U.S. patent number 3,674,219 [Application Number 05/058,081] was granted by the patent office on 1972-07-04 for green-wood fibrating means and method.
This patent grant is currently assigned to Tennessee Valley Authority. Invention is credited to Herbert c. Harvey, Jr..
United States Patent |
3,674,219 |
Harvey, Jr. |
July 4, 1972 |
GREEN-WOOD FIBRATING MEANS AND METHOD
Abstract
A process and apparatus for converting solid pieces of timber
into slender, splinter-like strands of wood fiber of more or less
uniform thickness. Timber first passes through a series of rolls
revolving at uniform or variable controlled speeds. The rolls have
varying thread-like configurations and are vertically activated
under controlled pressure of such magnitude as to cause the solid
wood to be separated into splinter-like strands along the grain.
The spongy mass of loosely matted fiber strands are then passed
through a scrubbing device to be pulled apart.
Inventors: |
Harvey, Jr.; Herbert c.
(Knoxville, TN) |
Assignee: |
Tennessee Valley Authority
(N/A)
|
Family
ID: |
22014553 |
Appl.
No.: |
05/058,081 |
Filed: |
July 24, 1970 |
Current U.S.
Class: |
241/152.2;
241/155; 144/367; 241/235; 144/2.1 |
Current CPC
Class: |
B27L
11/08 (20130101) |
Current International
Class: |
B27L
11/00 (20060101); B27L 11/08 (20060101); B03c
021/00 (); B27l 011/08 () |
Field of
Search: |
;144/2,3,320,809,326D
;241/235,28,159,152R |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Schran; Donald R.
Claims
What we claim as new and desired to secure by Letters Patent of the
United States is
1. In a device, for forming small splinter-like strands of wood of
relatively uniform lengths and diameters and having the axes
thereof substantially parallel along the grain of wood pieces from
which said strands are formed, said strands formed from solid forms
of low-quality wood selected from the group consisting of round
logs, semi-round logs, square edge cants, thick flitches and
mixtures thereof, and said strand eminently suitable for use in
forming and molding lumber products including structural members
having strength characteristics equal or superior to commercially
available wood members; a frame, said frame being generally
L-shaped in a horizontal plane and having later mentioned (a)
roller means about the longer portion of said L-shaped frame (b)
scrubber means about the shorter portion of said L-shaped frame and
(c) transfer table means mounted about the corner portion of said
L-shaped frame, a first and second series of bottom rolls rigidly
supported on said L-shaped frame juxtaposed the longer portion
thereof for rotation thereon in a plane substantially parallel with
the long axes of said frame, braking means operably engaging said
first and second series of bottom rolls for restraining the
peripheral speed thereof, a first and second series of top rolls
mounted on said L-shaped frame with the axes thereof parallel to
the axes of said first and second series of bottom rolls and each
roll in said first and second series of top rolls being in vertical
alignment with its corresponding and companion bottom roll, means
operably engaging each roll in said first and second series of top
rolls for imparting thereto rotational movement about its axis at a
predetermined peripheral speed, means operably engaging each roll
in said first and second series of top rolls for imparting thereto
vertical reciprocating movement, said means for imparting both said
rotational and said reciprocating vertical movement to each roll in
said first and second series of top rolls, being operably
independent, said means for imparting rotational movement to each
roll in said first and second series of top rolls adapted to impart
thereto a peripheral speed greater than the peripheral speed of the
companion bottom roll aligned vertically therebeneath, said top
rolls in said first series having the cylindrical portions of their
peripheral surfaces in the form of screw threads, said screw
threads being left handed from about the horizontal midpoint of
said rolls and extending to the right hand horizontal terminus
thereof and said screw threads being right handed from about the
horizontal midpoint of said rolls to the left hand terminus thereof
when viewed along the axis of the long portion of said L-shaped
frame from a direction from said first series of top rolls to said
second series of top rolls; transfer means mounted on said L-shaped
frame ahead of said first series of companion bottom and top rolls
for introducing and carrying into said rolls said solid wood forms;
transfer means disposed between each roll in both said first and
said second series of said bottom rolls for effecting mechanical
transfer of the wood mat resulting from passage thereover, transfer
means disposed beyond said second series of companion top and
bottom rolls for effecting movement of the resulting wood mat onto
said transfer table means; drive means in association with said
transfer table means for changing the direction of travel of said
wood mat entering thereupon to substantially 90.degree. from its
original direction of travel to a direction of travel substantially
parallel with and in a direction along the shorter portion of said
L-shaped frame while maintaining the alignment of the individual
splinters in said wood mat in a direction parallel with the axis of
the long portion of said L-shaped frame, wood splinter scrubber
means juxtaposed said transfer table means mounted on said L-shaped
frame and disposed along the short portion thereof, said scrubber
means having a fixed lower platen and a moveable upper platen the
top surface of said lower platen and the bottom surface of said
upper platen being serrated with the grooves from said serrations
being substantially parallel to the long axis portion of said
L-shaped frame member, said serrations on the surfaces of both said
lower and said upper platen being in the form of teeth-like
members, the direction of bite thereof being in a direction away
from the corner of said L-shaped frame and toward the terminus of
the short portion thereof, and drive means operably engaged said
movable top platen for imparting thereto in the vertical plane an
egg-shaped eliptical orbit with the larger of the two minor radii
of said egg-shaped eliptical orbit disposed toward the corner
portion of said L-shaped frame member.
2. The device claimed in claim 1 wherein the screw thread type on
the cylindrical portion of the peripheral surfaces of said top
rolls in said first series are of the buttress type.
3. The device claimed in claim 2 wherein said buttress-type thread
has a depth in the range from about one-fourth inch to about
three-fourths inch and has a pitch in the range from about one-half
inch to 2 inches.
4. The device claimed in claim 3 wherein the cylindrical portion of
the surfaces of said first series of bottom rolls is relatively
smooth and the cylindrical portions of the peripheral surfaces of
said second series of bottom rolls are serrated with the grooves of
the serrations thereof being parallel to the axis of said second
series of bottom rolls.
5. The device claimed in claim 4 wherein said transfer means
mounted on said L-shaped frame ahead of said first series of
companion bottom rolls and top rolls and said transfer means
disposed beyond said second series of companion top and bottom
rolls are roller tables, and wherein said transfer means disposed
between each roll of said first and second series of said bottom
rolls are platens disposed in substantially a horizontal plane.
6. The device claimed in claim 5 including liquid restraining means
disposed vertically beneath both said first and second series of
bottom rolls for recovery of liquids removed from said solid forms
of wood passed thereover.
Description
My invention relates to a novel approach for the utilization of
substantially all portions of poorest quality timber such as logs,
bolts, and cants, into physical forms eminently suitable for
producing wooden particle board products. More particularly, my
invention relates to a method and means wherein substantially 100
percent of such logs, bolts, etc., are converted into physical form
suitable for the production of wood particle products whereby the
heretofore approximately 40 percent loss of the peeled log to mill
residue and sawdust is substantially eliminated. Still more
particularly my invention is directed to a novel means and method
whereby round bolts, round logs, half round pieces, square-edge
cants or thick flitches of wood of any species and poor quality may
be readily crushed into a sponge-like mat of long wooden splinters
loosely held together as mats, which mats are subsequently broken
apart into splinters of more or less uniform thickness and random
lengths, whereby substantially 100 percent of the low-quality logs,
etc. acted upon are converted into said splinters of more or less
uniform thickness and length, which splinters after drying and
refining can be used either in particle board or hard board
manufacture or more desirably may be prepared for molding into
products which can be more economically substituted for presently
derived low grades of lumber.
Traditionally, the building industry, particularly that segment
related to the construction of single-family residences, has relied
upon construction utilizing substantial amounts of structural wood
as its mainstay. Since the early 1950's the wood-using industries
have been called upon to meet increasing demands for wood products.
At the present time, it is projected that in this country alone
some 50 million dwelling units.sup.1 Frank S. Kristof, "Urban
Housing Needs Through the 1980's: An Analysis and Projection,"
National Commission of Urban Problems, Research Rept. 10,
Washington 1968, p.6) will need to be constructed over the next 2
decades to house the expanding population and to replace many
dwellings which may be either unsatisfactory or substandard. This,
of course, offers a challenge to both timber growers and wood-using
industries to supply a ready market of wood products without
seriously depleting the forest capital. Conversion of poorest
quality timber, heretofore uneconomic, into high-valve wood
products in strong demand meets this challenge.
As is commonly known, only upwards of about 60 percent of products
of logging operations from only the better quality trees can be
utilized by present-day methods in the production of useful lumber,
with the other 40 percent ending up as solid residue and sawdust.
Under current practices, about 25 of all peeled logs end up in the
form of solid residue, all of which can be used as chippable
material. Up to the present time, the challenge to the timber
growers and wood-using industries for complete utilization of the
wood has resulted in extended efforts to convert the great
proportion of the solid residue into useful forms or into useful
materials either by chemical methods, such as for example,
extracting wood sugars, alcohols, and the like from wood residues
or by converting such wood residues into pulp and paper products.
Alternatively, the mechanical approach for utilization of
low-quality timber and the solid wood residue has been in efforts
to convert such timber and residues into useful forms for the
production of cement fiber boards, particle boards, hard boards,
and the like, whereby such timber and solid residue is chipped,
shaved, or otherwise mechanically worked on to render the product
from such processes in a form whereby they can be utilized, as just
mentioned.
I have now discovered a new approach, means, and method for the
utilization of substantially all of a peeled, small, low-quality
log, whereby same is converted into a form eminently suitable for
the production of wood products fully equivalent or superior to the
lumber products heretofore recoverable from such logs. In my
process, I utilize essentially all of the peeled log, or the like,
for the ultimate production of the lumber equivalent product, as
contrasted to the art heretofore practiced wherein only upwards to
about 60 percent of such logs can be so utilized. In my process,
there is no sawdust by product, nor are there any substantial
amounts of wood residue produced. In my process, substantially all
of the stumpage ultimately is useful in the end product as a full
equivalent and substitute for conventional lumber as heretofore
utilized and relied upon by the building industry generally, and
the furniture industry, specifically. Basically, my invention
comprises a method for disintegrating a log or any portion thereof
into splinter-like strands of wood substance of more or less
uniform width and thickness and reduced moisture content from the
original moisture content of the solid piece. The wood strands are
subsequently formed into fiber board or panels having structural
strength equal to or superior to the strength of flake board panels
of the same size.
Further, I have found that, in carrying out my process, the wood
products made in accordance therewith contains all of the inherent
characteristic and properties of the original timber, except that
some of the free moisture will have been removed and the knots
eliminated. Inasmuch as the original log or piece, in my process,
is subjected to pressure and forces which exceed the maximum
crushing strength of the timer, and solid structure of the timber
is caused to disintegrate along the direction of the grain into
varying length splinter-like strands of woody material which takes
the form of a mat, which mat is subsequently broken apart into
splinters of more or less uniform thickness and random lengths.
These splinters, when subsequently molded into the desired shapes
and cemented together, yield a material which derives substantially
all of its strength from the inherent strength of the wood
splinters themselves, rather than from the cementing material.
Thus, molded panel boards will be at least as strong and in many
instances stronger than similar boards which are being made from
flakes or other particles with the added advantage that
substantially all of the low-quality log may be so utilized rather
than only upwards to about 60 percent under heretofore practiced
conventional sawmill procedures.
It is therefore an object of the present invention to disintegrate
a log or any portion thereof into splinters of more or less uniform
thickness and random lengths, a reduced moisture content from the
original content of the log, or portion thereof, whereby
substantially 100 percent of said log or portion thereof may be
ultimately utilized in the production of wood products of at least
the full equivalent, and in many instances, far superior, to
products made from wood particles of varying geometry.
Another object of the present invention is to disintegrate a
low-quality log or any portion thereof, into splinters of more or
less uniform thickness and random lengths, and reduced moisture
content from the original content of the log, or portion thereof,
whereby substantially 100 percent of said log or portion thereof
may be ultimately utilized in the production of formed wood
products of at least the full equivalent, and in many instances,
far superior to the products resulting from present-day sawmill
practice, and whereby the heretofore approximate 40 percent of wood
residue and sawdust resulting from said sawmill practice is
substantially eliminated thereby.
Still another object of the present invention is to disintegrate a
log, or any portion thereof, into splinters of more or less uniform
thickness and random lengths, and reduced moisture content from the
original content of the log, or portion thereof, whereby
substantially 100 percent of said log or portion thereof may be
ultimately utilized in the production of formed wood products of at
least the full equivalent, and in many instances, for superior to
the products resulting from present-day sawmill practice, by a
process wherein aid log or portion thereof is acted upon by forces
which exceed:
1. the maximum crushing strength of the timber in compression;
parallel and perpendicular to the grain;
2. the maximum shearing strength in shear parallel to the grain;
and
3. maximum cleavage or load to cause splitting.
A further object of the present invention is to disintegrate a log,
or any portion thereof, into splinters of more or less uniform
thickness and random lengths, and reduced moisture content from the
original content of the log, or portion thereof, whereby
substantially 100 percent of said log or portion thereof may be
ultimately utilized in the production of formed wood products of at
least the full equivalent, and in many instances, far superior to
the products resulting from present-day sawmill practice, by a
process wherein said log or portion thereof is acted upon by forces
which exceed:
1. the maximum crushing strength of the timber in compression;
parallel and perpendicular to the grain;
2. the maximum shearing strength in shear parallel to the grain;
and
3. maximum cleavage or load to cause splitting;
and wherein said forces in addition to yielding the desired
physical material reduce the original moisture content thereof by
literally squeezing some of the free moisture from the cell
cavities exposed to such forces whereby is acquired the liquid
material squeezed from the timer, which is subsequently processed
by appropriate chemical engineering principles and methods so as to
salvage such extractive substances as may be contained in the wood
naturally, including such substances as tannin from the oak
species, oils and their derivatives from the cedar species, and
resins and their derivatives from the pine species.
A still further object of the present invention is to disintegrate
a log, or any portion thereof, into splinters of more or less
uniform thickness and random lengths, and reduced moisture content
from the original content of the log or portion thereof, whereby
substantially 100 percent of said log or portion thereof may be
ultimately utilized in the production of formed wood products of at
least the full equivalent, and in many instances, far superior to
the products resulting from present-day sawmill practice, whereby
will be promoted a more extensive utilization of the low-quality
timber not economically feasible to convert, under existing
technology and conventional methods of manufacture, into useful
solid wood products, thereby contributing materially to the
conservation and wise use of our nation's timber resources and
capital.
Still further and more general objects and advantages of the
present invention will appear from the more detailed description
set forth below, it being understood however that this more
detailed description is given by way of illustration and
explanation only and not by way of limitation since various changes
therein may be made by those skilled in the art without departing
from the true spirit and scope of my invention.
My invention, together with further objects and advantages thereof
will be better understood from a consideration of the following
description taken in connection with the accompanying drawing in
which:
FIG. 1 is an isometric schematic illustration of the preferred
embodiment of a log defibrating apparatus used in accordance with
the practice and teachings of my invention.
FIGS. 2 and 3 are depictions drawn approximately to scale of the
splinters resulting from my invention as operated under two
different sets of parameters whereby in FIG. 2 it was desired to
have relatively short wood splinters of more or less uniform
lengths and diameters whereas in FIG. 3 are depicted wood splinters
of longer lengths.
FIG. 4 is an illustration of typical wood chips prepared by
conventional means from solid wood residues, which chips are
intended for use in the production of pulp and paper.
FIG. 5 is a depiction of just one of many typical shavings
resulting from a particular planer setting for producing flakes by
conventional means intended for use in the production of
particleboard by conventional methods.
FIG. 6 depicts both a typical green plank and a half log
illustrative of the low quality timber or stumpage which may be
expediently utilized according to the instant invention.
FIG. 7 is an illustration of what the solid wood plank or half log
from FIG. 6 looks like when processed according to my invention
into the spongy-like mat of long, splinter-like wood fiber strands
more or less firmly enough held together to remain as a unit mass
of material prior to treatment with my scrubber apparatus.
FIG. 8 is a schematic illustration of the detail of the top rolls
in the first series of rollers having the cylindrical portions of
their cylindrical surface in the form of screw threads, said screw
threads being left handed from about the horizontal midpoint of
said rolls and extended to the right hand horizontal terminus
thereof, and said screw threads being right handed from about the
horizontal midpoint of said rolls to the left hand terminus thereof
when viewed along the axis of the long portion of said L-shaped
frame from a direction from said first series of top rolls to said
second series of top rolls. As will be noted in later discussion,
the thread depth on rolls 2, 3, and 4 may vary from one-fourth to
three-fourths inch and the thread pitch may vary from one-half inch
up to 2 inches. In addition, FIG. 8 depicts the thread type on said
rolls as being of the buttress type, which is a thread type
commonly used wherein motion or thrust is required in but a single
direction such as in the breech of large guns, in jack stands, and
the like.
FIG. 9 is a schematic illustration of one type of drive means for
operably engaging the top platen for imparting thereto in the
vertical plane and egg-shaped, elliptical orbit with the larger of
the two radii of said egg-shaped elliptical orbit disposed toward
the corner portion of the L-shaped frame member. As may be seen
from the detail in FIG. 9, driving the two shafts at identical
speeds produces the desired elliptical orbit of the upper platen
due to the action of the two different size cam. For the sake of
convenience, the driving machinery for said shafts and the
supporting structures are not shown.
FIG. 10 is a depiction not to scale of the cylindrical portions of
the peripheral surfaces of the second series of bottom rolls which
may be serrated with the grooves of the serration thereof being
parallel to the axes of the second series of bottom rolls.
Referring now more specifically to FIG. 1, there is shown a
preferred embodiment of apparatus which I have had constructed and
operated for carrying out the objectives of my invention. As may be
seen, the apparatus comprises a sturdy L-shaped frame upon which
are mounted two series of roll sets 2-2a, 3-3a, 4-4a, and 8-8a,
9-9a, 10-10a and 11-11a. Each of the aforementioned roll sets
consists of a companion upper and lower roll. Lower rolls, 2a, 3a,
4a, and 8a, 9a, 10and 11a, are rigidly supported by the lower frame
of the machine to withstand the crushing load imposed upon the log
by upper rolls 2, 3, 4, and 8, 9, 10, and 11. The wood pieces,
i.e., log, half log, flitch, cant, or whatever to be processed
according to my invention, are fed into my apparatus by means of
roller table 1 whereby said pieces are first acted upon by roll set
2-2a.
The cylindrical surfaces of upper rolls 2, 3, and 4 are in the form
of screw threads right and left hand from the center of the rolls
to their ends. The thread form and pitch on each roll is that which
is most suited to the purpose of tearing apart and spreading the
wood fibers into a mat under pressure. As indicated, upper rolls 2,
3, and 4, in addition to being rotated by variable speed
motor-reducer 26, can be moved vertically. Vertical movement is
accomplished by hydraulic cylinders 25 so arranged and controlled
as to operate in unison, and capable of exerting the required
crushing force upon the log. The rotational and vertical drives for
these upper rolls are independent of each other. Wood material
passing through roll sets 2-2a and 3-3a to roll set 4-4a is
supported by platens 5 and 6.
Surfaces of bottom rolls 2a, 3a, and 4a are smooth or they may be
serrated with grooves parallel to the axes of the rolls. Speed of
bottom rolls 2a, 3a, and 4a is restrained by a dynamic braking
system utilizing motor-reducer 22 as a regenerative electric brake
so that the speed of the wood mass or log through my apparatus is
less than the peripheral speed of upper rolls 2, 3, and 4. Crushed
wood mass or logs leave roll set 4-4a as a mat supported and guided
into roll set 8-8a by platen 7. Likewise platens 12, 13, and 14
disposed between roll sets 8-8a, 9-9a, 10a, and 11-11a, as well as
the platens shown numbered as 5 and 6 on drawing and as noted above
disposed between roll sets 2-2a, 3-3a, and 4-4a support the wood
mat as it is formed and spread out progressively through the
apparatus mounted on the longer portion of the L-shaped frame.
Surfaces of upper rolls 8, 9, 10, and 11 are smooth while the
surfaces of lower rolls 8a, 9a, 10a, and 11a, although not shown,
are, in my most preferred embodiment, serrated with grooves
parallel to the axis of said rolls. I have observed that the
serration of these lower roll surfaces, although not absolutely
essential to the carrying out of my process, produces a more
desirable mat form. The peripheral speed of the lower rolls 8a
through 11a is identical to the speed of lower rolls 2a, 3a, and
4a.
Upper rolls 8 through 11 are provided with hydraulic cylinders, 23
for activating them vertically and also independently of each
other. One or more of the upper rolls 8 through 11 may be
oscillated vertically by controlled, repeated action of hydraulic
cylinders 23, to provide a beating action. Platens 12, 13, and 14
support the fiber mat through roll sets 8-8a through 11-11a. The
fiber mat, mat, as it leaves roll set 11-11a, is supported and
guided to transfer table 16 by roller table 15. For convenience,
one type of mechanism for actuating transfer table 16 is shown
removed from therebeneath consisting of hydraulic cylinder 16a for
providing reciprocal motion in a horizontal plane and rocker arms
16a for transferring the impulses from cylinder 16a to transfer
table 16. From transfer table 16 the fiber mat proceeds into the
fiber scrubber 17. Scrubber 17 is essentially a machine consisting
of fixed lower platen 18 and movable upper platen 19, together with
drive means not shown necessary to cause upper platen 19 to travel
in an egg-shaped, elliptical orbit, as indicated on the drawing.
Both upper platen 19 and lower platen 18 are grooved or serrated
across their juxtaposed surfaces with the grooves parallel to the
alignment of wood fibers as they pass through scrubber 17. As shown
in FIG. 1, the serrations or grooves in the top surface of the
lower platen 18 and the lower surface of the top platen 19 are
generally in the form of teeth-like members whose bite is in the
direction from the corner of the L-shaped frame toward the exit of
the scrubber. Thus, the wood mat leaving roller table 15 is moved
via transfer table 16 into the mouth of the scrubber jaws which
work on the mat bundle to pull, shred, roll, and otherwise work the
individual strands from the mat to be discharged for further
processing and molding into the desired forms. Such further
processing requires varying degrees of further drying of the
individual wood strands and, if desired, screening or sizing
thereof.
The loosely separated fiber strands, when discharged from the fiber
scrubber 17, drop onto belt conveyor 20 as a new geometric form of
wood resource ready for a variety of manufacturing processes.
Trough 21 catches liquids squeezed from the logs and drains the
liquid to a suitable tank for subsequent chemical processing.
As should now be apparent, the instant invention provides an
arrangement by means of which low quality round bolts, round logs,
half round pieces, square edge cants or thick flitches of any wood
species may be readily crushed into a sponge-like mat of long wood
splinters loosely held together, and as the mats are formed, are
acted upon by a first series of rotating sets of rolls containing
screw-thread-like configurations which, under pressure, cause
further disintegration of the wood into a mat of thin splinter-like
strands. Further action by a second series of rotating sets of
rolls having smooth and/or serrated surfaces (serrations parallel
to axis of the rolls) causes compression and spreading of the mat.
Further and subsequent action by the scrubber element causes the
resulting compressed and spread woody fiber mat to be broken apart
into individual splinters of more or less uniform and random
lengths. Actually, the individual elongated wood splinters are
themselves composed of almost hair-like individual strands held
together in their natural state as produced in the tree.
It should be appreciated that the thread sizes on rolls 2, 3, and 4
and their configuration, of course, might be varied over
substantial range; however, based on my experience with the
apparatus I have developed, I have found that the operable ranges
are as follows:
thread depth -- one-fourth inch to three-fourth inch
thread pitch -- one-half inch to 2 inches
thread lead -- same as pitch for single thread and twice the pitch
for double thread
A buttress type thread is the one used on rolls 2, 3, and 4 in the
apparatus shown in FIG. 1, and my experience has shown that this
appears to be thread configuration most suited to splitting and
spreading the wood mass.
The maximum range of pressures is, of course, controlled by the
maximum force available to the machine. The pressure on any given
thread form will depend upon the type and size of the thread and
the total area of contact of the thread with the wood. Thus, in my
device the initial pass of a log or the like will, in my most
preferred embodiment, be through a roll with a large pitch thread
and succeeding passes through rolls with progressively smaller
pitch threads.
In the apparatus depicted in FIG. 1, the maximum pressure available
on the hydraulic system as I used same was 3,000 p.s.i. With this
maximum pressure, the compressive force available at the top rolls
is about 93,000 pounds. Assuming that the initial penetration of
the threads has taken place such that a 2-inch length of crest on
two threads is in contact with wood, the pressure exerted thereby
is about 370,000 p.s.i. Assuming that the threads are embedded to
their full depth, the maximum pressure on the projected area
parallel to the surface of the top roll is then 34,000 p.s.i. As
the crushing proceeds, the mass of wood spreads out into a
spongy-like mat of increasing width and decreasing thickness. With
a 10-inch spread of wood mat, pressure exerted is about 3100 p.s.i.
With a mat spread of 20 inches, the pressure is reduced by about
one-half to about 1,550 p.s.i. At this stage, i.e., a mat spread of
about 20 to 22 inches, crushing is complete, the integrity of the
solid wood mass is completely destroyed, and the mat is ready to
pass through scrubber 17 for separation into thin individual
splinters or strands.
Because of the inherent properties of wood, green wood lends itself
to the above-described process quite readily and has advantages of
processing in addition to being processed immediately after
harvesting. Wood in the green state contains a considerable amount
of moisture, varying from about 30 to 40 percent (based on the
weight of the dry wood) in the heartwood of some of the pines to
over 200 percent in the sapwood of some other species. Part of this
moisture is held absorbed by the cell walls and part is held within
the cell cavities as water is held in a container. As wood dries,
the cell cavities must first be emptied of all their moisture
before the adjacent cell walls start to release their moisture. The
condition in which the cell walls are fully saturated and the cell
cavities empty is known as the "fiber saturation point." It varies
between species from approximately 25 to 30 percent moisture
content.
Strength begins to increase when the cell walls start to lose
moisture; that is, after drying continues below the fiber
saturation point. From this point on, most strength properties
increase rapidly as drying progresses. To illustrate, for the
strength properties most involved in this log defibrating process,
the following figures show the average variation of strength
properties of wood with change in moisture content: The percentages
show the average increase (or decrease) in value effected by
lowering (or raising) the moisture content 1 percent:
Maximum crushing strength in compression parallel to grain --
6percent
Fiber stress at proportional limit in compression perpendicular to
grain -- 5-1/2 percent.
Shearing strength parallel to grain -- 3percent
As a restriction for optimum operating conditions, it is therefore
stipulated that the timbers should be in the green state or at a
minimum moisture content of 30 percent, based on the oven-dry
weight of the wood.
A further stipulation for optimum operation of the process involves
temperature. It is known that tests in compression parallel to the
grain have shown strength values for green wood at temperatures
near the boiling point about one-fifth as great as at normal room
temperature. It is therefore stipulated that optimum defibration
conditions require that timbers, in addition to being in the green
state, also could best be defibrated if temperatures are raised
somewhat above room temperature and upwards. This could mean that
all timbers would undergo immersion in heated water vats prior to
defibrating.
In order that those skilled in the art may be better understand how
the present invention can be practiced, the following examples of
the methods I have used in disintegrating logs and other portions
of timber for producing the desired wood splinters and in some
instances the subsequent formation and molding of same into desired
structural members and board products are given by way of
illustration and not by way of limitation.
EXAMPLE I
Suppose it is desired to defibrate a green plank or a half log as
shown in FIG. 6, or any other shaped solid piece of timber. The
underlying idea of the instant invention is to completely crush the
solid wood plank or log into a spongy-like mat of long,
splinter-like wood fiber strands more-or-less firmly enough held
together to remain as a unit mass of material as shown in FIG. 7.
This is accomplished through roll sets 2, 3, and 4 within a range
of pressures between 1,500 and 3,000 p.s.i. As the spongy mass
passes through roll sets 8, 9, 10, and 11, the mass of more-or-less
firmly held together splinter-like wood fiber strands are more
finely divided and separation becomes more complete due to the
action of the changed configuration of threads on roll sets 8, 9,
10, and 11. Final separation of the then more-or-less loosely held
together mass is then accomplished through scrubber 17 by its
crushing, rolling, and pulling action of the woody mass between the
serrated top and bottom platens.
Another general embodiment of the instant invention deals with the
variability that can be encountered in the separation or
defibration process due to the grain of wood. Grain of wood in this
instance is defined as the arrangement and direction of alignment
of wood elements when considered en masse. Three type of grain are
recognized as basic wood grain structure; although they do occur in
combination: (1) Straight grain -- grain in which the direction of
the fiber alignment is straight or nearly so; grain in which the
fiber alignment is vertical or nearly so in the standing tree.
Defibration is quick and nearly complete resulting in long strands
of more-or-less uniform thickness. (2) Spiral grain -- grain in
which the fibers are aligned spirally in the standing tree.
Defibration is more difficult resulting in shorter strands due to
cutting action across the grain by the threaded roll sets 2, 3, and
4. More of the separation must be effected by scrubber 17. (3)
Interlocked grain -- grain in which the direction of the fiber
alignment alternates at intervals. Defibration is most difficult
with wood of this nature, but fortunately species of trees with
this inherent characteristic are in the minority. Defibration is
most difficult and requires more of the cutting action of the fine
thread configuration on roll sets 8, 9, 10, and 11, and the
additional scrubbing effect of scrubber 17. The resulting
splinter-like strands are the shortest of the three kinds of grain
but, since various length of strands is an asset in envisioned
product development, use of wood of this nature poses no series
problem.
Another general example, exemplifying the idea of the instant
invention deals with the recovery of liquid (free moisture
contained in the cell cavities of the wood) squeezed from the
timber under pressure. Collection of the varying amounts of liquid
due to species of wood and greenness of the wood entering the
machine is provided for by trough 19.
EXAMPLE II
A specific example of the instant invention portrays results of the
defibrating process under systemmatic test. Twenty-four black oak
(Quercus velutina Lam.) planks 3 .times. 5 .times. 7 were
defibrated to obtain optimum operating ranges of the equipment.
Controlling variables in the defibrating process are pressure,
speeds of top and bottom rolls and thread configuration on top
rolls. Best results were obtained with pressures between 1,550 and
1,950 p.s.i.; top and bottom roll speeds of 24.8 and 9 rpm's
respectively and a buttress type, single acting thread. After three
passes through a single roll set, average width and the thickness
of the original 5 -inch wide by 3 -inch thick plank was 16.5 inches
wide by 2 inches thick. The integrity of the wood was completely
destroyed resulting in a mat of more-or-less loosely held together
splinter-like strands of wood as shown in FIG. 7.
Another specific example of the instant invention deals with the
measured loss of moisture from the 3 .times. 5 ' 7 test planks
which were in their natural green condition at the time of the
test. Average moisture content (MC) before defibration was 83
percent (based on oven dry -- O.D. -- weight): after defibration it
was 75 percent. The measured moisture loss due to defibration
ranged between 0.24 and 2.64 lbs. per cubic foot of wood and
averaged 1-3/4 lbs. per cubic foot. Assuming a standard cord of
black oak wood to contain 72 cubic feet of solid wood, an average
of approximately 15-3/4 gallons of liquid per cord would be
salvaged for chemical processing.
EXAMPLE III
Three sheathing-type boards were experimentally made at the United
States Department of Agriculture's Forest products Laboratory,
Madison, Wisconsin. Using 2- to 3 -inch long splinters produced by
the present invention, three sheathing-type boards were made to the
following "basic" specifications:
Board size: 1/2 .times. 24 .times. 28 inches Board density: 40
pounds per cubic foot Resin type and content: Phenolic, 3 percent
(solids basis) Additives: 1 percent emulsion (solids basis) Press
cycle: 10 minutes at 350.degree. F, pressed to 1/2 -inch thickness
in 1 minute
Two boards, A and B were made from splinters as produced by the
invention. The third board, C, was made from splinters produced by
the invention after they were hammermilled. The splinters were fed
through a small agricultural hammermill without screen.
Board B had a moisture content of 15 percent, whereas boards A and
C had moisture contents of 10 percent. It was the hope of the
product development engineers that the boards with the higher mat
moisture content would have surfaces with fewer voids. However,
little difference was noticed.
Engineering test results on three critical properties of the new
sheathing-type board products are given below:
The results of the modulus of rupture, modulus of elasticity, and
nail tests are:
Board Lateral Nail No. M.O.R. M.O.E. Nail Pull Withdrawal
__________________________________________________________________________
(p.s.i.) (1,000 (Lbs.) (Lbs.) p.s.i.) A 1260 190 261 .sup.1 24
.sup.2 128 B 890 150 169 .sup.1 24 .sup.2 140 C 1320 210 338 .sup.1
28 .sup.2 125
__________________________________________________________________________
In addition to strength tests, an ovendry to vacuum-pressure-soak
dimensional movement test was made on each board with the following
results:
Board Length Change From Thickness Change No. O.D. to V.P.S. from
O.D. to V.P.S.
__________________________________________________________________________
A 0.92 percent 58.1 percent B 1.15 percent 62.6 percent C 1.04
percent 48.7 percent
__________________________________________________________________________
While I have shown and described particular embodiments of my
invention, modifications and variations thereof will appear to
those skilled in the art. I wish it to be understood, therefore,
that the appended claims are intended to cover such modifications
and variations which are within the true scope and spirit of my
invention.
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