can enjoy the classic look of wood siding without compromising on energy efficiency.

An inherent challenge associated with wooden siding lies in the potential for warping over time due to insufficiently dried wood during installation, and potential for pest infestations. Wood naturally contains moisture, and if the siding is not adequately dried before the insulation is integrated, the ongoing drying process can lead to deformation and warping. As the wood dries post-installation, it may shrink or expand unevenly, causing the siding to warp, buckle, or create gaps between panels. This warping not only compromises the aesthetic integrity of the siding but can also impact its functionality, potentially leading to decreased insulation effectiveness and reduced overall durability.

SUMMARY OF THE INVENTION

According to a first aspect, a cladding apparatus includes a thermally modified wooden body having a first side edge and a second side edge, a face portion, and a raised face portion. The apparatus further includes the first side edge includes a protruding portion and the second side edge includes an opening configured to receive the protruding portion of an adjacent cladding apparatus The apparatus further includes wherein the face portion contacts at least a portion of the raised face portion about a face transition edge.

In some embodiments, the face transition edge is chamfered.

According to many embodiments, the raised face portion is positioned about the first side edge.

In other embodiments, the face portion is positioned about the first side edge.

According to some embodiments, further comprising a thermally modified wooden body length and wherein the opening extends along the thermally modified wooden body length. In many embodiments, the thermally modified wooden body is a unitary structure.

According to other embodiments, the raised face portion has a raised face height and the face portion has a face height and the face height is at most about the raised face height.

In some other embodiments, the protruding edge of the first side edge has a radius. According to some other embodiments, the protruding edge of the first side edge is a rabbet.

In many embodiments, the face transition edge has a radius.

According to some embodiments, the face transition edge has a convex shape.

In other embodiments, the face transition edge has a concave shape.

According to many embodiments, the face transition edge has a profile that is non-continuous.

In some embodiments, the protruding portion is a plurality of protruding portions.

According to some other embodiments, the protruding portion is a plurality of protruding portions.

In many embodiments, the protruding portion is a continuous protruding portion.

According to some other embodiments, the second side edge includes a second protruding portion.

In some embodiments, the apparatus further includes a thermally modified wooden body length and wherein the protruding portion extends along the thermally modified wooden body length.

According to other embodiments, the raised face portion is positioned between the first and second side edges.

In some embodiments, the raised face portion is positioned closer to the first side edge.

According to many embodiments, the raised face portion is positioned closer to the second side edge.

According to a second aspect, a thermally modified cladding system for a building includes a plurality of thermally modified cladding members, each having a first side edge with a protruding portion, a second side edge with an opening configured to receive the protruding portion, and a face portion that contacts at least a portion of a raised face portion about a face transition edge. The system further includes wherein a first thermally modified cladding member of the plurality of thermally modified cladding members is positioned adjacent to a second thermally modified cladding member of the plurality of thermally modified cladding members such that the first side edge of the first thermally modified cladding member is received by the second side edge of the second thermally modified cladding member.

In some embodiments, the raised face portion of the first thermally modified cladding member is positioned about the second side edge.

According to many embodiments, the protruding portion of the first thermally modified cladding member has a radius.

In other embodiments, the protruding portion of the first thermally modified cladding member is a rabbet.

According to some embodiments, the first thermally modified member of the plurality of thermally modified cladding members is a unitary structure.

In many embodiments, each of the thermally modified cladding members has a length and the opening extends along the length.

According to other embodiments, the raised face portion of the first thermally modified cladding member has a raised face height and the face portion of the first thermally modified cladding member has a face height and the face height is at most about the raised face height.

According to a third aspect, a method of manufacturing a thermally modified cladding apparatus includes the step of thermally modifying a wooden member. The method further includes the step of forming a protruding portion about a first side edge of the thermally modified wooden member. The method further includes the step of forming an opening about a second side edge of the thermally modified wooden member, the opening being configured to receive the protruding portion. The method further includes the step of removing a portion of a top surface of the thermally modified wooden member to forma a raised face portion and face portion. The method further includes wherein the face portion contacts at least a portion of the raised face portion about a face transition edge.

In some embodiments, the protruding portion has a radius. According to many embodiments, the protruding portion is a rabbet.

In other embodiments, the face transition edge is chamfered.

According to a fourth aspect, a method of installing a thermally modified cladding system includes the step of providing a plurality of thermally modified cladding members, each having a first side edge with a protruding portion, a second side edge with an opening configured to receive the protruding portion, and a face portion that contacts at least a portion of a raised face portion about a face transition edge. The method further includes the step of positioning a first thermally modified cladding member of the plurality of thermally modified cladding members about a structure. The method further includes the step of positioning a second thermally modified cladding member of the plurality of thermally modified cladding members about the structure and adjacent to the first thermally modified cladding member such that the first side edge of the first thermally modified cladding member is received by the second side edge of the second thermally modified cladding member.

According to a fifth aspect, a cladding apparatus includes a thermally modified wooden body having a first side edge, a second side edge, a face portion, and a rear portion positioned opposite of the face portion having a rear opening. The cladding member further includes the first side edge includes a protruding portion and the second side edge includes an opening configured to receive the protruding portion of an adjacent cladding apparatus. The cladding member further includes an insulating member positioned at least partially within the rear opening.

In some embodiments, the insulating member is a closed cell foam insulating member.

According to many embodiments, the insulating member is an open cell foam insulating member.

In other embodiments, the insulating member is a mineral wool insulating member.

According to some embodiments, the rear opening has volume and the insulating member fills at most about the volume.

In many embodiments, the thermally modified wooden body has a length and wherein the rear opening extends along the length.

According to other embodiments, the thermally modified wooden body has a depth and the rear opening extends at least about halfway into the depth.

In some other embodiments, the protruding portion is a plurality of protruding portions.

According to some other embodiments, the protruding portion of the first side edge has a radius.

In many other embodiments, the protruding portion of the first side edge is a rabbet.

In some embodiments, the rear opening is positioned between the first side edge and the second side edge.

According to many embodiments, the rear opening is positioned closer to the first side edge.

In other embodiments, the rear opening is positioned closer to the second side edge.

According to some embodiments, the rear opening has a concave shape.

In many embodiments, the rear opening is non-continuous.

According to other embodiments, the protruding portion is a continuous protruding portion. In some other embodiments, the second side edge includes a second protruding portion.

According to other embodiments, the thermally modified wooden body has a length and wherein the protruding portion extends along the length.

In many embodiments, the rear opening has a first rear opening side surface and a second rear opening side surface, the first and second rear opening side surfaces have a side surface profile.

According to some embodiments, the side surface profile for first rear opening side surface is convex.

In many other embodiments, the side surface profile for first rear opening side surface is concave.

According to yet another embodiment, the side surface profile for first rear opening side surface is substantially shaped as a female rabbet.

In some embodiments, the side surface profile for first rear opening side surface is different from the side surface profile for the second rear opening side surface.

According to a sixth aspect, a thermally modified cladding system for a building includes a plurality of thermally modified cladding members, the plurality of thermally modified cladding members having a first side edge with a protruding portion, a second side edge with an opening configured to receive the protruding portion, a face portion, a rear portion positioned opposite of the face portion having a rear opening, and an insulating member positioned at least partially within the rear opening. The system further includes wherein a first thermally modified cladding member of the plurality of thermally modified cladding members is positioned adjacent to a second thermally modified cladding member of the plurality of thermally modified cladding members such that the first side edge of the first thermally modified cladding member is received by the second side edge of the second thermally modified cladding member.

According to a seventh aspect, a method of manufacturing a thermally modified cladding apparatus includes thermally modifying a wooden member. The method further includes forming a protruding portion about a first side edge of the thermally modified wooden member and forming an opening about a second side edge of the thermally modified wooden member, the opening configured to receive at least a portion of the protruding portion. The method further includes removing a portion of a rear surface of the thermally modified wooden member to form a rear opening. The method further includes positioning an insulating member at least partially within the rear opening.

In some embodiments, the insulating member is coupled to a rear opening surface.

According to many embodiments, positioning the insulating member at least partially within the rear opening further comprises spraying an expanding foam material into the rear opening.

According to an eighth aspect, a method of installing a thermally modified cladding system includes providing a plurality of thermally modified cladding members, the plurality of thermally modified cladding members having a first side edge with a protruding portion, a second side edge with an opening configured to receive the protruding portion, a face portion, a rear portion positioned opposite of the face portion having a rear opening, and an insulating member positioned at least partially within the rear opening. The method further includes positioning a first thermally modified cladding member of the plurality of thermally modified cladding members about a structure. The method further includes positioning a second thermally modified cladding member of the plurality of thermally modified cladding members about the structure and adjacent to the first thermally modified cladding member such that the first side edge of the first thermally modified cladding member is received by the second side edge of the second thermally modified cladding member.

According to a ninth aspect, a method of installing a thermally modified cladding system includes providing a plurality of thermally modified cladding members, the plurality of thermally modified cladding members having a first side edge, a second side edge, a face portion, a rear portion positioned opposite of the face portion having a rear opening, and an insulating member positioned at least partially within the rear opening. The method further includes positioning a first thermally modified cladding member of the plurality of thermally modified cladding members about a structure. The method further includes positioning a second thermally modified cladding member of the plurality of thermally modified cladding members about the structure and adjacent to the first thermally modified cladding member such that the first side edge of the first thermally modified cladding member is adjacent to the second side edge of the second thermally modified cladding member.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying representative figures, wherein like reference numerals refer to like elements, in which:

FIG. 1 is a schematic illustration of an embodiment of a wood thermal modification system.

FIG. 2 is a graph showing the temperature applied to the interior space of the kiln in relation to the time that it is applied to thermally modify a wooden material according to an embodiment.

FIG. 3 is a graph showing the temperature applied to the interior space of the kiln in relation to the time that it is applied to adequately dry the wooden material prior or in conjunction with thermally modifying the wooden material according to an embodiment.

FIG. 4 is a flowchart illustrating an example method for thermally modifying a wooden material according to an embodiment.

FIG. 5 is a flowchart illustrating a method for thermally modifying a wooden material according to another embodiment.

FIG. 6A is a front side perspective view of a thermally modified cladding member.

FIG. 6B is a rear side perspective view of a thermally modified cladding member.

FIG. 7 is a side profile view of a thermally modified cladding member.

FIG. 8 is a front side perspective view of a thermally modified cladding system.

FIG. 9 is a side profile view of a thermally modified cladding system.

FIG. 10 is a front side perspective view of a thermally modified cladding member with interlocking side profiles.

FIG. 11 is a side profile view of a thermally modified cladding member configured with rabbet joints.

FIG. 12 is a side profile view of a thermally modified cladding member with a face transition edge with a radius.

FIG. 13 is a side profile view of a thermally modified cladding member with a chamfered face transition edge.

FIG. 14 is a flowchart illustrating a method for manufacturing a thermally modified cladding member according to an embodiment.

FIG. 15 is a flowchart illustrating a method for installing a thermally modified cladding member according to an embodiment.

FIG. 16 is a front side perspective view of an insulated thermally modified cladding member or apparatus.

FIG. 17 is a side profile view of an insulated thermally modified cladding member.

FIG. 18 is a rear plan view of an insulated thermally modified cladding member.

FIG. 19 is a side profile view of an embodiment of an insulated thermally modified cladding member with an angular rear opening side surface profile.

FIG. 20 is a side profile view of an embodiment of an insulated thermally modified cladding member with a rounded rear opening side surface profile.

FIG. 21 is a side profile view of an embodiment of an insulated thermally modified cladding member with a rabbet shaped rear opening side surface profile.

FIG. 22 is a side profile view of an embodiment of an insulated thermally modified cladding member with a first rear opening side surface profile that is different from a second rear opening side profile.

FIG. 23 is a side profile view of an insulated thermally modified cladding system.

FIG. 24 is a flowchart illustrating a method for manufacturing an insulated thermally modified cladding member according to an embodiment.

FIG. 25 is a flowchart illustrating a method for installing an insulated thermally modified cladding member according to an embodiment.

FIG. 26 is a flowchart illustrating a method for installing an insulated thermally modified cladding system according to another embodiment.

The drawings are not necessarily to scale and certain features may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness.

DETAILED DESCRIPTION
Thermal Modification Process

Reference is now made to FIG. 1, which depicts an embodiment of a wood thermal modification system 100. The system 100 includes wooden material 10, a stick placer 12, a kiln 14 including one or more kilns 14, a vent 16, a cooling sub-system 18, and a finishing sub-system 28. Wooden material 10 is first sorted and stacked at by the stick placer 12 in such a configuration that the wooden material 10 is in condition for being thermally modified. The stacked and sorted wooden material 10 is then placed inside the kiln 14. The kiln 14 heats up and cools down the wooden material 10 in a specific manner and sequence to thermally modify wooden material 10, which will be discussed in greater detail below. Once the kiln 14 has finished its cool down sequence, the kiln vent 16 is opened to safely vent heated gases and other particulates that may become airborne during the thermal modification process. Then, the wooden material 10 is transferred to the cooling sub-system 18 for cooling the wooden material 10 down, such as to ambient temperatures, and for ensuring that the wooden material 10 has the proper moisture content. Then the wooden material 10 is transferred to the finishing sub-system 28 to be de-stacked by the destacker 20, molded by the moulder 22, have a coating applied by the coating applicator 24 and then have the coating cured in the curing oven 26.

Wooden material 10 is generally considered to be lumber that has been processed into consistent or standard shapes and sizes. Such sizes may include, for example, boards that have cross-sectional dimensions of 2 inches by 4 inches, 2 inches by 6 inches, 2 inches by 8 inches. It should be understood that the dimensional sizes listed are merely exemplary dimensions and any suitable cross-sectional dimensions can be treated by the process described herein.

With continued reference to FIG. 1, the stick placer 12 may be configured to organize or stack the wooden material 10 with consistent spacing between one piece of wooden material 10 and the next piece of wooden material 10. According to many embodiments, the wooden material 10 is stacked to have a consistent or sufficient spacing of at least 0.5 inches between each individual piece of wooden material 10. This is done by placing a first row of individual pieces of wooden material 10 with the desired horizontal spacing between each board, then placing a spacing stick on top of at least a portion of each board of the first row of wooden material 10. The spacing stick will have a thickness of the desired spacing between each board. For example, if it is desired that each board have a spacing of 0.5 inches between them, then the thickness of the spacing stick will be no more than 0.5 inches. The length and width of the spacing sticks may be any suitable dimension such that the desired spacing of the individual pieces of the wooden material 10 is maintained. It should be understood that a spacing of 0.5 inches is only one example and that other spacings are envisioned including 0.75 inches, 1 inch, or any other suitable spacing. The spacing between each individual piece of wooden material 10 ensures that the surface area of each piece of wooden material 10 is adequately exposed to the kiln's 14 interior temperature. The larger the spacing between individual pieces of wooden material 10, the fewer overall pieces can be thermally modified in the kiln 14 in a single process.

The kiln 14 is configured to receive the wooden material 10 that has been stacked by the stick placer 12 and thermally modify it. As shown in FIG. 2, the kiln 14 thermally modifies the wooden material 10 by heating the wooden material 10 over a first period of time 36 according to a heating rate 30 up to a holding temperature 32. The kiln 14 then maintains the holding temperature 32 for a second of period time 38. Finally, kiln 14 begins dropping the temperature of the kiln 14 over a third period of time 40 according to a cooling rate 34. During the heating cycle, the kiln 14 is configured to operate in a low oxygen environment and under a general vacuum. During the heating cycle, organic material in the wooden material 10 will begin to be extracted from the interior portions of the wooden material 10 to the surface of the wooden material 10, such as carbohydrates, sugar, or water. The organic material will either remain on the surface of the wooden material 10, become airborne and be removed from the kiln 14 under vacuum pressure, or remain airborne inside the kiln 14. It should be understood that the thermal cycle illustrated in FIG. 2 is only an example of how a wooden material may be thermally modified. A variety of other thermal cycles may be used in kiln 13 to remove or extract organic matter from a wooden material 10 or set of wooden material 10. Such thermal cycles may contain any number of steps or stages, such as those shown in FIG. 2.

In many embodiments, the oxygen deprived environment is accomplished via a vacuum pump system. The system is configured to exhaust or remove the airborne organic material extracted from the wooden material 10 out of the kiln 14. While the interior space of the kiln 14 does not reach a true vacuum, the low pressure applied to the interior of the kiln 14 is suitable if it is capable to remove at least some of the airborne extracted organic material from the interior of the kiln 14. The low pressure applied also mitigates the potential hazard of the wooden material 10 igniting inside the interior space of the kiln 14 by maintaining an oxygen level that is insufficient or unlikely to cause or sustain a portion of the wooden material 10 igniting.

The vacuum system generally includes at least one vacuum pump and a filter. The vacuum pump creates the low pressure in the interior space of the kiln 14 and then filters the air pulled from the interior space of the kiln 14 through the filter. The filter will need to be periodically replaced, serviced, or cleaned as it will become clogged or filled with the organic material extracted from the wooden material 10. In many embodiments, the vacuum pump is a plurality of vacuum pumps positioned about the exterior of the kiln 14. In many embodiments, the vacuum system is integral to a portion of the kiln 14 while in other embodiments, the vacuum system is positioned remotely from the kiln 14 with only the necessary piping connections from the interior the kiln 14 to the vacuum system. The vacuum system may be positioned on top of the kiln 14 or on one of the sides of the kiln 14.

Extracting the organic material from the wooden material 10 will increase the rot resistance of the wooden material 10 and thereby lengthen its overall lifespan. The organic material that is present inside the wooden material 10 acts as a food or nutrient source for many types of insects and fungi. Therefore, by extracting and removing a large portion of the organic material the wooden material 10 is not as susceptible to degrading due to being attacked or eaten away by said insects, fungi, or other biologicals.

The first period of time 36, the second period of time 38, and the third period of time 40 will all vary depending on the specifications of the wooden material 10 that is being thermally modified. For wooden material 10 that has a higher moisture content, the periods of time 36, 38, 40 will need to be extended to ensure that the moisture content is brought down to less than 1%. Similarly for thicker wooden material 10, the periods of time 36, 38, 40 will need to be extended or adjusted to ensure that the entire thickness of the wooden material 10 is thermally modified and not just the internal portions of the wooden material 10 that are proximate to the surface faces of the wooden material 10. It should be understood that while the starting temperature 42 of the kiln 14 is depicted as 80 degrees Fahrenheit, this temperature is only exemplary. For example, the kiln's 14 starting temperature 42 is whatever the ambient temperature is of the kiln 14 is. Accordingly, the periods of time 36, 38, 40 will need to be adjusted, either extended or shortened, based on the starting temperature 42 of the kiln 14.

Once the third period of time 40 has elapsed, the kiln vent 16 is opened to vent out remaining hot air inside the kiln 14 and any airborne organic material that remained airborne inside the kiln 14. According to many embodiments, the kiln vent 16 is manually operated while in other embodiments, the kiln vent 16 is automatically opened at the conclusion of the third period of time or other final stage of the thermal modification process. The operation of the kiln vent 16 allows for hot air to be vented directly to the exterior atmosphere while minimizing the impact on the internal temperature of the building that the kiln 14 operates in. This allows for lower cooling costs for the building that the kiln 14 is operated in because the majority of the hot air from inside the kiln 14 can be vented outside of the building that the kiln 14 is operating in. After the kiln vent 16 has been opened, the door to the kiln 14 may be opened and the wooden material 10 may be removed from the kiln 14.

In embodiments with multiple kilns 14, the kiln vent 16 may be a single vent 16 with connections made to each individual kiln 14. In other embodiments with multiple kilns 14, each kiln 14 has its own kiln vent 16 that is operated separately from the other kilns 14 and their respective kiln vents 16. Ensuring that the interior space of the kiln 14 is properly vented also mitigates a potential safety hazard of an operator unintentionally breathing in a unsafe amount of the airborne organic material.

With continued reference to FIG. 1, the cooling sub-system 18 is the system configured to cool the wooden material 10 heated by the kiln 14 down to the ambient temperature or other desired temperature. When the wooden material 10 exits the kiln 14, it is at an elevated temperature. In some embodiments, the elevated temperature is between about 170 degrees Fahrenheit and about 180 degrees Fahrenheit. The wooden material 10 may also generally have a moisture content of less than 1% by weight upon exiting the kiln 14. The cooling sub-system 18 will both cool the wooden material 10 down to the ambient or other desired temperature but also bring the moisture content of the wooden material 10 up, such as to about 6% moisture content by weight. In some embodiments, the cooling sub-system 18 is integrated with the kiln 14 such that when the kiln 14 concludes its cycle (i.e., the third period of time 40 has elapsed) then the cooling sub-system 18 will begin injecting steam into the interior of the kiln 14 to raise the moisture content of the wooden material 10 and cool it down to an ambient or other desired temperature. In other embodiments, the cooling sub-system 18 is a separate sub-system from the kiln 14 such that the wooden material 10 must be removed from the kiln 14 and transported to the cooling sub-system 18 for further cooling. In such embodiments with a separate cooling sub-system 18, the cooling sub-system 18 may be a temperature and humidity-controlled environment to facilitate the cooling of the wooden material 10 to ambient or other desired temperatures and bringing the moisture content up to the target moisture content level. In other embodiments, the separate cooling sub-system 18 may not be a temperature or humidity-controlled environment and the wooden material 10 is allowed to naturally cool to ambient or other desired temperatures and reach its target moisture content.

The finishing sub-system 28 includes a destacker 20, a moulder 22, a coating applicator 24, and a curing oven 26. Once the wooden material 10 is received by the finishing sub-system 20 from the cooling sub-system 18, the wooden material 10 is first de-stacked such that individual pieces of the wooden material 10 can be processed through the finishing sub-system 20.

The moulder 22 is configured to remove the impurities that remained on the surface of the wooden material 10 while the wooden material 10 was being heated and cooled in the kiln 14. The moulder 22 is also configured to mold the wooden material 10 into any desirable shape for various uses. In a preferred embodiment, the moulder 22 removes approximately 1/64 of an inch from the surfaces of the wooden material 10 to remove the top layer of impurities and ensure a level surface throughout. When the 1/64 of material is removed from the surfaces of the wooden material 10, sharp edges may remain where one surface of the wooden material 10 meets another surface. These sharp edges are both a safety hazard and a weak point for the wooden material 10 as the sharp edges can act as stress concentration nodes, allowing stress in the wooden material 10 to cause cracks in the wooden material 10 that originate from the sharp edges. To mitigate this, the moulder 22 is also configured to radius the sharp edges of the wooden material 10 such that the edges of the wooden material 10 may be rounded in certain implementations.

With continued reference to FIG. 1, the coating applicator 24 applies a coating to the wooden material 10. This coating can be a stain to attain a certain aesthetic look or it may be a coating that is intended to further seal and preserve the wooden material 10. Due to the relatively low moisture content of the wooden material 10 that has been thermally modified, the wooden material 10 will generally absorb the coating deeper into the wooden material 10 such that the coating will last longer without having to be reapplied. The curing oven 26 cures the particular coating that was applied by the coating applicator 24. The time that the wooden material 10 spends in the curing oven 26 is dependent on the particular type of coating that is applied to the wooden material 10. In certain embodiments, the wooden material 10 spends approximately 1 minute in the curing oven 26.

Reference is now made to FIG. 3, which depicts a temperature vs. time graph for a thermal modification heating and cooling cycle inside a kiln 14 with an additional drying period. If the wooden material 10 has an elevated moisture content, then the wooden material 10 must first be dried to a moisture content that is suitable for thermal modification. Generally, wooden material 10 with a moisture content above 15% by weight will need to be dried at a relatively low temperature until the moisture content is below 15% by weight. As shown in FIG. 3, the kiln 14 is first heated to a drying temperature 44 and held at the drying temperature 44 over a drying period of time 46.

Reference is now made to FIG. 4, which depicts a flowchart illustrating a method for thermally modifying a wooden material 400. The method 400 begins at block 402 where a wooden material 10 is deposited in an interior of a kiln 14 and the kiln 14 is sealed. The method 400 continues to block 404 where a lower pressure is applied to the interior of the kiln 14. The method 400 continues to block 406 where a cyclic heating is applied to the wooden material 10, wherein the cyclic heating is characterized by an increase rate applied for a first duration, a peak temperature value or range 32 is applied for a second duration to maintain a desired peak temperature, and a decrease rate applied for a third duration, wherein the second duration is less than the first duration or the third duration. It should be understood that the cycle described in block 406 may be any desired thermal cycle having any number of intermediate thermal steps or stages. The method 400 continues to block 408 where a vent 16 is opened that is configured to remove heated air from the interior of the kiln 14 as well as airborne organic material.

Reference is now made to FIG. 5, which depicts a flowchart illustrating another method for thermally modifying a wooden material 500. The method 500 begins at block 502 where a wooden material 10 is provided and the wooden material 10 has a first moisture content. The method 500 continues at block 504 where the wooden material 10 is placed in an interior space of a kiln 14. The method 500 continues at block 506 where a low pressure is applied to the interior space of the kiln 14. The method 500 continues to block 508 where the interior space of the kiln 14 is heated to a first temperature over a first period of time 36 up to a desired peak temperature value or range 32, maintaining the desired peak temperature value or range 32 for a second period of time 38, and lowering the temperature of the interior space of the kiln 14 to a second temperature value over a third period of time 40. Just as with block 406 described above in connection with FIG. 4, block 508 may include any number of intermediate heating, cooling, and/or temperature maintaining steps or stages. The method 500 concludes at block 510 where at least a portion of the heated interior space of the kiln 14 is vented, wherein after venting the interior space of the kiln 14 the wooden material 10 has a second moisture content that is lower than the first moisture content.

Thermally Modified Cladding

While utilizing wooden material 10 for the exterior siding or cladding for a structure has various drawbacks such as such as rot or warping. Utilizing a wooden material 10 that has been thermally modified addresses many of those drawbacks. For example, thermally modified cladding members 110 can be affixed to a structure and will likely not rot or warp over time. Furthermore, thermally modified cladding members 110 will not have to be sealed or painted as often as similarly structured members formed of wooden material 10 that has not been thermally modified.

Reference is now made to FIGS. 6A and 6B, which respectively depict a front and rear side perspective views of a thermally modified cladding member 110. A thermally modified cladding member 110 includes a face portion 112, a raised face portion 114, a first side edge 116, a second side edge 118, and a face transition edge 120. The raised face portion 114 can be positioned about the first side edge 116, the second side edge 118, or any position there in between. The raised face portion 114 adds structural rigidity along the length of the thermally modified cladding member 110. In the embodiments depicted in FIGS. 6A and 6B, the face portion 112 extends from the first side edge 116 Along the width of the thermally modified cladding member 110 up to the face transition edge 120. When the raised face portion 114 is positioned about the first side edge 116 or the second side edge 118, the thermally modified cladding member 110 resembles a board and batten exterior siding or cladding section.

Reference is now made to FIG. 7, which depicts a side profile view of a thermally modified cladding member 110. As shown, the first side edge 116 has a protruding portion 122 and the second side edge 118 has an opening 124 formed therein. The opening 124 is configured to receive the protruding portion 122 of an adjoining or adjacent thermally modified cladding member 110. In this manner, a plurality of thermally modified cladding members 110 may be positioned adjacent to one another to form a thermally modified cladding system 200 as shown in FIGS. 8 and 9 and discussed in further detail below.

With continued reference to FIG. 7, the raised face portion 114 also includes a first raised face side 117 and a second raised face side 119. The distance between the first raised face side 117 and the second raised face side 119 defines the width of the raised face portion 114. As shown in FIG. 7, the first raised face side 117 is coextensive with the second side edge 118 of the thermally modified cladding member 110. The lower portion of the second raised face side 119 that contacts the face portion 112 defines the face transition edge 120. It should be understood that while the second raised side 119 is depicted to perpendicularly contacts the face portion 112, other configurations are also envisioned. For example, the second raised side 119 can contact the base portion 112 at an angle that is greater than 90°, an angle that is less than 90°, or any other suitable angle or curved transition. It should also be understood that while the embodiments depicted in FIGS. 6A-7 have only one face transition edge 120, other configurations are also envisioned. For example, the raised face portion 114 may be positioned in between the first side edge 116 and the second side edge 118 such that both the first raised side face 117 and the second raised side face 119 contact the face portion 112. In such an embodiment, the points where the first raised side face 117 contacts the face portion 112 is a first face transition edge 120 and the points where the second raised side face 119 contacts the face portion 112 is a second face transition edge 120.

It should be understood, that while the raised face portion 114 and the face portion 112 is currently depicted in an arrangement such that the face portion 112 and the raised face portion 114 resemble a piece of a board and batten cladding design, other configurations are also envisioned. For example, in some embodiments the thermally modified cladding member 110 is formed such that the raised face portion 114 substantially covers the top surface of the thermally modified cladding member 110 and the face portion 112 is formed in the shape of thin channels that extend along the length of the raised face portion 114. In such embodiments, the face portion 112 and the raised face portion 114 resemble a “beadboard” design. The raised face portion 114 and the face portion 112 can be arranged in any suitable or desired arrangement.

With continued reference to FIG. 7, the face transition edge 120 is the point about which the face portion 112 and the raised face portion 114 contact or abut one another. The face transition edge 120 maybe a sharp edge created by the raised face portion 114 contacting the face portion 112 about a perpendicular angle. However, as shown in FIGS. 12-13, the face transition edge 120 can have various profiles. For example, FIG. 12 depicts a side profile view of a thermally modified cladding member 110 with a convex face transition edge 132. The convex shape of the convex face transition edge 132 is configured to reduce the stress concentration about the face transition edge 120, to reduce or minimize the likelihood of cracks originating about the face transition edge 120. The convex shape of the convex face transition edge 132 can also be configured to have an ornamental top design to mimic the look of caulking being applied to the face transition edge 120. Another example of the various types or configurations of the face transition edge 120 is shown in FIG. 13 which depicts a side profile view of a thermally modified cladding member 110 with a chamfered face transition edge 134. The raised or chamfered shape of the chamfered face transition edge 134 similarly is configured to reduce the stress concentration about the chamfered face transition edge 134 to reduce or minimize the likelihood of cracks originating about the chamfered face transition edge 134. The chamfered or raised shape of the chamfered face transition edge 134 can also be configured to have an ornamental top design to mimic the look of caulking being applied to the face transition edge 120. The face transition edge 120 can be configured to have a continuous outer profile or an outer profile that is non-continuous. A non-continuous outer profile can help to mimic the look or appearance of a joint that has had caulking applied to it by a user in the manner that most joints between adjoined or adjacent thermally modified cladding members 110 will have some caulking applied thereto to prevent or minimize the potential for water to seep through the joint and behind the thermally modified cladding system 200.

With continued reference to FIG. 7, the raised face portion 114 has a raised face height 115 and the face portion 112 has a face height 113. It should be understood that while the raised face height 115 is shown as being approximately 1.5 times the face height 113, other configurations are also envisioned. For example, the raised face height 115 can be equal to the face height 113, be approximately half of the face height 113, or any other suitable configuration.

It should be understood, that while the protruding portion 122 is depicted as having a rounded or generally convex shape, the protruding portion 122 can have a concave shape, a convex shape, an angular shape, or any other suitable shape such that it can be received by the opening 124. For example, FIG. 11 depicts a side profile view of a thermally modified cladding member 110 with a male rabbet 128 positioned about the first side edge 116 and a female rabbet 130 positioned about the second side edge 118. In the embodiment depicted in FIG. 11, The protruding portion 122 protrudes out perpendicularly from the first side edge 116 with a male rabbet end 128 formed therein. The male rabbet end 128 is defined by an end that protrudes out and has at least two interior right angles such that the outer profile consists substantially of three substantially flat sides. The female rabbet 130 is configured to receive the male rabbet end 128 of an adjoining or adjacent thermally modified cladding member 110.

Reference is now made to FIGS. 8 and 9, which respectively depict a front side perspective view and a side profile view of a thermally modified cladding system 200. As shown, thermally modified cladding system 200 includes at least a first thermally modified cladding member 110A and a second thermally modified cladding member 110B. The first thermally modified cladding member 110A and the second thermally modified cladding member 110B can be configured identically or similarly to the thermally modified cladding member 110 as described throughout this disclosure. A thermally modified cladding system 200 is configured to link, connect, or couple together a plurality of thermally modified cladding members 110 to cover or clad the interior or exterior walls of a structure. To create or form a thermally modified cladding system 200, the first side edge 116 of the second thermally modified cladding member 110B is positioned to interface with or otherwise couple to the second side edge 118 of the first thermally modified cladding member 110A. The protruding portion 122 of the first side edge 116 of each thermally modified cladding member 110 in the thermally modified cladding system 200 is configured to interface with or otherwise coupled to the opening 124 in the second side edge 118 of each adjoining or adjacent thermally modified cladding member 110. The protruding portion 122 or male coupling portion is configured to be received by the opening 124. The interface between the protruding portion 122 and the opening 124 can be configured to generate sufficient bonding forces such that when the protruding portion 122 is received by the opening 124, no further components or actions are necessary to join or couple the adjacent thermally modified cladding members 110 to one another. In other embodiments, an adhesive such as glue, wood glue, or any other suitable adhesive maybe added to the interface between the protruding portion 122 and the opening 124 to generate sufficient bonding forces to prevent the separation or decoupling of the adjacent thermally modified cladding members 110.

In some implementations, for enhanced pest control measures, a pest repellant such as a boratic salt solution can be strategically applied to the different surfaces of the thermally modified cladding member 110. The pest repellant can be applied to the surfaces of the opening 124 and the protruding portion 122. In implementations that utilize an adhesive to couple the protruding portion 122 to the opening 124, the adhesive can be mixed with and applied with a pest repellant solution contained therein such that the adhesive and pest repellant are applied in a single operation. The pest repellant creates a deterrent barrier against unwanted insects and pests, such as wood eating insects like termites, from burrowing between the protruding portion 122 and the opening 124. As the space between the opening 124 and the protruding portion 122 is not commonly accessible when the thermally modified cladding member 110 is installed, it is advantageous to use a pest repellant with a prolonged duration of effectiveness, for example, a boratic salt solution. Borates act as a slow-acting poison to insects, disrupting their digestive systems and ultimately leading to their demise. Unlike some conventional pesticides that may degrade quickly, borates have a persistent impact. The duration of efficacy depends on various factors such as environmental conditions, exposure to elements, and the specific application method. In indoor settings with minimal exposure to weather, a properly applied boratic salt solution can remain effective for an extended period, often several months to even years. A boratic salt solution tends to adhere well to surfaces, forming a protective barrier that continues to repel pests over time. It should be understood that a pest repellant can be applied to any or all of the surfaces of the thermally modified cladding member 110.

Other examples of suitable pest repellants include boric acid, copper-based products, aluminum sulfate, essential oils, and cedarwood oil. Boric acid, which, similar to borates, is an effective deterrent against termites. Boric acid disrupts the digestive systems of pests and acts as a slow-acting poison. Boric acid can remain effective for an extended period, providing long-lasting protection against termites. For copper-based products, copper compounds, such as copper naphthenate or copper borate, are known for their termite-resistant properties as they create a barrier that termites avoid. Copper-based products have a lasting effect and can provide ongoing protection against termites. Aluminum sulfate disrupts the feeding and digestive processes of termites. It is effective in deterring termites from infesting wood. While not as persistent as some other repellents, aluminum sulfate can offer mid-term protection and may require periodic reapplication. Certain essential oils, such as clove, thyme, and neem, have repellent properties against termites as they interfere with the insects' ability to feed and survive. Essential oils provide a natural and eco-friendly option, but their longevity may require more frequent application. Cedarwood oil is known for its termite-repelling qualities as it disrupts the nervous system of termites and acts as a deterrent. Cedarwood oil provides moderate-lasting protection, and reapplication may be necessary for sustained effectiveness.

Reference is now made to FIG. 10, which depicts a front side perspective view of an embodiment of a thermally modified cladding member 110 with a first side edge 116 having a plurality of protruding portions 126 interspersed between a plurality of openings 127 (not expressly shown in FIG. 10). The plurality of protruding portions 126 are positioned along the first side edge 116 and have a respective opening 127, of the plurality of openings 127, positioned between each respective protruding portion 126, of the plurality of protruding portions 126. In other embodiments, the plurality of openings 127 may be provided as one continuous opening configured to receive the plurality of protrusions 126. In many such embodiments, the first side edge 116 and the second side edge 118 will have substantially identical outer profiles as one another.

Reference is now made to FIG. 14, which depicts a flowchart illustrating a method for manufacturing a thermally modified cladding system 1400. The method 1400 begins at block 1402 with thermally modifying a wooden member 110. The method 1400 continues at block 1404 with forming a protruding portion 122 about a first side edge 116 of the thermally modified wooden member 110. The method 1400 continues to block 1406 by forming an opening 124 about a second side edge 118 of the thermally modified wooden member 110, the opening 124 configured to receive the protruding portion 122. The method 1400 continues to block 1408 by removing a portion of a top surface of the thermally modified wooden member 110 to form a raised face portion 114 and face portion 112. The method 1400 concludes at block 1410 wherein the face portion 112 contacts at least a portion of the raised face portion 114 about a face transition edge 120. It should be understood that the order of the performance of the blocks of this method 1400 may be arranged and/or performed in any suitable or desired manner.

Reference is now made to FIG. 15, which depicts a flowchart illustrating a method for installing a thermally modified cladding system 1500. The method 1500 begins at block 1502 where a plurality of thermally modified cladding members 110 are provided and each having a first side edge 116 with a protruding portion 122, a second side edge 118 with an opening 124 configured to receive the protruding portion 122, and a face portion 112 that contacts at least a portion of a raised face portion 114 about a face transition edge 120. The method 1500 continues at block 1504 with positioning a first thermally modified cladding member 110 of the plurality of thermally modified cladding members 110 about a structure. The method 1500 concludes at block 1506 with positioning a second thermally modified cladding member 110 of the plurality of thermally modified cladding members 110 about the structure and adjacent to the first thermally modified cladding member 110 such that the first side edge 116 of the first thermally modified cladding member 110 is received by the second side edge 118 of the second thermally modified cladding member 110.

It should be understood, that while the thermally modified cladding member 110 may be thermally modified using a wood thermal modification system 100 according to the method 400 or the method 500, other configurations are also envisioned. For example, the thermally modified cladding member 110 may be thermally modified utilizing any known or otherwise existing wood thermal modification process.

Thermally Modified Wood with Insulating Insert

While utilizing wooden material 10 for the exterior siding or cladding of a structure has various drawbacks such as rot and warping. Utilizing a wooden material 10 that has been thermally modified addresses many of those drawbacks. For example, insulated thermally modified cladding members 110 can be affixed to a structure and will likely not rot or warp over time and will add an extra insulating barrier for the structure. Furthermore, insulated thermally modified cladding members 210 will not have to be sealed or painted as often as similarly structured members formed of wooden material 10 that has not been thermally modified.

Reference is now made to FIG. 16, which depicts a front side perspective view of an insulated thermally modified cladding member 210. An insulated thermally modified cladding member 210 includes a front or top surface 212, a first side edge 216, a second side edge 218, and a rear opening 214 with an insulating member 220 positioned therein. the first side edge 216 has a protruding portion 217 and the second side edge 218 has an opening 219 formed therein. The rear opening 214 includes a rear opening surface 226, a first rear opening side surface 228, and a second rear opening side surface 230. The rear opening 214 has a has a rear opening width that is defined by the distance between the first rear opening side surface 228 and the second rear opening side surface 230. The opening 219 is configured to receive the protruding portion 217 of an adjoining or adjacent insulated thermally modified cladding member 210. In this manner, a plurality of insulated thermally modified cladding members 210 may be positioned adjacent to one to form an insulated thermally modified cladding system 300 as shown in FIG. 23 and discussed in further detail below.

Reference is now made to FIGS. 17 and 18, which respectively depict a side profile view and a rear plan view of an insulated thermally modified cladding member 210. As shown, the insulated thermally modified cladding member 210 has a depth 224 that is defined by the distance between the rear or bottom surface 215 and the top surface 212. Similarly, the rear opening 214 has an opening depth 222 that is defined by the distance between the bottom surface 215 and the rear opening surface 226. It should be understood, that while the rear opening depth 222 is shown to be approximately half of the depth 224 of the insulated thermally modified cladding member 210, other configurations are also envisioned. For example, the rear opening depth 222 can be ¼ of the depth 224, the rear opening depth 222 can be ⅓ of depth 224, the rear opening depth 222 can be ⅔ of depth 224, or any other suitable fraction of the depth 224. The larger the depth 222 is the deeper the insulating member 220 can extend into the insulated thermally modified cladding member 210.

Insulating member 220 is shown to have an insulation depth 225 And to substantially fill the volume of the rear opening 214 has defined by the area between the first rear opening side surface 228, the second rear opening side surface 230, and the rear opening depth 222. It should be understood, that while the insulating member 220 is shown to completely fill the rear opening volume, other configurations are also envisioned. For example, in many embodiments the insulating member 220 does not fill the rear opening volume entirely. In other embodiments, insulating member 220 has an insulation depth 225 that is greater than the rear opening depth 222. In such embodiments the insulating member 220 extends beyond or past the bottom surface 215 such that when the insulated thermally modified cladding member 210 is placed or affixed to a structure the insulating member 220 will be compressed between the walls of the structure and the rear opening surface 226 such that the insulating member 220 substantially fills the rear opening volume.

Insulating member 220 is coupled to the rear opening 214 by an adhesive applied to the various surfaces of the rear opening 214, such as the first rear opening side surface 228, the second rear opening side surface 230, and the rear opening surface 226. The adhesive can be applied to all of such surfaces or only a subset of the surfaces. Also, the insulating member 220 can be coupled to the rear opening by the fit between the insulating member 220 and the various surfaces of the rear opening 214, such as the first rear opening side surface 228, the second rear opening side surface 230, and the rear opening surface 226 contact and collectively hold the insulating member 220 therein. In embodiments that utilize an insulating member 220 that is formed of a material that can be sprayed into the rear opening 214, such as and expanding spray foam, the insulating member 220 expands upon application, filling gaps and adhering to the various rear opening surfaces.

In some implementations, for enhanced pest control measures, a pest repellant such as a boratic salt solution can be strategically applied to the different surfaces of the rear opening 214 prior to positioning the insulating member 220 about or within the rear opening 214. The pest repellant can be applied to the first rear opening side surface 228, the second rear opening side surface 230, or the rear opening surface 226. In implementations that utilize an adhesive to couple the insulating member 220 to the rear opening 214, the adhesive can be mixed with and applied with a pest repellant solution contained therein such that the adhesive and pest repellant are applied in a single operation. The pest repellant creates a deterrent barrier against unwanted insects and pests from burrowing between the insulating member 220 and the surfaces 226, 228, 230 of the rear opening 214.

As the space between the insulating member 2120 and the surfaces 226, 228, 230 of the rear opening 214 are not commonly accessible when the insulated thermally modified cladding member 210 is installed, it is advantageous to use a pest repellant with a prolonged duration of effectiveness, for example, a boratic salt solution. Borates act as a slow-acting poison to insects, disrupting their digestive systems and ultimately leading to their demise. Unlike some conventional pesticides that may degrade quickly, borates have a persistent impact. The duration of efficacy depends on various factors such as environmental conditions, exposure to elements, and the specific application method. In indoor settings with minimal exposure to weather, a properly applied boratic salt solution can remain effective for an extended period, often several months to even years. A boratic salt solution tends to adhere well to surfaces, forming a protective barrier that continues to repel pests over time.

Reference is now made to FIGS. 19-22, which respectively depict side profile views of an insulated thermally modified cladding member 210 with various rear opening side surface profiles. In FIG. 19, the first rear opening side surface 228 and the second rear opening side surface 230 of an insulated thermally modified cladding member 210 have angular rear side surface profile 232. As shown, the angular rear side surface profile 232 extends laterally into the first rear opening side surface 228 and the second rear opening side surface 230 respectively. In this manner, an angular edge insulating member 233 with similarly shaped side edges as the angular rear side surface profile 232 is mechanically held within the the rear opening 214 by the fitment of the angular rear side surface profile 232 and the angular side edges of the angular edge insulating member 233. In FIG. 20, the first rear opening side surface 228 and the second rear opening side surface 230 of an insulated thermally modified cladding member 210 have a rounded rear side surface profile 234. As shown, the rounded rear side surface profile 234 extends laterally into the first rear opening side surface 228 and the second rear opening side surface 230 respectively. In this manner, a rounded edge insulating member 235 with similarly shaped side edges as the rounded rear side surface profile 234 is mechanically held within the rear opening 214 by the fitment of the rounded rear side surface profile 234 and the rounded side edges of the rounded edge insulating member 235. In FIG. 21, the first rear opening side surface 228 and the second rear opening side surface 230 of an insulated thermally modified cladding member 210 have a rabbet shaped rear side surface profile 236. As shown, the rabbet shaped rear side surface profile 236 extends laterally into the first rear opening side surface 228 and the second rear opening side surface 230 respectively. In this manner, a rabbet shaped edge insulating member 237 with similarly shaped side edges as the rabbet shaped rear side surface profile 236 is mechanically held within the rear opening 214 by the fitment of the female rabbet shaped rear side surface profile 236 and the male rabbet shaped side edges of the rabbet shaped edge insulating member 237. It should be understood, that while the various side surfaces profiles 232, 234, 236, are shown to extend laterally into the insulated thermally modified cladding member 210, other configurations are also envisioned. For example, the various side surface profiles 232, 234, 236, can extend laterally into the rear opening 214 such that they are received by the side edges of the insulating members 233, 235, 237. In other embodiments, rear opening surface 226 may include a uniform or non-uniform surface profile such that the insulating member 220 resides in or adjacent to such profiles.

Reference is now made to FIG. 22, which depicts a side profile view of an insulated thermally modified cladding member 210 that has a first rear opening side surface 228 and a second rear opening side surface 230 with different side profiles. As shown, the first rear opening side edge 228 has a rounded rear side surface profile 234 and the second rear opening side edge 230 has an angular rear side surface profile 232. It should be understood, that while the insulated thermally modified cladding member 210 is depicted with an angular side surface profile 232 and a rounded side surface profile 234, other configurations are also envisioned. For example, the insulated thermally modified cladding member 210 can have a rabbet shaped side profile 236 and an angular side surface profile 232. Any combination of the side surface profiles 232, 234, and 236, or other side profiles are envisioned and may be utilized by embodiments of the insulated thermally modified cladding member 210.

The insulating member 220 is formed, in one embodiment, of a closed-cell foam type material. Closed-cell foam is a type of rigid foam insulation characterized by its sealed cellular structure, in which individual cells are completely enclosed and not interconnected. This unique composition imparts the material with excellent insulation properties, as the closed cells create a barrier that restricts the passage of air and moisture. Due to its high thermal resistance and resistance to water absorption, closed-cell foam is commonly used in applications such as insulation. Insulating member 220 can also be formed of open-cell foam material. Open-cell foam is a type of flexible foam insulation with interconnected cells that are not completely sealed, allowing air to permeate the material. This composition lends open-cell foam a softer and more pliable texture compared to closed-cell foam. Open-cell foam has a high degree of sound absorption. Insulating member 220 can also be formed of a mineral wool material or fiberglass insulating material. Mineral wool insulation is a type of thermal insulation made from natural or synthetic minerals, typically basalt or rock, processed into fibers. Its excellent fire resistance, moisture repellence, and thermal performance make it a popular choice for exterior insulation systems. Applied as rigid boards or batts, mineral wool insulation serves as a durable and effective solution for enhancing a building's energy efficiency and weather resistance when used as exterior insulation.

It should be understood, that while the protruding portion 217 is depicted as having a rounded or generally convex shape, the protruding portion 217 can have a concave shape, a convex shape, an angular shape, or any other suitable shape such that it can be received by the opening 219. For example, an insulated thermally modified cladding member 210 with can have a protruding portion 217 with a male rabbet positioned about the first side edge 216 and a female rabbet positioned about the second side edge 218. In such implementations, the protruding portion 217 protrudes out perpendicularly from the first side edge 216 with a male rabbet end formed therein. The male rabbet end is defined by an end that protrudes out and has at least two interior right angles such that the outer profile consists substantially of three substantially flat sides. The female rabbet is configured to receive the male rabbet end of an adjoining or adjacent insulated thermally modified cladding member 210. In other embodiments, the protruding portion 217 may include two or more protrusions and opening 219 will provide one or more openings to accommodate such a protruding portion 217.

Reference is now made to FIG. 23, which depicts a side profile view of an insulated thermally modified cladding system 300. An insulated thermally modified cladding system 300 includes a plurality of insulated thermally modified cladding members 210. As shown, an insulated thermally modified cladding system 300 includes at least a first insulated thermally modified cladding member 210A and a second insulated thermally modified cladding member 10B. The first insulated thermally modified cladding member 210A and the second insulated thermally modified cladding member 210B can be configured identically or similarly to the insulated thermally modified cladding member 210 as described throughout this disclosure. An insulated thermally modified cladding system 300 is configured to link, connect, or couple together a plurality of insulated thermally modified cladding members 210 to cover or clad the interior or exterior walls of a structure. To create or form an insulated thermally modified cladding system 300, the first side edge 216 of the second insulated thermally modified cladding member 210B is positioned to interface with or otherwise couple to the second side edge 218 of the first insulated thermally modified cladding member 210A. The protruding portion 217 of the first side edge 216 of each insulated thermally modified cladding member 210 in the insulated thermally modified cladding system 300 is configured to interface with, be at least partially received by, or otherwise coupled to the opening 219 of the second side edge 218 of each adjoining or adjacent insulated thermally modified cladding member 210. The protruding portion 217 or male coupling portion is configured to be received by the opening 219. The interface between the protruding portion 217 and the opening 219 can be configured to generate sufficient bonding forces such that when the protruding portion 217 is received by the opening 219, no further components or actions are necessary to join or couple the adjacent insulated thermally modified cladding members 210 to one another. In other embodiments, an adhesive such as glue, wood glue, or any other suitable adhesive maybe added to the interface between the protruding portion 217 and the opening 219 to generate sufficient bonding forces to prevent the separation or decoupling of the adjacent insulated thermally modified cladding members 210.

Reference is now made to FIG. 24, which depicts a flowchart illustrating a method for manufacturing a thermally modified cladding system 2400. The method 2400 begins at block 2402 with thermally modifying a wooden member. The method 400 continues at block 404 with forming a protruding portion 217 about a first side edge 216 of the thermally modified wooden member. The method 2400 continues to block 2406 by forming an opening 219 about a second side edge 218 of the thermally modified wooden member, the opening 219 configured to receive the protruding portion 217. The method 2400 continues to block 2408 by removing a portion of a rear surface of the thermally modified wooden member to form a rear opening 214. The method 2400 concludes at block 2410 with positioning an insulating member 220 at least partially within the rear opening 214. It should be understood that the various blocks of method 2400 may be performed in any suitable order.

Reference is now made to FIG. 25, which depicts a flowchart illustrating a method for installing an insulated thermally modified cladding system 2500. The method 2500 begins at block 2502 where a plurality of thermally modified cladding members 210 are provided. The plurality of thermally modified cladding members 210 having a first side edge 216 with a protruding portion 217, a second side edge 218 with an opening 219 configured to receive the protruding portion 217, a face portion 212 and a rear portion positioned opposite of the face portion 212 having a rear opening 214, and an insulating member 220 positioned at least partially within the rear opening 214. The method 2500 continues at block 2504 with positioning a first thermally modified cladding member 10 of the plurality of thermally modified cladding members 210 about a structure. The method 2500 concludes at block 2506 with positioning a second thermally modified cladding member 210 of the plurality of thermally modified cladding members 210 about the structure and adjacent to the first thermally modified cladding member 210 such that the first side edge 216 of the first thermally modified cladding member 210 is received by the second side edge 218 of the second thermally modified cladding member 210.

Reference is now made to FIG. 26, which depicts a flowchart illustrating a method for installing an insulated thermally modified cladding system 2600. The method 2600 begins at block 602 where a plurality of thermally modified cladding members 210 are provided. The plurality of thermally modified cladding members 210 having a first side edge 216, a second side edge 218, a face portion 212, a rear portion positioned opposite of the face portion 212 having a rear opening 214, and an insulating member 220 positioned at least partially within the rear opening 214. The method 2600 continues at block 2604 with positioning a first thermally modified cladding member 210 of the plurality of thermally modified cladding members 210 about a structure. The method 2600 concludes at block 2606 with positioning a second thermally modified cladding member 210 of the plurality of thermally modified cladding members 210 about the structure and adjacent to the first thermally modified cladding member 210 such that the first side edge 216 of the first thermally modified cladding member 210 is adjacent to the second side edge 218 of the second thermally modified cladding member 210.

It should be understood, that while the insulated thermally modified cladding member 210 and the insulated thermally modified cladding system 300 may be thermally modified using a wood thermal modification system 100 according to the method 400 or the method 500, other configurations are also envisioned. For example, the insulated thermally modified cladding member 210 or the insulated thermally modified cladding system 300 may be thermally modified utilizing any known or otherwise existing wood thermal modification process.

Although embodiments of a thermally modified cladding member 110, an insulated thermally modified cladding member 210, insulated thermally modified cladding system 300, method for manufacturing a thermally modified cladding system 1400, method for manufacturing an insulated thermally modified cladding system 2400, and method for installing an insulated thermally modified cladding system 2500, have been described in detail, those skilled in the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.

In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “left” and “right,” “front” and “rear,” “above” and “below” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including,” and thus not limited to its “closed” sense, that is the sense of “consisting only of.” A corresponding meaning is to be attributed to the corresponding words “comprise,” “comprised” and “comprises” where they appear.

In addition, the foregoing describes some embodiments of the disclosure, and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.

Furthermore, the disclosure is not to be limited to the illustrated implementations, but to the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the disclosure. Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.

Number	Date	Country
63579760	Aug 2023	US
63616375	Dec 2023	US
63616367	Dec 2023	US

THERMALLY MODIFIED WOOD PRODUCTS AND PROCESSES

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CPC

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CROSS-REFERENCE TO RELATED APPLICATIONS

Provisional Applications (3)