AU2017216557B2 - Product and method - Google Patents

Product and method Download PDF

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Publication number
AU2017216557B2
AU2017216557B2 AU2017216557A AU2017216557A AU2017216557B2 AU 2017216557 B2 AU2017216557 B2 AU 2017216557B2 AU 2017216557 A AU2017216557 A AU 2017216557A AU 2017216557 A AU2017216557 A AU 2017216557A AU 2017216557 B2 AU2017216557 B2 AU 2017216557B2
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AU
Australia
Prior art keywords
veneer
substrate
wood veneer
timber
wooden board
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Revoked
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AU2017216557A
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AU2017216557A1 (en
Inventor
Craig Howard
Jack Howard
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Howard Heritage Holdings Pty Ltd
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Howard Heritage Holdings Pty Ltd
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Publication date
Priority to AU2016903292 priority Critical
Priority to AU2016903292A priority patent/AU2016903292A0/en
Application filed by Howard Heritage Holdings Pty Ltd filed Critical Howard Heritage Holdings Pty Ltd
Publication of AU2017216557A1 publication Critical patent/AU2017216557A1/en
Assigned to Howard Heritage Holdings Pty Ltd reassignment Howard Heritage Holdings Pty Ltd Amend patent request/document other than specification (104) Assignors: Craig Howard & Son
Application granted granted Critical
Publication of AU2017216557B2 publication Critical patent/AU2017216557B2/en
Revoked legal-status Critical Current
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Abstract

Il:\KzhInterwovn\NRPortbl\DCC\KZllIA5545916l.docx-8/08/2017 A method of producing a wood veneer, which method comprises cutting a veneer from a wooden board having a moisture content of 6- 15 %.

Description

- 1PRODUCT AND METHOD
Field of the invention
The present invention relates to wood veneer, to the production of wood veneer and to products in which wood veneer is used.
Background to the invention
Wood veneer is a thin facing layer of wood that can be applied to a substrate in order to impart an aesthetic timber appearance. Conventionally, commercial production of veneer involves peeling or slicing a thin layer of wood (typically 0.6-0.8 mm thick) from green timber. It is important that the wood has a (green) moisture content of at least about 60%; otherwise the veneer is likely to splinter or crack. After production, the veneer is dried by exposure to elevated temperature. This will usually be undertaken using an electric heater or the like.
It would be desirable to provide an alternative technique by which wood veneer may be produced.
Summary of the invention
The present invention provides a method of producing a wood veneer, which method comprises air drying a wooden board for a period of from about 6 to about 24 months, 25 optionally in conjunction with further drying the wooden board in a dehumidifier, and cutting a veneer from the air dried or air dried and dehumidified wooden board having a moisture content of 6-15%.
In the following reference to “wooden board” or “board” in the context of the invention should be taken to embrace a “flitch” (i.e. a slab of timber cut from a tree trunk) and a “plank” (a long thin piece of timber).
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-2An advantage of producing wood veneer in this way is that drying of the as-formed veneer is not necessary. This avoids the need for a careful drying protocol required in the conventional method as described above.
The invention also provides a wood veneer produced by the method of the invention.
Wood veneer produced in accordance with the invention may be used in the same way as veneer produced by the conventional method. Accordingly, the present invention also provides a product comprising wood veneer produced in accordance with the invention 10 fixed to a substrate.
The invention also provides a method of producing the product, which method comprises fixing the wood veneer to a substrate.
Throughout this specification and the claims which follow, unless the context requires otherwise, the word comprise, and variations such as comprises and comprising, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.
Detailed discussion of the invention
An important distinction between the method of the present invention and the conventional method for producing wood veneer is that the present invention involves cutting of timber 30 that has been dried. The conventional method requires slicing or peeling of green timber with subsequent drying of the as-formed veneer.
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-3 In the method of the invention the veneer is cut to desired thickness from a wooden board. The boards may be sized in length and width according to intended application of the veneer. By way of example, the board may be 25-150 mm thick, for example 25-100 mm thick, 1 SOSOO mm wide, for example 150-400 mm. Typically, the length is at least 300 mm and generally no longer than about 5000 mm, for example up to about 4500 mm in length. The invention may readily be implemented on a commercial or semi-commercial scale with a likely output of at least 500 m2 of veneer per year, and possibly significantly higher than this, for example about 2000 m2 of veneer per year.
Before cutting into veneer, the board has a moisture content of 6-15%, for example, 6-12% such as 6-10% in practice achieving a moisture content of below 6% may be difficult. This may be determined for example using a calibrated moisture meter. Boards useful in the invention are produced by cutting of green timber, usually in the form of logs, into suitably sized boards. These boards will have a moisture content corresponding to the green moisture content of the logs (typically at least about 60%). The boards are then racked and air dried for a period from about 6 to about 24 months. This drying removes most of the moisture in the green timber and allows much of the tension in the timber to be relieved. After this air drying the moisture content of the boards will be about 12 to about 15%. The boards may then subjected to further drying in a dehumidifier at approximately 50°C in order to reduce the moisture content to from 6-15% (or 6-12% or 6-10%). Typically this can take between 6 and 20 days, for example between 6 and 14 days. In this step the intention is to further reduce the moisture content of the timber but at a relatively slow rate.
When compared with the conventional approach described above the step of air drying in accordance with the invention provides a more economic and environmentally beneficial overall process. Air drying is less energy intensive and has a lower carbon footprint and lower emissions profile.
The boards may be cut into veneer using conventional techniques for example using a band 30 saw or band re-saw which applies a cutting action rather than a peeling or slicing action to
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-4produce a wood veneer from the board. The wood veneer is cut to a desired thickness, depending upon the intended application of the wood veneer. After cutting, the veneer may also be sanded to enhance its finish and to refine its thickness. This said, there is a minimum thickness which can be achieved by cutting and this is typically about 3 mm.
This thickness may be reduced further by sanding back of the veneer, for example using a drum sander or a wide belt sander. In this case the thickness of the resultant veneer is likely to be from 1.5 to 2.5 mm, for example from 1.5 to 2 mm.
One advantage of the method of the invention is that it enables relatively thick veneers to be produced, for example thicknesses greater than 3 mm. This will involve cutting to a thickness in excess of the desired final veneer thickness and sanding to that desired final thickness. For example, cutting may take place to a thickness of 3.8 mm with sanding back to 3.5 mm. There may be variations between species of timber, but this thickness may not readily be achievable by peeling/slicing in accordance with the conventional methodology. Advantages associated with using thick veneers are that thick veneers will have the same attributes and characteristics of solid timber, but at a fraction of the thickness. Thus, thick veneers provide durability, flexibility of use in forming finished products, depth of finish and/or depth of colour. These are also advantages associated with thick veneers when compared with thin veneers for example thin veneers having a 20 thickness less than 1 mm.
The invention may be applied to a range of different timber types, including but not limited to, Huon Pine, Black Heart Sassafras, Blackwood, Myrtle, Celery Top Pine, Eucalypt, Silver Wattle and King Billy Pine.
Depending upon the intended application, appearance etc. the invention may also be implemented using forest residues, such as lower grade logs. Use may also be made of timber off-cuts. In these ways, the invention may allow use of timber sources that might otherwise be disposed of as waste.
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-5 The wood veneer produced in accordance with the invention may be fixed to a variety of substrates depending on intended application. The substrate may be a product in its own right such as a piece of furniture or it may be a substrate that is used in construction of a finished product. For example, the wood veneer may be fixed to a substrate that is used to 5 fit-out a boat, caravan, office or the like. In these cases, the wood veneer is intended to impart a cosmetic/aesthetic appearance without needing to use solid timber. The veneer may also be to impart a desirable timber appearance to furniture, for example to the legs of furniture (e.g. chairs and tables), to door fronts, drawer front and table tops and in relation to larger pieces such as (architectural) doors and panelling.
The invention may be applied to produce large pieces of veneer and this is beneficial for certain applications because it avoids the need to match and join individual pieces of veneer together to achieve suitable coverage. It may be desirable to use large pieces of veneer for certain applications to avoid joins/seams that may detract from the overall 15 aesthetic appearance.
The wood veneer may be fixed to a variety of substrates such as polymer-based products (e.g., commercially available from Gurit® under the name Corecell™), polystyrene foam, especially extruded polystyrene foam (e.g., Styroboard™ XPS or EPS available from 20 Foamex), plywood especially light plywood (Goldcore Light available from Atkar) and
MDF. Products formed from polymer based products may be used for boat fit-outs, caravan fit-outs, office furniture and the like. Fixing of the veneer to polystyrene foam may yield products useful in applications where thermal and/or acoustic insulation is called for. This aspect of the invention will therefore be useful in producing wall, ceiling and/or 25 floor panels. Products formed from polystyrene foam may also be used in boat fit-outs and caravan fit-outs. Products formed from light plywood may have similar applications. Products formed from MDF are typically used for office furniture.
The substrate may have fire retardant or fire resistant properties. For example, the substrate may be a metallic structure. For example, the substrate may be made of aluminum and provided with a honeycomb structure to provide light weight, strength and
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-6rigidity. An example of such a material is available from Ayres under the product name Venturelite. In particular reference may be made to Venturelite 2010. In an embodiment the resultant products may be useful as building construction materials and components.
Typically, the wood veneer of the invention will be fixed to a substrate using an adhesive such as a two-pack epoxy product, PVA product, epoxy resin or contact adhesive. Polyurethane adhesives may also be used. The choice of suitable adhesive may vary as between substrates. Vacuum pressing may be employed to ensure enhanced bonding of the veneer to the substrate. The veneer may be bonded to one side of the substrate or to 10 both sides, the latter possibly giving increased strength and robustness, improved overall appearance and/or improved stability. Thick veneers may also provide a more sustainable product since damage to the surface of the veneer that occurs post-production may be remediated by sanding and possibly staining. This is generally not possible with thin veneers since they are too thin to be remediated in this way. Thick veneers may also be 15 susceptible to better finishing, especially with natural oils. Such finishing is generally not recommended with thin veneers since they do not have the depth to allow adequate penetration for the finishing agent to act as a sealant.
The invention uses timber and as such offers a sustainable approach to producing veneers. 20
Example
The following example describes production of a composite piece in which a (thick) veneer is bonded to a substrate.
Logs of the desired timber are cut into slabs, boards, plank or flitches using a horizontal band mill, selecting the best possible grain/feature and colour for the intended end product. These slabs, boards, plank and flitches have a moisture content of at least 60%. A saw bench could also be used for the cutting of the timber.
The slabs, board, plank and flitches can vary in dimensions. Typically dimensions are:
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-725 -150 mm thickness;
up to 500 mm width; and up to 5000 mm length.
The slabs/boards/planks/flitches are racked out with racking sticks in between each piece every 400mm. The racking sticks are about 20mm thick and 30-40mm wide.
The slabs/boards/planks/flitches are air dried for 6-24 months. This allows air in the environment to remove a significant amount of moisture from the timber making it more 10 stable and enabling increased productivity/less wastage. This is because air drying will also relieve tension/stresses in the timber so that there should be less movement, cracking and/or checking as the timber is processed further in accordance with the invention.
The slabs/boards/planks/flitches are then moved to a timber dehumidifier. A temperature 15 of up to about 50°C is applied for from 6-20 days. This brings the moisture content down to from 6-12%.
After this the slabs/boards/planks/flitches are selected based on suitability for veneer production based on such characteristics as grain pattern, features and colour. The 20 slabs/boards/planks/flitches are then cut into thick veneer of about 3 to 5 mm thickness off the saw. A band re-saw or bandsaw with a thin kerf tungsten carbine blade is used.
As individual pieces of veneer are cut, they are laid down the same way they came off the saw, saving time later as grain matching does not need to be undertaken. The edges of the 25 veneer are checked for straight edges (needed for a good joint line) and any necessary adjustments are made. Pieces of veneer are glued and taped at the edges to provide a veneer panel. The panel is then sanded on both sides to provide flat, even surfaces that will provide a good bonding surface. The panel is then laid down and glued to a substrate to provide a composite piece. The composite piece may be pressed or placed in a vacuum 30 bag or press for bonding.

Claims (12)

  1. THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:
    1. A method of producing a wood veneer, which method comprises air drying a wooden board for a period of from about 6 to about 24 months, optionally in conjunction with further drying the wooden board in a dehumidifier, and cutting a veneer from the air dried or air dried and dehumidified wooden board having a moisture content of 615%.
  2. 2. The method of claim 1, wherein the board is 25-150 mm thick, 150-500 mm wide and up to 5000 mm long.
  3. 3. The method according to claim 1 or 2, wherein the wooden board is dried in the dehumidifier at a temperature of up to 50°C.
  4. 4. The method of any one of claims 1 to 3, wherein the wooden board is dried in the dehumidifier for between 6 and 20 days.
  5. 5. The method of any one of claims 1 to 4, wherein the moisture content is 6-12%.
  6. 6. The method of any one of claims 1 to 5, wherein the veneer has a thickness of at least 3 mm.
  7. 7. A wood veneer produced by the method of any one of claims 1 to 6.
  8. 8. A product comprising a wood veneer as claimed in claim 7 fixed to a substrate.
  9. 9. The product of claim 8, wherein the substrate is polystyrene foam, plywood, medium density fiberboard or a metal structure.
  10. 10. The product of claim 8 or 9, in the form of furniture or a component of furniture, wall panel, ceiling panel, floor panel or door.
    C:\Interwoven\NRPortbl\DCC\SXN\l 851542 7_ 1 .docx-26/02/2019
    2017216557 26 Feb 2019
  11. 11.
  12. 12.
    -9A method of producing the product of claim 8, which method comprises fixing a wood veneer produced by the method of any one of claims 1 to 6 to a substrate.
    A product when produced by the method of claim 11.
AU2017216557A 2016-08-19 2017-08-18 Product and method Revoked AU2017216557B2 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU2016903292 2016-08-19
AU2016903292A AU2016903292A0 (en) 2016-08-19 Product and method

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AU2017216557A1 AU2017216557A1 (en) 2018-03-08
AU2017216557B2 true AU2017216557B2 (en) 2019-05-16

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Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE543314C2 (en) * 2018-12-18 2020-11-24 Ikea Supply Ag A method for producing a furniture board product

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3986268A (en) * 1973-09-17 1976-10-19 Drywood Corporation Process and apparatus for seasoning wood
US4942084A (en) * 1988-06-30 1990-07-17 Prince Kendall W Reconstituted wood veneer covered structural elements
US20080268273A1 (en) * 2007-04-24 2008-10-30 The Diller Corporation Wood veneer surfaced decorative laminate product and method of making same
JP2014104686A (en) * 2012-11-29 2014-06-09 Shonai Tekko Kk Slice veneer and manufacturing method thereof

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3986268A (en) * 1973-09-17 1976-10-19 Drywood Corporation Process and apparatus for seasoning wood
US4942084A (en) * 1988-06-30 1990-07-17 Prince Kendall W Reconstituted wood veneer covered structural elements
US20080268273A1 (en) * 2007-04-24 2008-10-30 The Diller Corporation Wood veneer surfaced decorative laminate product and method of making same
JP2014104686A (en) * 2012-11-29 2014-06-09 Shonai Tekko Kk Slice veneer and manufacturing method thereof

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Owner name: HOWARD HERITAGE HOLDINGS PTY LTD

Free format text: FORMER NAME(S): CRAIG HOWARD & SON

FGA Letters patent sealed or granted (standard patent)
ROP Revocation of patent

Effective date: 20211021