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Patent 2438632 Summary

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(12) Patent Application: (11) CA 2438632
(54) English Title: LAMINATED CROSS LUMBER AND METHOD OF MAKING SAME
(54) French Title: ELEMENT EN BOIS LAMELLE A PLI TRANSVERSAL ET METHODE DE REPRODUCTION
Status: Dead
Bibliographic Data
(51) International Patent Classification (IPC):
  • B32B 21/00 (2006.01)
  • B27G 11/00 (2006.01)
  • B27M 1/08 (2006.01)
  • B27M 3/00 (2006.01)
(72) Inventors :
  • BRUNET, ALAIN (Canada)
(73) Owners :
  • PINEXEL INC. (Canada)
(71) Applicants :
  • PINEXEL INC. (Canada)
(74) Agent: NORTON ROSE FULBRIGHT CANADA LLP/S.E.N.C.R.L., S.R.L.
(74) Associate agent:
(45) Issued:
(22) Filed Date: 2003-08-29
(41) Open to Public Inspection: 2005-02-28
Examination requested: 2008-04-10
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data: None

Abstracts

English Abstract





A method for making a laminated cross lumber beam
comprising the step of stacking elongated wood members and
bonding adjacent longitudinal faces thereof along a bonding
plane to form intermediary beams. The method further
includes a step of selecting intermediary beams having a
width greater than a predetermined value and cutting them
lengthwise perpendicularly to the bonding planes such as to
form panels. The panels and uncut intermediary beams then
form sub-beam elements. The method also includes a step of
bonding at least two sub-beam elements together side by side
to form the laminated cross lumber beam. This method is
simplified by the use of small wood members which eliminates
the need to cut the intermediary beam to form the sub-beam
element. It requires a minimum of steps, thus minimizing
costs. The product of this method is a beam with optimized
mechanical properties and visual appearance.


Claims

Note: Claims are shown in the official language in which they were submitted.





I CLAIM:

1. A method for making a laminated cross lumber beam
comprising the steps of:
a) Providing a plurality of elongated wood
members, each having a top longitudinal face and a bottom
longitudinal face extending between a pair of opposed
longitudinal sides;
b) Stacking a plurality of elongated wood members
with the top and bottom longitudinal faces of adjacent
stacked elongated wood members bonded to one another along a
bonding plane such as to form a number of intermediary beams
of similar height generally corresponding to a desired
height of the laminated cross lumber beam to be made;
c) Cutting each intermediary beam having a width
greater than a predetermined value along a lengthwise plane
generally perpendicular to the bonding planes thereof such
as to form a plurality of panels, the panels and uncut
intermediary beams forming sub-beam elements having opposed
longitudinal sides generally perpendicular to the bonding
planes thereof;
d) Joining at least two sub-beam elements together
with the opposed facing longitudinal sides of adjacent sub-
beam elements bonded to one another to form the laminated
cross lumber beam.

2. A method for making a laminated cross lumber beam
according to claim 1, wherein the elongated wood members are
composed of softwood.

3. A method for making a laminated crass lumber beam
according to claim 1, wherein at least one of the elongated
wood members is partially composed of flash.

4. A method for making a laminated cross lumber beam
according to claim 1, wherein at least one of the elongated

-10-


wood members is composed of at least two wood pieces joined
together end to end.

5. A method for making a laminated cross lumber beam
according to claim 1, wherein before step b the method
further comprises a step of planing the elongated wood
members in order to maximize contact therebetween along the
bonding planes.

6. A method for making a laminated cross lumber beam
according to claim 1, further comprising a step of planing
at least one of two surfaces defined by the sides of the
superposed elongated wood members of at least one of the
intermediary beams obtained in step b.

7. A method for making a laminated cross lumber beam
according to claim 1, further comprising a step of planing
at least one of the opposed sides of at least one of the
sub-beam elements obtained in step c.

8. A method for making a laminated cross lumber beam
according to claim 1, wherein step c further comprises
adhering one of at least two panels and at least two
intermediary beams end to end, thereby forming a sub-beam
element having at least a joint.

9. A method for making a laminated cross lumber beam
according to claim 8, wherein the joint is a S joint.

10. A method for making a laminated cross lumber beam
according to claim 8, wherein between steps c and d, the
method further comprises a step of selecting the sub-beam
elements to insure that the joint in the sub-beam element is
sufficiently apart from similar joints in the adjacent sub-
beam elements in the laminated cross lumber beam to avoid a
weakening thereof.

-11-



11. A method for making a laminated cross lumber beam
according to claim 1, wherein between steps c and d, the
method further comprises a step of selecting the sub-beam
elements to insure that adjacent sub-beam elements in the
laminated cross lumber beam are from different intermediary
beams.

12. A method for making a laminated cross lumber beam
according to claim 1, wherein between steps c and d, the
method further comprises a step of selecting the sub-beam
elements to optimize a final visual appearance of the
laminated cross lumber beam.

13. A method for making a laminated cross lumber beam
according to claim 1, further comprising the step of:
e) Adhering at least two laminated cross lumber
beams end to end in order to obtain a laminated cross lumber
beam of a desired length.

14. A method for making a laminated cross lumber beam
according to claim 1, further comprising the step of:
e) Planing at least one longitudinal surface of
the laminated cross lumber beam in order to obtain desired
final dimensions.

15. A method for making a laminated wood timber from a
plurality of elongated wood members, comprising the steps
of:
a) Using the wood members to make at least two
laminated beams having a width corresponding generally to a
width of the elongated wood members, wherein a plurality of
the wood members are joined together face to face along
joining planes to form each of the laminated beams;
b) Cutting lengthwise the laminated beams having a
width greater than a predetermined value into panels, the
panels and uncut laminated beams forming sub-timber

-12-



elements, each sub-timber element having longitudinal sides
generally perpendicular to the joining planes thereof;
c) joining at least two sub-timber elements side
by side to form a laminated wood timber.

16. A method for making a laminated wood timber according to
claim 15, wherein the elongated wood members are composed of
softwood.

17. A method for making a laminated wood timber according to
claim 15, wherein at least one of the elongated wood members
is partially composed of flash.

18. A method for making a laminated wood timber according to
claim 15, wherein at least one of the elongated wood members
is composed of at least two wood pieces joined together end
to end.

19. A method for making a laminated wood timber according to
claim 15, wherein before step a the method further comprises
a step of planing the elongated wood members in order to
maximize contact therebetween along the joining planes.

20. A method for making a laminated wood timber according to
claim 15, further comprising a step of planing at least one
of two longitudinal surfaces extending perpendicularly to
the joining planes of at least one of the laminated beams
obtained in step a.

21. A method for making a laminated wood timber according to
claim 15, further comprising a step of planing at least one
of the longitudinal sides of at least one of the sub-timber
elements obtained in step b.

22. A method for making a laminated wood timber according to
claim 15, wherein step b further comprises adhering one of
at least two panels and at least two laminated beams end to

-13-



end, thereby forming a sub-timber element having at least a
joint.

23. A method for making a laminated wood timber according to
claim 22, wherein the joint is a S joint.

24. A method for making a laminated wood timber according to
claim 22, wherein between steps b and c, the method further
comprises a step of selecting the sub-timber elements to
insure that the joint in the sub-timber element is
sufficiently apart from similar joints in the adjacent sub-
timber elements in the laminated wood timber to avoid a
weakening thereof.

25. A method for making a laminated wood timber according to
claim 15, wherein between steps b and c, the method further
comprises a step of selecting the sub-timber elements to
insure that adjacent sub-timber elements in the laminated
wood timber are from different beams.

26. A method for making a laminated wood timber according to
claim 15, wherein between steps b and c, the method further
comprises a step of selecting the sub-timber elements to
optimize a final visual appearance of the laminated wood
timber.

27. A method for making a laminated wood timber according to
claim 15, further comprising the step of:
d) Adhering at least two laminated wood timbers
end to end in order to obtain a laminated wood timber of a
desired length.

28. A method for making a laminated wood timber according to
claim 15, further comprising the step of:
d) Planing at least one longitudinal surface of
the laminated wood timber in order to obtain desired final
dimensions.

-14-

Description

Note: Descriptions are shown in the official language in which they were submitted.



CA 02438632 2003-08-29
LAMINATED CROSS LUMBER AND METHOD OF MAKING SAME
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to static wood
s structures. More particularly, the present invention relates
to a method for making a laminated wood product.
Background Art
A variety of laminated wood beams are used in
construction work today as joists, girders, posts, columns
~o or other structural pieces. Laminated wood beams are known
to be stronger, more resistant and more dimensionally stable
than continuous wood beams. Unfortunately, the fabrication
of traditional laminated beams requires the use of wood
members of dimensions and quality that have become
i5 increasingly harder to obtain due to the fact that nowadays
the trees available are a lot smaller than they once were.
Thus, the wood members are often cut from trees of
relatively small diameter, such as trees from plantation or
northern forests, thereby producing members of low grade,
zo small dimensions and with a high proportion of flash.
Also, the cutting of wood for various elements
required in construction work generates a great quantity of
pieces of small dimensions, difficult to reuse thus usually
considered as waste. This high proportion of wasted material
z5 greatly increases fabrication costs.
Accordingly, a number of alternative laminated
wood products methods have been developed in order to be
able to use smaller wood members and/or wood members of
lower grade. One example of such a product is presented in
3o US Patent No. 4,568,577 issued February 4, 1996 to
Fischetti, where squared timbers of uniform thickness are
joined edge to edge and end to end in order to form a
laminated structure with at least one longitudinal void.
While this configuration allows for the recycling of timbers
-1-


CA 02438632 2003-08-29
of small length by joining them end to end through a pencil
joint, it does not allow the use of timbers of varying
thicknesses. Moreover, defects such as flash must be removed
before assembling the timbers, thereby reducing the
proportion of waste material that can be reused.
A number of alternative methods gave also been
developed to produce laminated wood products. US Patent No.
6,466,412 issued September 10, 2002 to Mathis presents a
method of making glulam wood beams using strips of planks of
io identical thickness glued side to side. Careful planning in
the placement of the planks of various widths is needed to
avoid aligned joints in the beam causing beam weakness. If
the joints between planks are aligned, a strip can be cut
from the beam perpendicularly to the original strips and
then attached thereto to reinforce the beam. However, this
additional strip greatly increases the time and costs of
manufacturing by augmenting the number of steps in the
process.
CA Patent Application No. 2,350,380 filed June 13,
zo 2001 by Grenier presents a method for making a lamellated
wood product of high mechanical properties from wood slats
of uniform thickness. The wood slats are bonded end to end
to a desired length and edge bonded into a panel, the panel
is cut into smaller panels of identical width, the small
z5 panels are face bonded to form a beam, the beam is cut to
form smaller beams, and the small beams are cut into
lamellated wood product. This process requires numerous
steps in order to obtain the final product. Moreover, the
requirement of uniform thickness prevents the use of slats
3o containing defects such as flash.
Accordingly, there is a need for a method of
making laminated wood beams that requires a minimum of
steps, while easily integrating the use of potential waste
material such as small wood members of non standard
35 dimensions and wood members containing flash.
-2-


CA 02438632 2003-08-29
SUN~?ARY OF INVENTION
It is therefore an aim of the present invention to
provide a method for making a laminated cross lumber beam
that is simple.
s It is another aim of the present invention to
provide a method for making a laminated cross lumber beam
that can be further simplified by the use of small wood
members.
It yet another aim of the present invention to
~o provide a method for making a laminated cross lumber beam
that easily integrates the use of wood members containing
flash.
It is an additional aim of the present invention
to provide a method for making a laminated cross lumber beam
~s that easily integrates the use of wood members of non
standard dimensions.
It is a further aim of the present invention to provide a
method for making a laminated cross lumber beam that
produces a beam of superior mechanical properties and
2o pleasing visual appearance.
Therefore, in accordance with the present
invention, there is provided a method for making a laminated
cross lumber beam comprising the steps of:
a) Providing a plurality of elongated wood members,
2s each having a top longitudinal face and a bottom
longitudinal face extending between a pair of opposed
longitudinal sides;
b) Stacking a plurality of elongated wood members with
the top and bottom longitudinal faces of adjacent
3o stacked elongated wood members bonded to one another
along a bonding plane such as to form a number of
intermediary beams of similar height generally
corresponding to a desired height of the laminated
cross lumber beam to be made;
3s c) Cutting each intermediary beam having a width
greater than a predetermined value: along a lengthwise
plane generally perpendicular to the bonding planes
-3-


CA 02438632 2003-08-29
thereof such as to form a plurality of panels, the
panels and uncut intermediary beams forming sub-beam
elements having opposed longitudinal sides generally
perpendicular to the bonding planes thereof;
s d) Joining at least two sub-beam elements together with
opposed facing longitudinal sides of adjacent sub-beam
elements bonded to one another to form the laminated
cross lumber beam.
Further in accordance with the present invention,
~o there is provided a method for making a laminated wood
timber from a plurality of elongated wood members,
comprising the steps of:
a) Using the wood members to make at least two
laminated beams having a width corresponding generally
is to a width of the elongated wood members, wherein a
plurality of the wood members are joined together face
to face along joining planes to form each of the
laminated beams;
b) Cutting lengthwise the laminated beams having a
zo width greater than a predetermined value into panels,
the panels and uncut laminated beams forming sub-timber
elements, each sub-timber element having longitudinal
sides generally perpendicular to the joining planes
thereof;
z5 c) joining at least two sub-timber elements side by
side to form a laminated wood timber.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus generally described the nature of the
invention, reference will now be made to the accompanying
3o drawings, showing by way of illustration a preferred
embodiment thereof and in which:
Fig.l is a perspective view of a laminated cross
lumber beam according to a preferred embodiment of the
present invention;
-4-


CA 02438632 2003-08-29
Fig.2A to 2C are perspective views of wood members
used as starting material in the method according to a
preferred embodiment of the present invention;
Fig.3 is a perspective view of a beam obtained by the face
s to face lamination of the wood members;
Fig.4 is a perspective view showing the step of
cutting the beam shown in Fig.3;
Fig.5 is a perspective view of panels produced by
the cutting operation illustrated in Fig.4; and
~o Fig.6 is a perspective view illustrating the step
of joining two panels to provide for the fabrication of
beams of greater length.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to Fig. l, a laminated cross lumber
15 beam or timber 10 is composed of a plurality of elongated
wood pieces 11 bonded together face to face and side to
side. This laminated cross lumber beam 10 presents the
advantages of superior mechanical and physical properties
and a visual aspect similar to a standard laminated beam,
zo while being produced using a simple method that can be
further simplified by the use of small wood members as a
starting material. The simplicity of the process minimizes
fabrication costs. The method used to produce this laminated
cross lumber beam is described in the following.
z5 The starting material for the method according to
the present invention is a plurality of elongated wood
members. 12. The wood members 12 include two longitudinal
sides 14 and top and bottom wider longitudinal faces 16.
Shown in Fig.2 are different examples of wood members 12
3o that can be used: integral members (Fig.2A), smaller members
joined end to end through finger joints 18 or any other
appropriate joints (Fig.2B), and members partially composed
of flash 20 (Fig.2C). The wood members 12 are preferably
made of high density softwood such as black spruce or jack
35 pine of low grade (no. 3 and/or economy). Of course, other
-5-


CA 02438632 2003-08-29
types and grades of wood can be used, as needed. The wood
members also need to have an appropriate humidity content,
for example between 12o and 150. Preferred dimensions for
the wood members are a thickness (Xl) of 0.75 to 2 inches, a
s width (Y) of I.5 to 8 inches and a length (Z) of 6 inches to
20 feet, but of course any other appropriate dimensions can
be used.
An optional preliminary step of evening the
dimensions of the wood members 12 can be performed, for
~o example by planing. This can be done t:o eliminate all or
part of the variations in width and/or thickness within the
wood members 12, thereby optimizing the adhesion between
adjacent wood members 12 by increasing the surface of
contact therebetween. This step also allows the removal of
at least part of the flash 20 if so desired. The wood
members 12 are selected and/or transformed so as to obtain
groups of wood members 12 of similar width (Y).
Glue is then put on the longitudinal faces 16 of the wood
members I2 of similar width (Y) before pressing them
zo together face to face in order to form a beam 22 as shown in
Fig.3. For a product required to perform according
to mechanical criteria, the glue used is preferably a
structural wood glue such as polyurethane (PUR),
isocyanates, phenol-resorcinol-formaldehyde (PRF),
zs resorcinol or any other appropriate adhesive. For a product
required to perform according to chemical criteria, a non-
structural wood glue can be used, such as polyvinyl acetate
(PVA), urea melamine (UM), urea formaldehyde (UF), or any
other appropriate adhesive. The thickness (X) of the beam 22
3o is the sum of the thicknesses (X1) of the wood members 12
used, whereas the width (Y) of the beam 22 is determined by
the width of the widest wood member 12 used.
If required, a step of planing the beam 22 can
then be performed in order to obtain a more uniform width
35 (Y). This can be done, for example,. by longitudinally
running the beam 22 through an edging station. This step
-6-


CA 02438632 2003-08-29
also allows for removal of at least part of the flash 20 if
so desired.
The beam 22 is then cut perpendicularly to the
longitudinal faces 16 of the wood members 12 as shown in
s Fig.4. This will produce a number of panels 22a,b,c having a
smaller width (Y') that can be, for example, between 0.5 and
4 inches . For beams 22 that have a small enough width ( for
example, 2 inches or less), this step can be omitted. Thus,
the method of the invention can be simplified when the
~o starting material is smaller.
Some of the panels 22a,b,c, 24a,b,c, 26a,b,c are
then pressed and glued together along faces 28 parallel to
the longitudinal sides of the wood members 12 to produce the
laminated cross lumber beam 10, as shown in Fig.l. The
adhesive used can be the same as previously used or another
appropriate adhesive. The width (Yf) of the laminated cross
lumber beam 10 is the sum of the widths (Y' ) of the panels
used, whereas the height (X) of the laminated cross lumber
beam 10 is determined by sum of the thicknesses (X1) of the
2o wood members 12 used. Of course, small beams that have not
been cut into panels are assembled in a similar manner, and
can be used alone or in combination with panels to form a
laminated cross lumber beam 10. In a preferred embodiment,
the panels are selected so that adjacent panels come from
z5 different beams (see Fig.5 in conjunction with Fig.l). In
the example shown, a panel 24a from beam 24 is sandwiched
between panels 22b and 22a from beam 22, panel 22a being
also adjacent to a panel 26b from beam 26. This distribution
favors the discontinuity of wood fibers between the panels
3o and optimizes the distribution of weakness points within the
laminated cross lumber beam 10. Thus, a better distribution
of internal forces can be achieved, causing a low
variability in mechanical properties between different
laminated cross lumber beams 10. Selecting the panels also
35 allows to place panels with a better visual appearance to
form the exterior surfaces 30, thereby improving the
esthetic qualities of the laminated cross lumber beam 10.


CA 02438632 2003-08-29
To produce longer laminated cross section beams
10, the panels (here 22b and 22c) can be joined end to end,
as shown in Fig.6. Preferably, the joint 32 is S-typed
combined with an appropriate adhesive, but any other
equivalent joint can be used. For structural reasons, it is
preferable that joints are not aligned between assembled
adjacent panels in the laminated cross section beam 10. Of
course, it is also possible to join together entire sections
of laminated cross section beam 10 as well, using any
io appropriate type of joint.
Finally, if required, a planing of surfaces of the
laminated cross section beam is done ~>o as to obtain the
final desired dimensions.
The described method presents several advantages,
~5 one of which, as stated above, being the fact that the use
of smaller starting material simplifies the fabrication
process by allowing the omission of a step, namely the
cutting of the beams into panels. Thus, this method allows
for easy recuperation of scrap wood of small dimensions.
2o This method also allows the use of other scrap wood, such as
wood members of non standard dimensions and wood members
containing flash, either as is or after removing it
completely or partially. Moreover, this method allows for
the positioning of the panel pieces in the laminated cross
z5 lumber beam in order to maximize mechanical properties and
esthetic appearance. The laminated cross lumber beam has
mechanical properties superior to the wood members composing
it as well as a low variability of these properties between
laminated cross lumber beams, namely because of wood fiber
3o discontinuity and the distribution of weakness points
brought by the cross lumber positioning of the panels.
Finally, the laminated cross lumber beams produced by this
method are produced rapidly in a minimum of steps, thus
minimizing costs by diminishing handling, required equipment
ss and workers, etc.
It will be appreciated that the invention is not
limited to the specific embodiments described, which are
_g_


CA 02438632 2003-08-29
merely illustrative. Modifications and variations will be
readily apparent to those skilled in the art. Accordingly,
the scope of the invention is deemed t:o be in accordance
with the claims as set forth below.
_g_

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date Unavailable
(22) Filed 2003-08-29
(41) Open to Public Inspection 2005-02-28
Examination Requested 2008-04-10
Dead Application 2010-08-30

Abandonment History

Abandonment Date Reason Reinstatement Date
2007-08-29 FAILURE TO PAY APPLICATION MAINTENANCE FEE 2008-04-10
2009-08-31 FAILURE TO PAY APPLICATION MAINTENANCE FEE

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Registration of a document - section 124 $100.00 2003-08-29
Application Fee $150.00 2003-08-29
Maintenance Fee - Application - New Act 2 2005-08-29 $100.00 2005-08-29
Back Payment of Fees $50.00 2006-07-17
Maintenance Fee - Application - New Act 3 2006-08-29 $50.00 2006-07-17
Request for Examination $800.00 2008-04-10
Reinstatement: Failure to Pay Application Maintenance Fees $200.00 2008-04-10
Maintenance Fee - Application - New Act 4 2007-08-29 $100.00 2008-04-10
Maintenance Fee - Application - New Act 5 2008-08-29 $200.00 2008-04-10
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
PINEXEL INC.
Past Owners on Record
BRUNET, ALAIN
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Abstract 2003-08-29 1 24
Description 2003-08-29 9 378
Claims 2003-08-29 5 201
Drawings 2003-08-29 3 72
Representative Drawing 2003-11-03 1 13
Cover Page 2005-02-08 1 45
Assignment 2003-08-29 5 166
Prosecution-Amendment 2008-04-10 2 63
Fees 2008-04-10 2 47