Converted log structural products and method

Abstract

Converted log structural products are produced from conventionally unusable or marginally useful sections of logs transversely cut into suitable lengths and then cut longitudinally by perpendicular cuts into log parts of either right-angled sector or right triangle cross-section. Four log parts matching in size and shape, and positioned so that their right angles form the corners of a rectangle, are assembled into a converted log, the interior space between the four log parts being filled selectively with braces, supports, insulation, concrete for various applications.

Description

BACKGROUND OF THE INVENTION

This application is related to my U.S. Pat. No. 5,115,609, issued May 26, 1992, 50 60 of the adjacent one, whereby the registering, aligning and interlocking of converted logs is aided, whether vertically, as shown, or horizontally joined. Centrally disposed opening 64, running the length of converted log 50, may be provided advantageously for convenient installation of electrical conduits, piping or the like.

In FIG. 5, larger log 70 has its outer portion 72 to be used in the conventional manner by being cut into thin layers while log 70 is being rotated. The resulting veneers are to be laminated together to produce plywood (this plywood process not shown, being not directly pertinent to this invention). When log 70 has been reduced by this process to a diameter in the range of 6-71/2 inches, cutting is stopped, and remaining core 74 is conventionally set aside as useless for anything other than firewood or pulp. However, for this invention, core 74 represents an ideal inexpensive raw material source, the wood therein being the densest and strongest of all wood from entire log 70.

By longitudinally bisecting core 74 with cuts along perpendicular planes 76, 78, and optionally flattening one or both peripheral edges 80 of the four log parts 82 formed thereby, the component log parts 82 for constructing converted log product 84 of FIG. 6 are provided. In this embodiment, concrete 86, with conventional steel reinforcing bars 88 optionally inserted, is shown filling interior space 90 of converted log product 84. Concrete 86 and reinforcement 88 may be inserted into 84 either at the factory or on location, where the resulting converted log product 84 may be advantageously and economically used to replace railroad ties, in retaining walls and for temporary roads and bridges, to support the weight and resist the stresses of heavy machinery and trucks passing over them. It may be noted that log parts 82, as well as the log parts of all preferred embodiments, may be treated with preservatives, etc. and/or kiln-dried before being assembled into converted log products.

The embodiment illustrated in FIG. 7 is converted log product 92 shown in position for assembly but before interior space 94 has been filled. The two log parts 96 shown onthe on the left are of one species of wood, for example, Douglas fir, while the two log parts 98 are of a different species of wood, for example, cedar. In this way, a wall built with converted log products 92 would provide different interior and exterior surfaces, taking advantage of the unique qualities of grain, hardness, strength and resistance of each species. Many combinations and designs using various suitable woods are possible using this concept.

FIG. 8 illustrates schematically another way to upgrade timber. Length of lumber 100 shown therein has been previously cut to a square cross-section, and may be converted by diagonal longitudinal cuts along planes 102 and 104 through the corners of lumber 100 and perpendicular to each other. Two or four of outer corners 106 of lumber 100 may be trimmed off and flattened, as desired, producing right-triangular log parts 108 to be used as shown in FIGS. 9-11. Converted log product 110 of FIG. 9 has two corners 106 flattened and is assembled by rotating parts 108, positioning them to form a peripheral rectangular cross-section. Interior space 112 created by this arrangement is illustratively shown fittingly filled with square-shaped filler piece 114 of poor quality wood, such as cottonwood, which is soft, of inadequate strength and therefore impractical for use by itself as structural lumber. However, cottonwood, when used as filler 114, combined with and substantially surrounded by strong log parts 108 and optionally further strengthened and braced as illustrated and described hereinafter with respect to FIG. 10, is transformed into more than adequate inexpensive converted log 110, increased in size more than 40% as compared to timber 110 from which it is made.

In FIGS. 10 and 11, converted log product 120 has its log parts 108 flattened at all corners 106 and thereby presents a square cross-sectional configuration. As seen in FIG. 10, cross-braces 116 may be installed in the assembly of log product 120 and may be spaced along the length thereof, while wedge-shaped braces 118, secured to the inner corners where log parts 108 meet, may extend the length of log product 120 or optionally be intermittently spaced and secured for increased strength and stability of the assembly. FIG. 11 shows interior space 122 of log product 120 filled with wood shavings and/or wood chips 124, which may have been treated prior to installation for resistance to fire, fungus, termites and the like, then moistened with adhesive and blown into interior space 122 to impart effective insulative qualities to converted log product 120. Other insulative materials, both loose and in the form of fiberglass batts, as well as concrete 86 shown in the embodiment of FIG. 6, may be used in place of wood shavings 124. It may be noted that log product 120 is increased in overall size almost 40% over timber 100 from which it is made.

The larger log 130 of FIG. 12 is divided by horizontal chordal cut lines 132, 134, leaving log portion 136 to be further processed into conventional lumber by conventional cutting techniques. The remaining two log portions are then each split in half by cuts 138 perpendicular to cuts 132, 134. The resulting asymmetric log parts 140 optionally may have their outer edges longitudinally trimmed to flattened areas 142. If log 130 is large enough in diameter, a second set of log portions 140 may be cut therefrom by rotating log 130 90 degrees and repeating cuts 132, 134 and 138; remaining portion 136 would then be largely square in cross-section (not shown). As seen in FIG. 13, log parts 140 may be rearranged in a manner analogous to that of the other embodiments of this invention to form converted log 144, which may then be braced and filled with insulative or strengthening matter as hereinabove described in connection with other embodiments.

FIG. 14 shows a log 150 to be cut into preselected lengths by transverse cuts 152 for use in the practice of this invention.

The converted log products and method of producing them of this invention have been described in full detail. Various combinations, substitutions and alternative procedures in the practice of this invention are possible without departing from its concepts, spirit or scope, which are defined and limited only by the ensuing claims, wherein:

Claims

1. Converted log product, which comprises:

four equally sized parts cut longitudinally from at least one log, said log parts having been cut each to have a three-sided cross-section with two of said three sides being flat and meeting at a right angle, the third of said three sides being selected from the group consisting of: having an arcuate contour, each of said log parts thereby being a right-angled sector in cross-section, and having a flat contour, each of said log parts thereby being a right triangle in cross-section; and

support means for bracing and strengthening the converted log product, said bracing means being positioned at intervals along the length of said log parts within the interior space formed when said log parts are assembled and secured; and

means for securing said four equal right-angled log parts and said bracing support means together, said right-angled log parts being positioned when assembled so that said third side of each said log part faces inwardly toward each other, said two of said three sides facing outwardly and oriented to form a rectangular cross-sectional outline for the assembled converted log product.

2. The converted log product of claim 1, wherein said four log parts are right-angled sectors cut at the periphery of said at least one log, remaining portions of said log being available for use as conventional lumber.

3. The converted log product of claim 1, wherein said four log parts are right-angled sectors cut from the conventionally discarded core of at least one log, the outer portion of said at least one log having been removed from said core for conventional uses.

4. The converted log product of claim 3, wherein said log core to be cut into said sectors may range in diameter from 4 four to eight inches.

5. The converted log product of claim 2, wherein said four right-angled sectors have been cut from said at least one log's periphery by a first longitudinal chordal cut followed by a second radial cut at right angles to and bisecting said first chordal cut.

6. The converted log product of claim 1, wherein said four equally sized log parts are formed from a log portion previously trimmed to a square cross-section, said square log portion having been quartered by two diagonal corner-to-corner diagonal cuts, said cuts having been made perpendicular to each other.

7. The converted log product of claim 1, wherein each of said four log parts has at least one of its two corners connecting said third side with one of said two of three sides trimmed off and flattened to provide a flat surface perpendicular to one of said two of three sides. 8. The converted log product of claim 1, further comprising means for bracing and strengthening the converted log product, said bracing means being positioned within the interior space formed when said log parts are

assembled and secured.9. The converted log product of claim 1, further comprising insulating and strengthening means filling the interior space remaining between said four log parts and being secured to said parts, forming a unitary converted log product, said insulating and strengthening means being selected from the group consisting of: foam plastic, preformed rigid extruded foam plastic conforming in shape and size to said interior space, loose insulation particles, fiberglass batts, treated wood shavings, treated wood chips, shaped softwood logs, concrete

and reinforced concrete. 10. The converted log product of claim 1, further comprising means for interlocking, aligning and registering any two

converted log products. 11. The converted log product of claim 1, wherein said four log parts may be selected from wood of at least two species, whereby different contrasting wood surfaces may face the exterior and interior of a building constructed with converted log products so

assembled. 12. The converted log product of claim 6, further comprising right-angled wedges secured fittingly in the corners of the interior space created when said four log parts are assembled, thus bracing and

strengthening the converted log product resulting therefrom. 13. The method of converting logs into finished dressed structural lumber which comprises the steps of: trimming the logs; cutting logs transversely into selected lengths; cutting log parts therefrom by perpendicular longitudinal cuts so that each log part has a three-sided cross-section with the first two of the three sides having been cut flat and at right angles to each other, the third side being selected from the group consisting of: having an arcuate contour, forming a right-angled sector in cross-section, and having a flat contour, forming a right triangle in cross-section; and assembling the lengths of the four log parts into position so that the third side of each of the four log parts face toward each other, while the flat first two sides thereof face outwardly and are arranged in a rectangular cross-sectional configuration; and inserting into the interior space formed in the arranged rectangular configuration, at intervals between and along the length of the four log parts, selectively placed support braces.

4. The method of claim 13, further comprising at least one step following the longitudinal cutting into three-sided log parts and selected from the group consisting of: treating the log parts with preservatives, kiln-drying the log parts and plane-milling the first two of the three

sides of the log parts, in the order here listed. 15. The method of claim 13, further comprising the step of filling the interior space, formed when the three-sided log parts have been assembled in the arranged rectangular configuration, with means for securing the assembled log parts and for strengthening and insulating the resultant converted log assembly. 16. The method of claim 15, further comprising the step of inserting into the interior space and securing to the log parts selectively placed support braces, prior to the step of filling the space with strengthening and insulating means.