AU2002301038B2 - Teak Wood Board with Straight-Line Grain Surface - Google Patents

Description

13102 2007 15:24 FAX +61 2 94090101 HIGISH&JcNE 0/4 HOOGKINSON McINNES 1a007/040 Cl TEAK BOARD WITH STRAIGHT-LINE GRAIN AND MANUFACTURING PROCESS THEREFOR en BACKGROUND OF THE INVENTION Field of the Invention 00 o This invention relates to the manufacturing of wood board, and more particularly to using teak heartwood and teak sapwood for making wood boards having surfaces en with straight-line grain.

o Description of the Related Art Teak is a precious wood which has become increasingly rare in natural forests.

Consequently, most teak wood now comes from trees cultivated in plantations where growth is managed so that a high proportion of trees will reach a good average height before flowering sets in, making branching more profuse. To obtain high quality wood from a cultivated tree it must have aged for over twenty-five years to be big enough to consist of a relatively large amount of heartwood compared to the amount of sapwood.

1s The brown heartwood can be transformed into wooden boards with surfaces which have aesthetically pleasing straight-line grain patterns and are resistant to termites and to other insects and fungi- The white sapwood, which usually lacks line grain and is highly susceptible to fungus infection, is cut out and discarded. In managing a teak plantation it is necessary to do a thinning six or seven years after a "stand" is planted, in order that the remaining trees can have space to grow, Because the young, small trees cut down consist of a relatively large amount of sapwood compared to the amount of heartwood, their lumber generally is not used to manufacture boards but as flammable material or in cheap wall partitions.

OBJECTS OF THE INVENTION 2S It is an object of the present invention to provide processes for cutting teak lumber which allow portions of teak trees which heretofore have been discarded or used for low quality applications such as building cheap partitions and providing fuel, to be suitable for higher quality applications such as making furniture and decorative articles.

COMS ID No: SBMI-06235926 Received by IP Australia: Time 15:39 Date 2007-02-13 13/02 200? 15:24 FAX +61 2 84090101HOJISN&MINEIj06/4 HODGKINSON NcINNES R008/040 o 2 Another object of the invention is to provide processes for cutting teak sapwood 0) lumber into logs which can be used to make boards having surfaces with straight-line grain pattern.

These and other objects as well as features and advantages of the invention will 00 s become further apparent from the detailed description and accompanying figures that follow. In the figures and description, numerals indicate the various features of the invention, like numerals referring to like features throughout both the drawings and description.

o SUMMARY OF THE INVENTION In one aspect the invention provides a process for manufacturing a teak board having at least one surface with straight-line grain. The process includes: cutting a teak timber across its annual ring to form an end with a planar surface bounding four sectors having non-bud structure and four sectors having bud structure, the sectors alternating between non-bud and bud type with each including heartwood and sapwood; is cutting longitudinally through the planar surface along a first plurality of generally parallel lines and a second plurality of generally parallel lines generally orthogonal to the first plurality of lines, thereby forming a plurality of logs each having at least one side with straight-line grain; and forming a board by aligning and contiguously attaching the logs so that at least one of the composite surfaces so formed has straightline grain.

In another aspect the invention provides a teak wood board including a plurality of contiguously attached logs. Each log is predominately sapwood and has at least one surface with straight-line grain. The logs are aligned so that straight-line grain surfaces of the logs collectively form a straight-line grain surface of the board.

In still another aspect the invention provides a teak wood board including a plurality of contiguously attached logs. Each log is entirely sapwood and has at least one surface with straight-line grain. The logs are aligned so that straight-line grain surfaces of the logs collectively form a straight-line grain surface of the board.

COMS ID No: SBMI-06235926 Received by IP Australia: Time 15:39 Date 2007-02-13 13/02 2007 15:.25 FAX +61 2 94090101 HIGISN&IcNE 0/4 HDOGKINSON McINNES 1a009/040 o3 Cl In yet another aspect the invention provides a teak wood board including a plurality of contiguously attached planks. Each plank is entirely sapwood and has at least one surface with straight-line grain. The logs are aligned so that straight-line grain surfaccs of the planks collectively form a straight-line grain surface of the board.

00 BRIEF DESCRIPTION Of THE DRAWINGS o FIG. I shows a top plan view of a teak timber cut across the annual ring without en any bud sectors.

o FIG. 2 shows a top plan view of a teak timber cut across the annual ring having Cl four relatively large non-bud sectors and four relatively small bud sectors.

FIG. 3 illustrates, using the FIG. 2 timber as an example, a coordinate system for describing the relative disposition of non-bud and bud sectors.

FIG. 4 shows a perspective view of a teak timber having one lengthwise region with bud structure.

FIG. 5 shows the prior art process for cutting the FIG. 2 timber which forms two 2s logs each having a combination of non-bud and bud structure. The dotted lines depict where the longitudinal cuts are made.

FIG. 6 shows the logs formed by the FIG. 5 process.

FIG. 7 shows a board made from the FIG. 6 log having a surface with bud-type grain- FIG. 8 shows a process for cutting the FIG. 2 timber according to a first embodiment of the invention wherein four logs are formed, each having one surface with bud structure.

FIG. 9 shows the logs formed by the FIG. 8 process.

FIG. 10 shows a piece of wood cut fromn any one of' the four FIG. 9 logs, having a surface with straight-line grain.

COMB ID No: SBMI-06235926 Received by IP Australia: Time 15:39 Date 2007-02-13 13/02 2007 15:-25 FAX +61 2 94090101 HJOISN&MeNE j01/0 HODGKINSON McINNES la 010/040 o4 Cl FIG. 11 shows four FIG. 10 pieces each smoothed on opposed sides before being aligned parallel and contiguously glued to forma a board having an upper surface with straight-line grain, and a combination of straight-line and bud-type grain on one edge.

00 s FIG. 12 shows a process for cutting the FIG. 2 timber according to a second en embodiment wherein four logs with bud structure are formed.

o FIG. 13 shows the logs formed by the FIG. 12 process.

o FIG. 14 shows the FIG. 13 logs, each smoothed on opposed sides before being ci aligned parallel and contiguously glued to form a board having an upper surface with straight-line grain, and an edge combining straight-line and bud-type grain.

FIG- 15 shows a process for cutting the FIG. 2 timber according to a third embodiment wherein the cuts made avoid bud-type sectors so that four rectangular cross-section logs and four wedge-shaped cross-section logs are formed, all with nonbud structure.

is FIG. 16 shows the FIG. 15 rectangular cross-section logs, each smoothed on opposed sides before being aligned parallel and contiguously glued to form a board having atn upper surface and an edge with straight-line grain.

FIG. 17 shows a process according to a fourth embodiment for cutting a FIG. wedge-shaped cross-section log to form thin pieces with straight-line grain.

FIG. 18 shows a thin board made by aligning and contiguously gluing a plurality of HIG. 17 pieces.

FIG. 19 shows how the FIG. 18 board can be strengthened by gluing underneath it a low quality board.

FIG. 20 shows a process for cutting the FIG. 2 timber according to a fifth embodiment wherein eight logs are formed each having non-bud structure.

no., 21 shows the logs produced by the FIG. 20 process.

COMS ID No: SBMI-06235926 Received by IP Australia: Time 15:39 Date 2007-02-13 13/02 2007 15:25 FAX +61 2 84090101HOJISO MINEIj01/4 HODGKINSON McINNES la 0 11/040 Cl DESCRIPTION OF THEf PREFERRED EMBODIMENTS Introduction While the present invention is open to various modifications and alternative constructions, the preferred embodiments shown in the drawings will be described 00 herein in detail. It is to be understood, however, there is no intention to limit the o invention to the particular forms disclosed. On the contrary, it is intended that the o invention cover all modifications, equivalences and alternative constructions falling ci within the spirit and scope of the invention as expressed in the appended claims.

c-I Where wsed herein the term "bud sector" or "bud-type sector" denotes a portion of a timber having bud structure cut from a teak tree across the annual ring crosscut generally transverse to the tree's length), the top surface of which (seen in a top plan view) is roughly a geometric sector whose vertex is proximate to the pith area. The term "bud-type grain" connotes a surface of a log, board or plank having a gnarled pattern- Similarly, where used herein the term "non-bud sector" connotes a portion of a timber having non-bud structure, and-the terms "straight-line" and "straight-line grain" mean that the log, board or plank referred to has at least one surface with a straight-line grain pattern. Where used herein the word "attached" means that the logs, boards or planks referred to are aligned and then glued or otherwise adhesively bonded together.

However other forms of attachment may be suitable, consistent with simplicity of manufacture and reliability of the finished product.

Generally, when timber is cross-cut from a teak tree the annual ring appears as in FIG. 1. As one ring normally is forned each year, the eight rings in the FIG. 1 example imply the tree was eight years old. As a teak tree matures it develops protuberances called "buds" from which branches eventually grow. B3uds form as opposed pairs along the trunk length, the two buds at a particular level are l8O* apart, which are separated in phase by 90' from the bad pairs imunediately above and below themn. As the tree grows, sapwood is created just interior to the three outermost trunk layers, the outer bark, inner bark and cambium. Sapwood helps to transport sap and stores food for additional growth. Heartwood, which is interior to the sapwood, consists of inactive cells that have already performed their functions. Whether a timber COMS ID No: SBMI-06235926 Received by IP Australia: Time 15:39 Date 2007-02-13 13/02 2007 15:25 FAX +81 2 94090101 HDKHO cNE 1/4 HOOGKINSON McINNES la 0 12/040 o 6 portion consists of heartwood or sapwood or a combination of the two generally depends on radial distance fromu the pith, the small growth center of the tree. A particular heartwood or sapwood portion can have bud or non-bud structure, depending on whether or not it is proximate to a bud. In young trees where relatively little S heartwood has formed, the nonbud and bud portions are likely to consist primarily if not 00 totally of sapwoocL Heretofore the sapwood portion of a teak timber has been o considered useless for applications such as makcing board for high quality furniture.

o Only the heartwood portion has been used for making board with or without straightc-I line grain depending, respectively, on whether the timber does or does not have only o1i non-bud structure.

Referring to FIG. 2, generally planar surface 30S is one end of a typical crosscut teak timber 30 having a generally circular cross-section. Timber 30 includes four relatively large non-bud sectors HI1, H2, H3. H4, and four reclatively small bud sectors S I, S2, S3, 54 resulting from two pairs of opposed buds. The eight sectors extend along is the length of the timber which terminates in an opposed cross-cut end. The vertex of each sector arbitrarily coincides with innermost ring R I which circumscribes pith area 301'. Using timber 30 as an example, FIG. 3 illustrates a coordinate system for describing the relative, disposition of non-bud and bud sectors. (Detailed, descriptions of four of the five preferred embodiments are also referenced to FIG. The convention is to identify sectors on surface 305 in terms of points on a compass. Thus, bud sectors SI1, S2,53, S4 are at points N, E, 5, W. respectively, and non-bud sectors Hi, H-2, H3, H4 are at points NE, SE, SW, NW, respectively. FIG. 4 schematically shows a teak timber 32 having a single longitudinal region 34 with bud structure as exemplified by knots 36A, 36B.

With reference to timber 30, FIGS. 5 and 6 show the prior art process for longitudinally cutting a teak timber to obtain logs. The first step is to square off the timber. Portions 40A, 40B, 40C, 40D are canved away by cutting along two pairs of generally parallel dashed lines 42, 44 and 46, 48. Each dashed line is the intersection of a generally vertical cutting plane with the surface 30S. Next cuts are made along the ic0 opposed generally parallel pair of dashed lines 50, 52 to form a first log 54 having a relatively large amount of bud-type structure, and a second log 56 with a relatively COMS ID No: SBMI-06235926 Received by IP Australia: lime 15:39 Date 2007-02-13 13/02 2007 15:26 FAX 461 2 94090101 HDKNO cNE 1/4 HODGKINSON McINNES la 0 13/040 o7 Cl small amount of bud structure. Both logs have a rectangular cross-section. This process, universal in the teak harvesting industry, wastes most of the timber and yields only a single desirable log. FIG. 7 shows a board 60 made from log 54, having a surface whose bud-type grain pattern is typical of boards made from either sapwood or s hardwood, depending upon the te's age. In contrast, the present invention provides 00 board with straight-line grain made from timber harvested from young teak trees which o axe substantially or even totally sapwood.

en Embodiment 1 o FIGS. 8 and 9 show how Uimber 30 is cut according to a first embodiment of the present invention to yield four square or rectangular cross-section logs from which pieces having a straight-line grain surface can be cut. Firstly, portions 62A, 62B, 62C, 62D are canved away by cutting along dashed lines 64, 66, 68, 70, respectively.

Secondly, longitudinal cuts are made along opposed generally parallel dashed lines 72, 74, and opposed generally parallel dashed lines 76, 78 generally orthogonal to fines 72, is 74, thereby forming four rectangular or square cross-section logs 80, 82, 84, 86 each having bud-type structure. In FIG. 8, line pairs 72, 74 and 76, 78 are symmetrically disposed with respect to pith area 30P so that the lines are approximately equidistant from the pith area, resulting in square cross-section logs. FIG. 10 shows a piece 90 with one straight-line grain surface 905 which may be cut from any one of the logs. FIG. 11 shows how logs 80, 82, 84, 86 after being smoothed on opposed sides can be aligned parallel and contiguously glued to form a board 92 having an upper surface 92U with straight-line grain, and an edge surface 94S having a combination of straight-line and bud-type grain. Most of the bud-type grain is hidden from view on lower surface 92L.

Embodiment 2 2S FIGS. 12 and 13 show the timber 30 cut according to a second embodiment of the invention to yield four square cross-section logs 100, 102, 104, 106 each having a straight-line grain surface. Firstly, portions I10A, I10B, 1 10C, i1101) are canved away by cuffing along dashed lines 112, 114, 116, 118, respectively. Secondly, longitudinal diametral cuts through pith area 30P are made along generally orthogonal dashed lines 120, 122 which generally bisect the non-bud sectors Hi, H12, H3, H14 (see FIG. 2), COMS ID No: SBMI-06235928 Received by IP Australia: Time 15:39 Date 2007-02-13 13/02 2007 15:26 FAX +61 2 94090101 HDKNO cNE 1/4 HODGKINSON McINNES la 014/040 o8 thereby quartering the timber. Tirdly, longitudinal cuts are madec along opposed, generally parallel dashed lines 124, 126 proximate to innermost ring R1, thereby forming logs 100, 102, 104, 106. FIG. 14 shows the logs) after being smoothed ont opposed sides, aligned and glued together to form a board 128 having an upper surface s 128U with straight-line grain, and an edge surface 1305 with bud-type grain.

00 M Embodiment 3 o FIG. 15 shows the Uimber 30 cut according to a third embodiment of the Cl invention to yield four rectangular cross-section logs 130, 132, 134, 136 which are o entirely sapwood but have non-bud structure. Firstly, portions 140A, 140B, 140C, 140D ao are carved away by cutting along dashed lines 142, 144, 146, 148, respectively.

Secondly, longitudinal cuts are made along opposed, generally parallel dashed lines 150, 152 proximate to annual ring R2, dividing the timber into a generally rectangular block-shaped portion 154 and two semnicylindrical-shaped portions 156, 158 Thirdly, portion 154 is longitudinally cut along opposed, generally parallel dashed lines 160, 162 is proximate to ring R4 to form rectangular-shaped logs 134, 130, respectively. Fourthly, portions 156 and 158 ame longitudinally cut along opposed, generally parallel dashed lines 168, 170 and 172, 174, respectively, and along dashed lines 176, 178, respectively, to form rectangular loss 136 and 132, respectively. Also fanned are wedge-shaped pcoions 184, 186, 188, 190. FIG. 16 shows the logs 130, 132, 134, 136, after being smoothed on opposed sides, aligned and glued together to form a board 192 having an upper surface 192U and an edge surface 192S with straight-line grain.

Embodiment 4 In a fourth embodiment of the invention, FIG. 17 shows how a wedge-shaped portion 200 formed as a byproduct of the third embodiment can be cut to form thin planks with straight-line grain. Because portion 200 has only non-bud structure, surfaces 200A, 200B and ends 202A, 202B all have straight-line grain. A longitudinal cut along dashed line 204 yields a plank 206 whose upper and lower surfaces 206U3, 206L, respectively, and ends 206E, 206F all have straight-line grain. As shown in FIG.

18, a single portion can yield a plurality of planks which can be glued together to form a thin board 208 with upper and lower surfaces 20813, 208L, respectively. As shown in COMS ID No: SBMI-06235926 Received by IP Australia: Time 15:39 Date 2007-02-13 13/02 2007 15:26 FAX *61 2 94090101HDJINO &MINEIj01/4 HODGKINSON McINNES R015/040 o 9 FIG. 19, the board can be strengthened by gluing a ]ow quality board 209 to surface C) 208L.

Embodiment FIGS. 20 and 21 show the timber 30 cut according to a fifth embodiment of the 00 5 invention to yield eight rectangular cross-section logs 210, 212, 214, 216, 218, 220, o 222, 224 which include both heartwood and sapwood and have non-bud structure.

0 Firstly, portions 226A, 226B, 226C, 2261) are carved away by cutting along dashed Cl lines 230, 232, 234, 236, respectively. Secondly, longitudinal diametral, cuts through o pith area 30P are made along generally orthogonal dashed lines 240,242 which generally bisect the non-bud sectors H11,1H2, H3, H14 (see FIG. thereby dividing the timber into four sector-shaped portions 244, 246, 248, 250- Thirdly, two pairs of generally orthogonal cuts are made in each portion to form two logs. In portion 244 the cuts are along dashed lines 252, 254 and 256, 258; in portion 246 the cuts are along dashed lines 260, 262 and 264, 266; in portion 248 the curs are along dashed lines 268, Is 270 and 272, 274; and in portion 250 the cuts are along dashed lines 276, 278 and 280, 282. Each of these cuts, which are generally parallel to diametral line 240 or 242, extends between an endpoin t located between annual rings R I and R2 and a squared-off end formed by cutting along line 230, 232, 234 or 23 6. As in the third embodiment, since the logs have only non-bud structure, they or boards made from them will have only straight-line grain on their upper and lower surfaces and opposed ends (see FIG.

16).

Trees from which timber is obtained should be at least four Years old. Boards or planks produced according to any of the five embodiments must be chemically treated to protect against termites, insects and fungi. If the color of the timber portions from which logs are cut is not brown the logs must be dried before gluing before the manufacture of boards or planks can proceed. Finished boards and planks can be colored as desired with appropriate stains.

COMS ID No: SBMI-06235926 Received by IP Australia: Time 15:39 Date 2007-02-13

Claims (9)

1. A process for manufacturing a teak board having at least one surface with straight-line grain, comprising the steps of; cutting a teak timber determined by a circumferential outer surface across its 00 5 annual ring thereby forming an end with a generally planar surface bounded by a Cn Scircumferential perimeter, said planar surface bounding first, second, third and fourth Ssectors having non-bud structure, and first, second, third and fourth sectors having bud C, structure, each bud and non-bud sector having an inner heartwood portion and an outer o sapwood portion, said inner and outer portions contiguous along a boundary, each bud sector contiguous to and disposed between two non-bud sectors, each non-bud sector contiguous to and disposed between two bud sectors, each sector having a vertex proximate to the pith area and terminating at said outer surface; cutting longitudinally through said planar surface along a first plurality of generally parallel lines and a second plurality of generally parallel lines generally orthogonal to said first plurality of lines, each line determined by preselected endpoints on the planar surface, thereby forming a plurality of Jlogs with a preselected common cross-section, each log having at least one side with straight-line grain; and forming a board by aligning and contiguously attaching the logs so that at least one of the composite surfaces so formed has straight-line grain- ao

2. The process of claim I wherein: said first plurality of lines is four including an outer pair of opposed lines, each line having endpoints proximate to said perimeter and transiting sapwood in one bud sector and one non-bud sector, and an inner pair of opposed lines, each line having endpoints proximate to said perimeter and transiting sapwood and heartwood in two bud sectors and two non-bud sectors; said second plurality of lines is four including an outer pair of opposed lines, each line having endpoints proximate to said perimeter and transiting sapwood in one bud sector and one non-bud sector, and an inner pair of opposed lines, each line having endpoints proximate to said perimeter and transiting sapwood and heartwood in two bud sectors and two non-bud sectors; and COMS ID No: SBMI-06235926 Received by IP Australia: Time 15:39 Date 2007-02-13 13/02 2007 15:27 FAX +61 2 94080101 HOGINH MINEIj01/4 HODGKINSON McINNES la 017/040 Cl said plurality of logs is four.

I The process of claim 2 wherein each said log is predominate ly sapwood and has en a generally square cross-section and two generally rectangular and mutually orthogonal sides having straight-line grain. 0s

4. The process of claim I wherein: 0 said first plurality of lines is three including a diametral line transiting the pith 0 area and sapwood and heartwood in two opposed non-bud sectors, and an outer pair of o opposed lines, each line having endpoints proximate to said perimeter arnd transiting o sapwood and heairtwood in two bud sectors and one non-bud sector; said second plurality of lines is five including a diamnetral Line transiting the pith area and sapwood and heartwood in two opposed non-bud sectors, an outer pair of opposed lines, each line having endpoints proximate to said perimeter and transiting sapwood in tow bud sectors and one non-bud sector, and an inner pair of opposed lines, each line having endpoints proximate to said boundary and transiting heartwood in is opposed non-bud sectors; and said plurality of logs is four.

The process of claim 4 wherein each said log includes heartwood and sapwood, and has a generally square cross-section and one generally rectangular side having straight-line grain.

6. The process of claim 1 wherein: said first plurality of lines is six including an outer pair of opposed lines, each line having endpoints proximate to said perimeter and transiting sapwood in one bud sector and one non-bud sector an inner pair of opposed lines, each line having endpoints proximate to said perimeter and transiting sapwood and heartwood in two bud sectors and two non-bud sectors and a pair of opposed lines disposed between said outer and inner lines, each line having endpoints, proximate to said boundary and transiting one bud sector and one non-bud sector; COMS ID No: SBMI-06235926 Received by IP Australia: Time 15:39 Date 2007-02-13 13/02 2007 15:28 FAX +61 2 94090101 HOOGKINSON McINNES la018/040 0 12 0 C, said second plurality of lines is eight including an outer pair of opposed lines, Seach line having endpoints proximate to said perimeter and transiting sapwood in one bud sector and one non-bud sector, a pair of opposed lines, each line approximately tangential to said boundary and having endpoints at its intersections with said inner pair S of opposed lines of said first plurality of lines, and first and second inner pairs of 00 opposed lines, each line having an endpoint proximate to said perimeter and an endpoint O at its intersection with one of said inner pair of opposed lines of said first plurality of Slines; and C^ said plurality of logs is four. C, 10

7. The process of claim 6 wherein each said log is entirely sapwood and has a rectangular cross-section and one generally rectangular side with straight-line grain.

8. The process of claim 1 wherein: said first plurality of lines is four including first and second pairs of opposed lines, each line having one endpoint on said perimeter and one endpoint proximate to said boundary; said second plurality of lines is four including first and second pairs of opposed lines, each line having one endpoint on said perimeter and one endpoint at its intersection with one of said first plurality of lines; and said plurality of logs is four.

9. The process of claim 8 wherein each said log is entirely sapwood and has a wedge-shaped cross-section and two generally rectangular and mutually orthogonal sides with straight-line grain. The process of claim 1 wherein: said first plurality of lines is five including a diametral line transiting the pith area and sapwood and heartwood in two opposed non-bud sectors, an outer pair of opposed lines, each line having endpoints proximate to said perimeter and transiting sapwood in one non-bud sector, and an inner pair of opposed lines, each line having endpoints proximate to said boundary and transiting heartwood in one non-bud sector; COMS ID No: SBMI-06235926 Received by IP Australia: Time 15:39 Date 2007-02-13 13/02 2007 15:28 FAX 461 2 84090101 HODGKINSON McINNES Ij013/040 o 13 Csaid secoud plurality of lines is nine including a diametral line transiting the pith area and sapwood and heartwood in two opposed non-bud sectors, an outer pair of opposed lines, each line having endpoints proximate to said perimeter and transiting sapwood in one non-bud sector, an inner pair of opposed lines the length of said outer pair of lines, each line transiting heartwood in one non-bud sector, and first and second 00 pairs of opposed lines syrmnetric with respect to said diametral line, each line having an o endpoint proximate to said perimeter and an endpoint at its intersection with one of said o inner pair of lines of said first plurality of lines; and C said plurality of logs is eight. 1. ac 11. The process of claim 10 wherein each said log includes heartwood and sapwood, and has a generally rectangular cross-section and two opposed generally rectangular sides having straight-line grain. COMS ID No: SBMI-06235926 Received by IP Australia: Time 15:39 Date 2007-02-13