WO2001012402A1 - Procede de realisation de moulures façonnees - Google Patents

Procede de realisation de moulures façonnees Download PDF

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Publication number
WO2001012402A1
WO2001012402A1 PCT/US1999/018015 US9918015W WO0112402A1 WO 2001012402 A1 WO2001012402 A1 WO 2001012402A1 US 9918015 W US9918015 W US 9918015W WO 0112402 A1 WO0112402 A1 WO 0112402A1
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Prior art keywords
ofthe
moulding
mouldings
veneer
wood
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PCT/US1999/018015
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English (en)
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Marc A. Seidner
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Individual
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Individual
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Priority to PCT/US1999/018015 priority Critical patent/WO2001012402A1/fr
Priority to AU54726/99A priority patent/AU5472699A/en
Publication of WO2001012402A1 publication Critical patent/WO2001012402A1/fr
Anticipated expiration legal-status Critical
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27M—WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
    • B27M3/00—Manufacture or reconditioning of specific semi-finished or finished articles
    • B27M3/0013—Manufacture or reconditioning of specific semi-finished or finished articles of composite or compound articles
    • B27M3/0026—Manufacture or reconditioning of specific semi-finished or finished articles of composite or compound articles characterised by oblong elements connected laterally
    • B27M3/0053—Manufacture or reconditioning of specific semi-finished or finished articles of composite or compound articles characterised by oblong elements connected laterally using glue
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27M—WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
    • B27M3/00—Manufacture or reconditioning of specific semi-finished or finished articles
    • B27M3/08—Manufacture or reconditioning of specific semi-finished or finished articles of specially shaped wood laths or strips

Definitions

  • the present invention relates to wooden blanks and mouldings, and more particularly to mouldings that have substrates covered by a machinable wooden veneer.
  • a reengineered rip saw as described herein preferably is used to form a plurality of lineal mouldings in parallel simultaneously.
  • mouldings such as base (floorboard skirting), flat and split door jambs, crown (ceiling surrounds), rabbeted jambs (frames), brick mould, and casing (door and window surrounds), are well known. Mouldings generally are decorative, and provide architectural detail. Some mouldings, however, support light loads such as door jambs that support the hinges and doors. It is important that the wood used in the mouldings be of at least a quality corresponding to the type of finish use desired, and the type of load supported.
  • mouldings are to be left natural or varnished, then the wood is usually desired to be clear and bright, free of knots, fungus stains, pitch, wood discolorations, glued joints, or other visible blemishes.
  • Such mouldings are known in the construction business as “clear solid grade lineal mouldings,” or simply “solid clear mouldings.”
  • paint grade mouldings intended to be covered by paint (or something else that hides the glue joint, color, grain or defect ofthe wood) are known as "paint grade mouldings."
  • the construction industry uses paint grade mouldings in most applications. Using a lower grade knotty or defective or discolored woods, or otherwise imperfect wood, in the fabrication of paint grade mouldings is especially desirable considering that higher quality clear and bright grade woods are generally less plentiful and more expensive. Lower grade woods are less expensive than solid clear mouldings, and the finger joint manufacturing process involved in the fabrication of paint grade mouldings, removes defects that are unpaintable in finished mouldings.
  • the use of paint grade moulding results in a lower cost ofthe finished moulding applications because long clear bright lengths of natural finished wood are not required. In recent years, the use of clear solid grade mouldings has declined while the use of paint grade mouldings has become more common.
  • Finger joint moulding is produced using a fifty year old process created to provide paint grade moulding in desired dimensions.
  • Each finger joint moulding is formed by a lengthy multi-step process that includes: 1 ) ripping strips from a thick plank of wood; 2) cross cutting blocks of paintable and fmger-jointable defect-free segments out of each strip by removing those segments having knots, splits, blemishes, or other defects; 3) occasionally reripping the cut blocks strips to a narrower width to remove any broken or wane edges; 4) finger jointing by machining and glueing the resulting accumulated clear blocks to form finger joint blanks ofthe desired length and dimension; 5) resawing if necessary, with a band saw or rip saw the finger joint blanks in a desired dimension or beveled shape; 6) passing the resulting blank through a multi-headed profiled knife moulder in lineal fashion to form mouldings in their final cross sectional contoured shape; and 7) precision trimming and dado processing the mouldings into the final desired length
  • finger joint moulding is a widely accepted and used paint grade moulding, there are several undesirable characteristics associated with the prior art techniques used to manufacture finger joint mouldings.
  • the entire board footage volume of finished finger joint moulding profiles fabricated is constituted by an equivalent volume of high quality clear solid wood.
  • the lumber materials used in the fabrication of finger joint moulding are expensive and of limited availability.
  • the finished product being formed from solid bright clear wood is likewise expensive and in limited supply.
  • each discrete section of wood or blank used in finger joint moulding is composed from multiple smaller blocks or discrete wood sections. Therefore, each discrete wood section is susceptible to its own natural characteristic tendencies of wa ⁇ ing, splitting, bowing, cupping, twisting, and other problems common to discrete lengths of wood. Wood moulding that warps, cracks, or otherwise distorts is difficult and frustrating to work with, and increases scrap. Additional unpredictable waste is generated during the manufacturing process. If the process exposes a defect previously hidden inside the wood and it becomes apparent that a section or block is defective in that manner after it is fabricated into a blank, it can usually result in the entire blank being deemed defective and subject to complete remanufacture to remove such newly apparent defects.
  • a third undesirable characteristic of prior art finger joint mouldings is that each moulding piece usually has to be moulded separately. Rarely are more than two pieces machined simultaneously in one moulding machine, and two pieces may be machined simultaneously only when the profile has a very small cross sectional dimension as most moulders are not wider than eight inches, and all moulders are not wider than twelve inches. Machining one or two work-pieces at a time (especially when using modern and expensive moulders) is costly in both machine time and labor. Such slow, individual, work processing adds to the expense ofthe moulding significantly and usually results in smaller mouldings being only slightly less costly than mouldings having larger cross sections, or solid clear grade lineal mouldings formed from higher quality wood. Since each moulding piece is moulded separately and since cross cutting is a separate operation, each piece also has to be handled, measured, and cross cut by itself.
  • veneer mouldings are formed as substrates that have veneers covering some or all of their surfaces. Veneers are much more common in furniture component construction than in moulding fabrication. In prior art veneer mouldings, an inexpensive substrate of wood, or other material such as medium density fiberboard, is machined or formed in a quality fashion to the desired shape ofthe final moulding. A thin strip of veneer (usually cut or sliced from a high quality wood) is then bent or contoured in a shape that conforms directly to the surface ofthe substrate. The veneer is then adhered to the exposed surfaces of the substrate. If made correctly, veneer mouldings can have an attractive appearance resembling, but being less costly than, solid clear wood mouldings. Veneer moulding is, however, more expensive than finger joint paint grade moulding. The use of veneer mouldings is usually commercially reserved to low volumes of high quality expensive veneer hardwood species where solid wood of that species is difficult or too costly to obtain.
  • the present veneer mouldings have several shortcomings, however. To form a thin veneer into certain generally commercial standard industry household moulding profiles or desired angles or shapes, the veneer has to be bent sharply to conform to sharply angled contours ofthe profile. Most veneers are formed from a wood that cannot adapt to very sharp bending, and attempting to bend them sharply causes cracking. Such cracking may occur after the moulding leaves the factory, and perhaps during installation ofthe moulding. However, most cracking occurs in manufacturing. Sharp angles are therefore not usually found on veneered mouldings. In addition, the adhesive used to attach the veneer to the substrate may fail, allowing the veneer to peel away. The use of veneer mouldings is not very desirable, for most ofthe large volume of mouldings consumed, because of these cracking and peeling problems.
  • veneer mouldings are still expensive and require a careful machining of the substrate in a linear fashion before the application of the veneer that is also accomplished in a linear fashion.
  • veneer mouldings often do not have the appearance of a solid or finger joint wood, and are often equated with either lower valued casegood products or furniture, cabinets, and picture frames.
  • the costs associated with acquiring veneers and veneering is relatively high.
  • Moulding machines are commonly used to shape contoured lineal surfaces ofthe mouldings. Moulding machines are rarely able to produce a moulding or process a blank that is a foot wide or wider. The moulding machines are relied upon largely because they can provide cuts having extremely close tolerances and/or complex curves. If mouldings are milled by machines that do not operate within these tolerances, then certain edges ofthe work piece may be misshaped, the exposed wood ofthe mouldings may have raised or torn grains, or the lineal surfaces may have washboard surface effects. Further machining, or occasionally sanding, is necessary to smooth the surfaces of work pieces having such washboard surfaces.
  • Rip saws are also used in moulding fabrication to provide cuts that extend lineally through pieces of wood. Rip saw cuts do not have to generate much wood waste. However, forming curved or contoured lineal surfaces using rip saws is not possible. From these foregoing paragraphs, it should be evident that each ofthe moulders, planers, and rip saws have their own purposes in moulding fabrication. Not only does each prior art piece of machinery work on very few pieces at any one time (in a lineal fashion). Additionally, to form many mouldings, there are multiple necessary processing steps that often require different machines.
  • mouldings sold are standardized profile shapes and sizes that have a simple but well defined contoured cross section. These rectangular cross sectional rounded edges and simple "S" edges and radius curved cross sectional mouldings represent approximately 85 percent ofthe mouldings sold. Intricately curved and angled cross sectional mouldings and very complex profiles traditionally represent approximately 15 percent of moulding volume. Many prior art machines used to produce mouldings therefore are more complex, and can provide profiles of much greater intricate architectural detail and variations in design, than is necessary for the predominant volume of mouldings made and consumed by the housing and commercial construction industry.
  • the present inventions relate to a technique for forming an axially extending engineered lineal moulding that has at least one axially extending exposed surface.
  • An elongated wood section, and a substrate having at least one axially extending side, is provided.
  • the wood section is adhered to the axially extending side.
  • the wood section is contoured by moulding in a lineal manner, in an axial direction, to form, shape, and angle the exposed surface.
  • a feature of certain preferred embodiments ofthe present invention is that the substrate itself (that may be relatively inexpensive to fabricate) can replace and substitute for a large volume ofthe relatively expensive solid wood used in solid clear or finger joint mouldings.
  • the substrate is preferably taken from a material that can limit common solid wood moulding problems (or finger joint moulding problems) such as splitting, twisting, and warping. Since the wood forms an exposed outer surface ofthe engineered blank that may be contoured, the appearance and the longevity ofthe engineered moulding of the present invention is superior to traditional veneer mouldings, and resembles for all appearance purposes either solid wood clear mouldings or solid wood finger joint paint grade mouldings.
  • Another feature of the preferred embodiments of the present invention is to provide a reengineered and profiled wide plane multiple rip saw that can inexpensively, simultaneously, and yet accurately, form many multiple profiles ofthe mouldings.
  • the prior art moulding machines are replaced by those reengineered rip saws that are comparatively inexpensive to build and operate.
  • the reengineered wide plane rip saw can accurately machine multiple pieces of mouldings simultaneously in a lineal fashion and at a high speed from a single blank form, unlike prior art moulders.
  • the reengineered rip saw of preferred embodiments ofthe present invention has upper and lower arbors that hold cutter tool elements that are capable of providing continual, concentric, and smooth profile cuts that both separate multiple profiles ofthe distinct engineered mouldings from said composite panel form, and contour the engineered moulding surfaces as the workpiece panel passes into and through the machine.
  • the reengineered rip saw has additional guides and restraints to hold the composite panel moulding blanks and finished exiting mouldings in a manner that allows exact tolerances to be held.
  • FIG. 1 is perspective view of a board or plank of 8' to 16' length used to form a prior art finger joint moulding
  • FIG. 2 is a plan view of a rip strip cut from the Fig. 1 plank
  • FIG. 3 is a perspective view of a prior art block cut from a rip strip but having a broken or waney edge;
  • FIG.4A is a top or side assembly view of a plurality of prior art rip strips having finger jointed cut ends;
  • FIG. 4B is a top or side assembled view of the FIG. 4A prior art rip strips connected by glue in an end-to-end configuration;
  • FIG. 5 is an end perspective view illustrating using a band saw to form prior art straight finger joint blanks from other finger joint blanks
  • FIG. 6 is an end perspective view illustrating using a band saw to form prior art angled finger joint blanks from other larger finger joint blanks
  • FIG. 7 is a perspective view illustrating a prior art angled finger joint blank, the blank has an outline formed thereupon that defines the final cross sectional shape of the finger joint moulding;
  • FIG. 8A is perspective view of one embodiment of an axially extending composite panel form, used to form one type of engineered moulding;
  • FIG. 8B is a perspective view of an alternate embodiment of composite panel form used to form another type of engineered moulding
  • FIG. 9 is an end view of one embodiment of an engineered moulding that can be produced from the FIG. 8A composite panel form;
  • FIG. 10 is an end, partial cross sectional, view illustrating the formation ofthe edge boards that are applied to the FIG. 8A composite panel form;
  • FIG. 11 is an end, partial cross sectional, view illustrating the formation of machinable veneer strips that are applied to the FIG. 8A composite panel form
  • FIG. 12A is a top plan view illustrating the cutting apparatus that forms a preferred embodiment of engineered moulding from the FIG. 8A composite panel form
  • FIG. 12B is a side elevational view ofthe FIG. 12A cutting apparatus
  • FIG. 13 is across sectional elevational end view as taken along section lines 13-13 of FIG. 12B;
  • FIG. 14 is a cross sectional elevational end view as taken along section lines 14-14 of FIG. 12B;
  • FIG. 15 is a cross sectional view of one embodiment of composite pane form, illustrating cuts that define one embodiment of engineered moulding ofthe present invention.
  • FIG. 16 is a cross sectional view of another embodiment of composite panel form from FIG. 15, illustrating cuts that define another embodiment of engineered moulding ofthe present invention. DETAILED DESCRIPTION OF THE PRESENT INVENTION
  • the term “engineered” is defined as any element, such as a blank or a moulding, that is formed from a plurality of distinct elements affixed to each other in a specially conceived manner designed for finished appearance.
  • the term “reengineered rip saw” is defined as a rip saw having at least one cutting element that functions as a combination moulder knife and saw blade that can contour wood, and at least one cutting element that functions as a saw blade or splitter knife that can cut wood. Both types of cutting elements are mounted to at least one of its arbors.
  • FIGS. 1-7 thus illustrates a prior art process for producing finger joint mouldings.
  • This process begins with a board or plank 22 illustrated in FIG. 1.
  • the board 22 is cut lengthwise along lines 24, using a rip saw, to form a plurality of rip strips 26.
  • FIG.2 illustrates a plan view if one such rip strip.
  • Many rip strips contain one or more knots 28 or other imperfections.
  • Cross cuts along lines 30, as close as possible to the knots or other defects as shown in FIG. 2, are used to remove the defects that are not useable in finger joint moulding.
  • the positioning ofthe cut lines 30 must be chosen skillfully since, if the cut lines are too far from the defect, good wood is wasted. If the cut lines are too close together, then portions ofthe imperfection remain in the wood.
  • the cuts must be perpendicular to the axis of each rip strip to produce rectangular blocks with square cut ends so that finger joint blanks which are supposed to be straight are made from less wood, and less wood is lost in the finger joint moulding fabrication process.
  • the edges of some boards where tree bark was attached are waney or broken 32 as shown in FIG. 3.
  • many ripped boards are not perfectly square-edged and have at least one waney edge.
  • the block cut from that portion ofthe rip strip is re-ripped (recut) along dotted lines 34 as illustrated in FIG. 3. This process of re-ripping the rip strips to remove the broken edges must be done carefully since, if too much wood is removed, the excess wood is wasted. If too little wood is removed, then many rip strips still have a portion formed with a waney edge.
  • Such blocks are not suitable for further machining into finger joint mouldings of the original rip width, and using rip strips with waney edges can result in defective mouldings or a higher percentage of waste .
  • multiple shorter blocks have to be attached to each other in an end to end configuration.
  • ends 36 ofthe blocks 26 are cut with finger cut patterns 38 as illustrated in FIG. 4A.
  • the finger cut patterns of mating fingered ends have to mate tightly and gap-free with each other so that the ends can be connected to form a finger joint blank 40, illustrated in FIG.4B.
  • Each block used to form the finger joint blank must have a uniform thickness and width to ensure a sufficient quality and uniformity of the finger joint blank such that it is suitable for forming into a larger finger joint moulding.
  • the finger joint blank forms a continual elongated element that must be further machined to produce a finger joint moulding.
  • a saw (not shown), which is usually referred to as a resaw, has its blade oriented along axis 42 to cut the larger finger joint blank along the saw cut 44, in FIG. 5 and FIG. 6.
  • FIG. 5 illustrates the saw cut where the cutting blade is parallel to an edge ofthe finger joint blank 40.
  • Such cuts produce a plurality of thinner "straight" finger joint blanks having a smaller cross section than the original blank.
  • Flat blanks are any finger joint blank having a rectangular cross section.
  • FIG. 6 shows how the finger joint blank is tilted through an angle ⁇ , such that the resaw saw cut is not parallel to any face ofthe finger joint blank but is on a bevel.
  • a jig ir apparatus called a "tilting bed", that is fixed with normal saw infeed rollers (not illustrated) secures the finger joint blank in the tilted position during the resawing process.
  • the FIG. 6 configuration produces two angled finger joint blanks from a larger finger joint blank 40.
  • An angled finger joint blank is any bevel-faced finger joint blank that is not a flat finger joint blank.
  • the angled finger joint blanks are produced from a bevel resaw of a larger flat blank.
  • the finger joint blank 40 an angled finger joint blank is shown in FIG.
  • moulding machine that is not illustrated, but is well known in the art.
  • Such moulding machines vary in configuration, but in general, they cut and contour the engineered blanks with some profiled knives fixed into a rotating cutter head holding device to make continual concentric cuts which provide an elongated moulding having a uniform cross section formed from multiple lineal surfaces.
  • the cutting surfaces ofthe knife blades ofthe moulding machine cutter head form the outside surface shape ofthe moulding outline 46.
  • These moulding machines and cutter heads are expensive to purchase, maintain, and operate.
  • the moulding machines produce mouldings lineally, generally singularly, and therefore relatively slowly. Each moulding piece that is being cross cut or trimmed to a desired length therefore has to be measured, handled, and cut individually.
  • the finger joint moulding thus provided need not be sanded unless improperly made, but may be painted, and prepared for mounting.
  • Finger joint mouldings generally suffer from essentially the same defects as mouldings formed from a single piece of solid wood and as such are susceptible to warping, cupping, bowing, twisting, and splitting, but to a lesser degree. Finger joint moulding tends to be much more stable than the single-piece mouldings.
  • FIGS. 8- 16 certain preferred embodiments ofthe present invention, illustrated in FIGS. 8- 16, are now described in detail.
  • FIG. 8A illustrates an axially extending composite panel form 50 composed of solid wood and/or finger joint wood elements, and a wood or engineered wood substrate, or a composite wood substrate formed of other man made materials.
  • the composite panel form is cut along one or more cut lines 54 to form an assembled plurality of engineered blanks 52 that can be further machined, to form a completed engineered moulding 56, as illustrated in FIG.9.
  • the cutting along the cut lines 54 can occur simultaneously with the forming ofthe contoured surfaces in the preferred embodiment as described later.
  • the axially extending composite panel form 50 is generally oriented parallel to an axial direction 60 that is also the direction that the composite panel form is cut along.
  • the composite panel form is fabricated from axially extending edge boards 58, a plurality of axially elongated substrates or cores (hereinafter called “substrates”) 62, and a machinable veneer layer (hereinafter called “machinable veneer”) 64.
  • the machinable veneer may be formed from sliced or rotary veneer but the preferred embodiment is a high grade wood finger joint blank, planed, and sliced thinly or resawed into thin flat blanks of a preferred dimension and thickness.
  • engineered mouldings that can be formed from different embodiments of composite panel forms that are within the concepts of the present invention.
  • the composite panel forms are generally much more than one foot wide, and may be as wide as five feet.
  • FIG. 8B illustrates an alternate embodiment of composite panel form that comprises only one solid substrate 62 (not illustrated), two edge boards 58 positioned on either lateral side of the substrate, one machinable veneer layer 64 attached to the top ofthe substrate, and two end boards 63 positioned on either end ofthe substrate.
  • the FIG.8B composite panel form may be used to form such engineered mouldings as window sills, drawer fronts, panels, door panels, cabinet panels, and any other moulding configuration where it is desired to surround the substrate on five sides. Considering FIGS.
  • the desired configuration ofthe composite panel forms depends largely upon the final intended shape of the engineered moulding(s) that are being produced by the composite panel form, and from which angles such engineered mouldings are likely to be viewed when mounted.
  • the thin veneer lies on a substrate surface that has previously been roughly shaped.
  • the machinable veneers ofthe preferred embodiments ofthe present invention are of a suitable thickness, being thick enough to allow contouring ofthe machinable veneer itself to a desired depth while not allowing contouring into the substrate.
  • the machinable veneers themselves are machined similarly to, and have similar machining characteristics to, the wood of normal finger jointed blank.
  • the axially extending edge boards 58 are interspaced with, and adhere to, the substrates using a glue or resin.
  • the axis ofthe axially extending edge board is parallel to the axis ofthe substrates, and both axes are parallel to the longitudinal direction 60.
  • a substantially planer upper surface 66 is formed from the axially extending edge boards 58 and the substrates 62.
  • the machinable veneer 64 is bonded with a glue or resin to the upper substrate surface 66, so that the machinable veneer overlays nearly all of the axially extending edge boards 58 and substrates 62.
  • the machinable veneer may be formed as a single strip or more likely as a plurality of parallel strips abutted in an edge-to-edge configuration, depending upon the size ofthe composite panel form, and the dimensions ofthe available lumber.
  • Part ofthe substrate contacts surface 68 such as a wall, floor, etc. (See FIG. 9) when the engineered moulding is mounted in position.
  • a back out 125 is formed in the back side ofthe substrate.
  • the back out is similar to known prior art in mouldings, and provides a stress-reduction configuration and providing a location for loose pieces of wall board, tape, etc. to be located during mounting the moulding that would otherwise limit mounting the moulding flush relative to the mounting surface 68.
  • the three elements ofthe engineered blank 52 that are visible in the mounted final engineered moulding 56 (secured to a wall, etc.) are the edge boards 58, the machinable veneer 64, and the end boards 63 if used. These elements may be viewed as forming a channel in which the substrate is located. The wood forming the channel is machined, or contoured, by the reengineered rip saw to form any visible contouring in the finished and mounted mouldings.
  • the substrate 62 is not formed from the same material as the machinable veneer.
  • the substrate is formed from a material selected based upon its structural characteristics and low cost, not its appearance.
  • the substrate may be formed to be extremely light or very dense, and structural or not.
  • Such materials as lumber core, particle board, laminated veneer lumber (L.V.L.), medium density fiberboard (M.D.F.), hardboard, composite mineral core board, or oriented strand board (O.S.B.) are very satisfactory substrates.
  • the substrates may even be formed from other materials such as plastics, firm or rigid foam (polystyrenes, expanded PVCs, and other types) reconstituted recycled materials, or a combination ofthe materials of the types described in this paragraph.
  • the substrate is typically not visible when the engineered moulding is secured in position. However, the substrate should be selected for its functionality, including such traits as stability, consistency, weight, ease of machinability, availability, and low cost.
  • FIGS. 8A and 9 One consideration when viewing FIGS. 8A and 9 is that multiple engineered blanks 52 (or the associated engineered mouldings 56) can be simultaneously formed from a single wide composite panel form. In addition, much ofthe contouring and profiling of each ofthe engineered blanks 52 into desired engineered mouldings 56 can occur simultaneously, as well.
  • This application of simultaneous processing, or parallelism in machining moulding elements represents a major advantage that can be achieved with the present invention. The advantages become apparent when considering that the cost and use of moulders represent a major expense in moulding mills and that considerable machine time is required to fabricate each lineal length piece of finger joint moulding 22.
  • a reengineered rip saw described below, can perform this simultaneous cutting, contouring, and profiling.
  • Rip saws are designed to cut generally parallel to the wood grains using saw blades as the work piece passes through the machine- driven rotating saw. Lineal mouldings produced in any manner are cut in a direction parallel to the wood grains.
  • the cutting knife is turning in one direction concentrically while cutting into the workpiece which is moving against the direction ofthe cutting knife. Therefore, it is important that the wood ofthe axially extending edge board 58 and the machinable veneer 64 are both arranged such that their grains are parallel to the axial direction 60 ofthe composite panel form 50.
  • the rip saw (designed to cut parallel to the wood grain) can be adapted and reengineered to do a moulding function that will effectively shape the composite panel form instead of shredding the edges ofthe wood as would occur when the rip saw cuts into the grain ofthe wood. It is also possible that a standard rip saw can more efficiently and accurately cut the axially extending composite panel form 50 into multiple engineered blanks 52 ofthe same size, or varying sizes, and then a moulder machines each particular dimension of engineered blank 52 into engineered mouldings 56 in a similar manner as shown and described with reference to FIG. 7.
  • FIG. 10 illustrates the formation of edge boards 58 integrated into the FIG. 8A composite panel form. While the FIGS.
  • a finger joint blank ofthe type referred to above as 40, is cut by a rip saw 70 that includes an arbor 72 and a plurality of rip saw blades 74 (the rip saw blades above the arbor are broken off in FIGS. 10 and 11 for ease of display).
  • the arbor rotates about its axis.
  • Each rip saw blade 74 is spaced from each adjacent blade by a distance corresponding to a final desired dimension of the edge board, allowing for the dimension required for the cut.
  • a guide member 78 guides the finger joint blank along a prescribed direction within the horizontal plane during the cutting process, and roller hold down guides (not shown) provide straight tracking ofthe finger joint blank.
  • the edge boards are cut to a suitable thickness whereby all ofthe desired machining steps may be accomplished on each edge ofthe engineered moulding 56. This machining includes cutting the edge board approximately in half when the axially extending composite panel form 50 is cut into multiple engineered mouldings.
  • the edge boards should be thick enough so that the portion ofthe edge board that remains after cutting through a vertical plane, can concurrently be shaped to form the desired final contour ofthe engineered moulding.
  • the profile will usually be machined first with the splitting or separation machining done last. However, the choice is up to the production management at the time. FIG.
  • FIG. 11 illustrates one embodiment ofthe formation ofthe machinable veneers 64 that are integrated into the FIG. 8A composite panel form 50.
  • a finger joint blank, ofthe type referred to above as 40 is cut by a rip saw 80 that includes an arbor 82 and a plurality of rip saw blades 84. Each rip saw blade is spaced from an adjacent blade by a distance corresponding to maximum final desired thickness ofthe machinable veneer. Alternatively, a multiple saw jig type veneer saw may be used.
  • the machinable veneers are formed from a single piece of solid lumber or a finger joint blank 40.
  • a guide 88 for straight cutting is attached to a table 85 to guide the finger joint blank in a prescribed direction within the horizontal plane as it is being cut together with certain roller hold-down and guides (not shown).
  • the veneer strips 64 and edge boards 58 are cut to a suitable dimension whereby all of the desired machining steps may be accomplished on each edge of the engineered moulding 56. This machining includes the cutting of the edge board approximately in half.
  • monolithic rotary peeled veneers ofthe type that are not further shaped may be used in certain embodiments ofthe present invention where the outer shape ofthe surface ofthe machinable veneers facing away from the substrate, that are attached to the substrate, are the intended final shape when they are attached to the substrate.
  • High grade thin M.D.F. may also be used as a composite veneer substitute in those instances where the outer appearance ofthe M.D.F. is satisfactory for the specific application.
  • the engineered blank ofthe present invention includes an engineered substrate that is preferably of uniform thickness, density and material consistency.
  • the substrate for example, is preferably formed from O.S.B., M.D.F., particle board, firm foam, or another material formed from compressed and bonded wood fiber overlaid in alternating different directions or engineered in a unidirectional pattern. These materials are not as susceptible to wa ⁇ ing, twisting, cupping, bowing, and splitting as solid wood.
  • O.S.B., particle board, and M.D.F. are largely formed from less costly wood fiber strands, chips, and wood wastes, and as such are much less expensive than a comparable sized solid wood finger joint blank.
  • the material for the substrate can be selected based upon the particular application ofthe final engineered moulding.
  • a reengineered rip saw or saw apparatus 90 shown in FIGS. 12A and 12B, converts each composite panel form into a plurality of engineered blanks or engineered mouldings 56 (multiples).
  • the reengineered rip saw includes an arbor holding a number of moulder heads that cut the composite panel form into a variety of engineered mouldings depending upon certain prescribed dimensions of the cutting tools.
  • These prescribed dimensions of cutting tools include such parameters as the number of moulder heads, number of knives, number of cutter elements as described below, size of saws, number of engineered mouldings formed from each composite panel form, horsepower, RPM speed ofthe cutters, feed speeds ofthe component panel forms, etc. These prescribed dimensions are design choices that depend upon such considerations as the type of wood and substrate used in the formed moulding, the size ofthe moulding, and similar factors. These specifics are not detailed herein, but normal formulas and techniques applied to standard moulding machine applications may be applied, and are within the normal working knowledge of experienced saw designers.
  • the reengineered rip saw may also be applied to cut, mould, and contour multiple lineal pieces ofthe same size and profile or a variety of sizes and profiles of parallel mouldings from a wide engineered finger joint and edge-glued blank.
  • rip saws are much wider than 12- inches and are usually able to rip product 24-inches to as much as 60-inches wide. Mouldings much wider than can be made on any other moulder can be easily made on a reengineered rip saw.
  • the reengineered rip saw machining uniform solid clear wood blanks or finger joint blanks is also within the intended scope ofthe present invention.
  • the reengineered rip saw 90 illustrated in top plan view in FIG. 12A and in side elevational view in FIG. 12B, includes an infeed supply section 92, a transport roller section 94, a guide section 96, a hold down and infeed section 98, a cutting section 100, and an exit section 102.
  • the infeed supply section 92 contains composite panel forms 50 arranged so that one composite panel form after another can automatically be fed into the transport roller section 94.
  • the transport roller section 94 includes transport rollers 104 that continually rotate to feed the composite workpiece to the guide section and the hold down section.
  • the guide section 96 consists of measuring, indexing and line up apparatus besides a plurality of spaced guides or fences 106 that deflect the composite panel form 50 laterally, if necessary, into the correct position.
  • the hold down and infeed section 98 includes hold down rollers 108 and/or hold down guides (not illustrated) positioned above and below the path ofthe composite panel form, which securely contact each composite panel form as they travel to the cutting section 100.
  • the hold down rollers 108 are preferably motorized to drive the composite panel form through the cutting section.
  • the hold down guides do not need to rotate but are generally contoured to the shape ofthe composite panel form (such as including contours for rabbet joints or rabbet grooves).
  • the hold down guides may be used in addition to, or in replacement of, hold down rollers.
  • the use of hold down guides is well known in the wood working art.
  • the hold down guides can precisely position the composite panel form laterally relative to the reengineered rip saw.
  • the use of fences, hold down rollers, and hold down guides improve tolerances ofthe engineered moulding 56 by respectively reducing waver and flutter ofthe composite panel forms during cutting within the cutting section.
  • fences, hold down guides and hold down rollers may also be integrated into the cutting section to further limit waver and flutter during the cutting process and to aid in the feed through aspects of moving the moulded lineal product through the reengineered rip saw. Precisely controlling the position ofthe composite panel form within the cutting section ensures close tolerances ofthe engineered moulding.
  • the exit section 102 removes the engineered blanks or the finished engineered mouldings 56 formed by the cutting section 100.
  • the cutting section 100 includes an upper cutter element 110 and a lower cutter element 112. There is only need for one upper cutter element and one lower cutter element illustrated in FIGS. 12 and 13 for most profiles of household construction mouldings. If the desired engineered moulding 56 is especially complex or large, multiple upper cutter elements or multiple lower cutter elements may replace a single cutter element. Each cutter element then carries cutter heads that hold some cutter knife blades. Since the upper cutter element is spaced along the cutting path from the lower cutter element, it is important that close dimensional tolerances be maintained so that the lower cutter element is accurately positioned relative to cuts already made to the engineered moulding from the upper cutter element.
  • some embodiments ofthe present invention additionally use a laser tracking and displacement section or preformed guides to ensure close conformation ofthe profiles being produced by each successive cutter element with the desired contour shape ofthe engineered blank, at that point.
  • the laser tracking or preformed guides can align each successive cutter element with the cuts applied to the composite panel form by previous cutter element(s).
  • laser tracking devices which are commonly used in the sawmill industry, a laser measures the alignment to a desired reference machined surface.
  • the operator is alerted to readjust the mechanical hold down guides and preformed alignment fences so that the lower cutter elements are displaced relative to the axial cuts previously made to the workpiece to provide the properly aligned cut.
  • FIG. 13 illustrates an end elevational view ofthe upper cutter element 110 cutting the composite panel form 50, as taken in cross section along section lines 13-13 of FIG.12A.
  • FIG. 14 illustrates an end elevational view ofthe lower cutter element 112 cutting the composite panel form, taken in cross section along section lines 14-14 of FIG. 12 A, to form a plurality of engineered mouldings 56.
  • FIGS. 13 and 14 show how the contour ofthe upper cutter element and the lower cutter element combine to define the entire outline ofthe engineered moulding 56.
  • the upper cutter element shapes the surface of an upper portion 120 ofthe engineered moulding (see FIG. 13).
  • a bottom interconnection 121 ofthe composite moulding is still intact after the upper cutter element shapes the upper portion.
  • the lower cutter element then shapes the surface of a lower portion 123 ofthe engineered moulding plus cuts away the bottom interconnection, as shown in FIG. 14.
  • Junction points 127 of FIG. 14 distinguishes the surface formed primarily by the upper cutter element 110 from the surface formed primarily by the lower cutter element 112.
  • An up/down adjustment (not shown), more precisely geared for precision moulding, is provided to selectively move the arbor 122 up or down a prescribed and controllable distance. As the arbor moves up or down, so do the cutter elements, which control the combined depth of cut of all ofthe cutter elements on that arbor into the workpiece.
  • the upper cutter element 110 and the lower cutter element are each preferably formed as a modified moulder cutter head to slide onto and attach to form a portion ofthe reengineered rip saw.
  • rip saws have gained the reputation of being low tolerance, but inexpensive, cutting devices.
  • moulders are close tolerance, but expensive, cutting devices. Modifying rip saw technology to achieve comparable tolerances to moulders represents a major design feature of certain preferred embodiments ofthe present invention. While using moulders to form mouldings having complex curves may be desirable, the reengineered rip saw mechanism described herein can be applied to mouldings with complex curves, mouldings with routine curves, and also to rectangular mouldings.
  • mouldings account for more than 85 percent ofthe mouldings produced.
  • the vast difference in cost between moulders and reengineered rip saws makes it very attractive to use reengineered rip saws to form moulding whenever possible.
  • the element of operating cost related to units of production of lineal moulding output for labor, power and tooling costs favor the use ofthe reengineered rip saw over the prior art moulders, band saws, and planers.
  • the elements ofthe upper cutter element 110 ofthe reengineered rip saw 90 are now described. Similar structures and principles are used in both the upper cutter element 110 and the lower cutter element 112.
  • the upper cutter element includes a motor 118, a drive mechanism 121, an up/down adjustable arbor 122, at least one cutting blade 124, and a plurality of bearings 126.
  • the motor and drive mechanism are well known in the sawmill industry.
  • the reengineered rip saw is configured to generally carry more and/or wider cutting heads containing cutting tools and blades on each cutter element than prior art one, or multiple, straight saw blade through-cut rip saws.
  • the cutting tools and blades are non-rotatably affixed to the arbor using hydrolocking self-centering cutting heads wherein the cutting tools and blades are contained.
  • the reengineered rip saw can achieve closer tolerances than prior art rip saws used in industry due to the addition of heavier and more precise machine guides, hold downs, and tracking arrangements.
  • the composite panel form may be relatively wide since multiples of engineered mouldings 56 are machined therefrom in a parallel manner. It is preferable that the upper cutter element 110 and the lower cutter element 112 both are at least as wide as the composite panel form to provide a complete one-pass execution ofthe profile shape.
  • each engineered moulding can thereby be formed from the same respective upper cutter element and lower cutter element pair. This consistency of circumference and concentricity of depth of cut of upper and lower cutter elements makes the cuts applied to the engineered mouldings more uniform and results in smooth moulder machine surface quality.
  • vertical cutting blades 130 and horizontal contour cutting blades 132 there are two major distinct types of cutting tools and blades: vertical cutting blades 130 and horizontal contour cutting blades 132.
  • the function of the vertical cutting blades is to cut at least a portion of one vertical edge ofthe final machined engineered moulding 56 as illustrated in FIG. 14.
  • vertical cutting blade 130 on the upper cutter element 110 has a mating vertical cutting blade on the lower cutter element 112.
  • the vertical cutting blade 130 on the upper cutter element must cut down to a level that is at least as low as a level that the vertical cutting blade on the lower cutter element cuts up to (preferably there is some overlap between the levels that the lower and the upper cutter elements cut to).
  • the mating vertical cutting blades ofthe upper cutting element and the lower cutter element therefore removes all interconnecting wood 135 between the adjacent engineered mouldings.
  • the horizontal contour cutting tools and blade 132 shown in FIGS. 13 and 14 form the contoured surfaces 137 of the engineered moulding that are not vertical edges 134.
  • the horizontal contour cutting tool blades that are part of the upper cutter element 110 contour the upper portion 120 ofthe engineered moulding.
  • the horizontal contour cutting tool blades that are part ofthe lower cutter element 112 contour a lower portion 122 ofthe engineered moulding.
  • FIGS. 13 and 14 show all ofthe vertical cutting blades 130 and all ofthe horizontal contour cutting blades 132 as being located on two cutter arbor elements, it is possible to provide a different number of cutter elements having different blade configurations, etc. Therefore, one reengineered rip saw is capable of performing the production of a variety of prior art moulders, rip saws, band saws, and planers that operate lineally to form mouldings.
  • One advantage of cutting a composite panel form 50 comprising a substrate 62 formed from particle board, O.S.B., M.D.F. (or another substrate that is not formed from discrete solid wood, or is formed from inferior core quality wood) is that there is less possibility that wood sections cut by vertical cutting blades 130 will move relatively, or distort their shape, or wa ⁇ during the cutting process.
  • the two cut portions tend to move or wa ⁇ with respect to each other since there are considerable natural stresses present in discrete natural wood pieces. These natural stresses generally increase with the size ofthe discrete wood piece due to the grain directions or other natural characteristics ofthe wood.
  • Another advantage of using the reengineered rip saw as described below results from the multiple lineal lengths of moulding (referred to herein as "multiples") that are cut in parallel. If it is desired to cut many pieces of wood ofthe same length and having the same dado configurations, then the composite panel form 50 can be precision end trimmed and/or dado trimmed before feeding the composite form into the reengineered rip saw. Therefore, when the composite panel forms are cut into multiples using the reengineered rip saw, each resultant engineered moulding formed has the same dado cuts and/or precision end trim cuts. Being able to cut multiples from one composite form having nearly identical precision end trim cuts or dado cuts becomes especially desirable when producing such high- volume, similar dimensional, and close tolerance items such as door jambs.
  • FIG. 12A and 12B illustrate a variety of dado cuts and precision end trim cuts.
  • FIGS. 15 and 16 each illustrates a different embodiment of composite panel form ofthe present invention.
  • FIG. 16 illustrates a view similar to that of FIG. 15 except that the edge boards and the machinable veneers ofthe composite panel form are arranged in a different configuration.
  • the machinable veneer 64 is continuous, although it may be formed from several elements, and extends along the entire upper surface ofthe composite panel form 50. Both the substrate and the end boards alternatively contact a lower surface of the machinable veneer.
  • the lower surface ofthe machinable veneer only contacts the substrate, and the combined veneer/substrate alternates horizontally with the edge boards 58. The choice of whether a FIG.
  • FIGS. 15 and 16 composite panel form configuration is preferred depends upon the specifics ofthe assembling and forming the composite panel 1 o form, and is a design choice.
  • the dotted lines in FIGS. 15 and 16 illustrate an example ofthe final cuts that are provided by the reengineered rip saw ofthe present invention to form the engineered mouldings.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)

Abstract

L'invention concerne une technique permettant de former une moulure façonnée (56) s'étendant dans le sens axial, profilée, qui présente au moins une surface (64) visible s'étendant axialement. Selon la technique utilisée, on se munit d'une pièce de bois (64) extérieure de forme allongée, ainsi que d'un substrat (62) présent ant au moins un côté s'étendant axialement. On colle ladite pièce de bois (64) sur ledit côté s'étendant axialement. La pièce de bois est ensuite profilée de façon uniforme dans le sens axial, pour qu'elle présente la surface visible. Selon un mode de réalisation préféré, on utilise une scie refaçonnée pour débit longitudinal pour réaliser le profil de la pièce de bois. Il est également prévu que plusieurs moulures puissent être découpées simultanément par la scie refaçonnée pour débit longitudinal. Le découpage simultané par ladite scie pour débit longitudinal permet d'effectuer des mesures simultanées ainsi qu'une coupe transversale et un rainurage simultanés des moulures.
PCT/US1999/018015 1999-08-13 1999-08-13 Procede de realisation de moulures façonnees Ceased WO2001012402A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
PCT/US1999/018015 WO2001012402A1 (fr) 1999-08-13 1999-08-13 Procede de realisation de moulures façonnees
AU54726/99A AU5472699A (en) 1999-08-13 1999-08-13 Method of making engineered mouldings

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US1999/018015 WO2001012402A1 (fr) 1999-08-13 1999-08-13 Procede de realisation de moulures façonnees

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8480835B2 (en) 2010-09-03 2013-07-09 The Diller Corporation Apparatus and method to manufacture shaped counter top edges for custom counter tops

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR605065A (fr) * 1925-10-27 1926-05-19 Marly Freres Soc Procédé de fabrication de moulures en bois pour cadres de toutes sortes
FR1295269A (fr) * 1961-07-19 1962-06-01 Menuiseries en bois indéformables et procédé pour leur fabrication
WO1998041371A1 (fr) * 1997-03-14 1998-09-24 Seidner Marc A Procede de production de panneaux composites et de moulures façonnees

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR605065A (fr) * 1925-10-27 1926-05-19 Marly Freres Soc Procédé de fabrication de moulures en bois pour cadres de toutes sortes
FR1295269A (fr) * 1961-07-19 1962-06-01 Menuiseries en bois indéformables et procédé pour leur fabrication
WO1998041371A1 (fr) * 1997-03-14 1998-09-24 Seidner Marc A Procede de production de panneaux composites et de moulures façonnees

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8480835B2 (en) 2010-09-03 2013-07-09 The Diller Corporation Apparatus and method to manufacture shaped counter top edges for custom counter tops
US8726962B2 (en) 2010-09-03 2014-05-20 The Diller Corporation Apparatus and method to manufacture shaped counter top edges for custom counter tops

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