CN1214165C - Composite building components, and method of making same - Google Patents

Abstract

The invention relates to a composite building component including a non-planar molded composite web having two outer zones and two angled zones wherein the caliper of the angled zones differs from the caliper of at least one of the outer zones, and a flange disposed on an outer surface of an outer zone.

Description

Composite building element and method of manufacturing said composite building element

Cross-references to related applications

This application is a continuation-in-part of U.S. Patent Application Serial No. 09/538,766, filed March 30, 2000, pursuant to 35 U.S.C. §119(e), U.S. Patent Application Serial No. 09/538,766 Benefit of US Provisional Application 60/127,120 filed March 31, 1999.

Background of the invention

field of invention

The present invention generally relates to man-made composite building elements and methods of manufacture and assembly thereof. More specifically, the present invention relates to the production of composite framing members and monolithic members such as columns, walls, roofs, floors and columns.

Description of prior art

In conventional house construction, building elements such as walls, roofs, floors, and columns may be assembled from wooden framing members and decking. The framing members can be produced from natural wood, such as timber, cut to standard sizes from trees such as poplar, spruce, pine, and fir. Covering panels, usually made of plywood or oriented strand board (OSB), are fastened to building elements using mechanical fasteners and adhesives such as staples, nails, glue, screws, or urethane foam adhesives s frame.

Traditional lumber produced from natural wood often suffers from consistency, practicality and cost drawbacks. Likewise, building elements made from traditional materials have disadvantages in terms of consistency, cost, and ease of assembly.

Traditional woods from natural woods vary widely in quality. Since framing members such as nominal 2 x 4s (actual measurements roughly 1  in x 3 ) are cut from trees or logs as continuous sections throughout, they can have disadvantages inherent in natural wood, such as knots and crack. Knots generally result in reduced strength in a section of timber, thus requiring a high design safety factor leading to ineffective use of material, resulting in low use of material. It is also known under one condition that "chipping" wood cut from the outer surface of trees, especially from younger young trees, can have undesirably rounded rather than squared edges. Additionally, after milling, the wood can also exhibit humidity or dry out, which makes the board warped and unsuitable for its intended use. These shortcomings make 30-35% of the traditional wood quality rating lower.

Lumber suitable for use in construction also often must be trimmed, filled, fastened to fit or otherwise fit for use due to inconsistencies in dimensional accuracy. In addition, once installed, timber can be dimensionally unstable due to environmental factors or other factors mentioned above. For example, in the case of what is known as a nail pop, the wood being installed dries and shrinks, causing the fixture to shift or come out. Likewise, accidental contact with water or moisture can cause the wood to swell and warp permanently.

Due to the depletion of mature forests, natural wood for timber production is also becoming increasingly scarce, especially in large sizes. This lack naturally leads to a reduction in the quality and/or to an increase in the cost of traditional wood and residential and commercial homes built with traditional wood.

The present application also relates to cellulosic composite articles. One type of composite product is a wood composite, such as wood-based panels with glued wood elements and/or lignocellulosic materials, which are commonly referred to in the art by the following exemplary terms: fiberboard, such as hardboard, medium density fiberboard , and soft fiberboard; particleboard, such as wood plywood, veneer, beam board, OSB and plywood. Wood composites also include wood-based panels comprising combinations of these materials.

Many different methods of making OSB are known in the art, such as, for example, the methods described in Chapter 4.3 of the Wood Reference Handbook published by the Canadian Wood Council, and in The Complete Manual of Woodworking by Albert Jackson, David Day, Simon Jennings Said method, the disclosure of the above method is incorporated herein by reference.

The first step in the manufacture of wood composites is to obtain and sort the logs, which may be aspen, balsam fir, beech, birch, cedar, elm, locust, maple, oak, pine, poplar, spruce, or mixtures thereof . Logs can be soaked in hot water to soften the wood for easier peeling. Once barked, the logs are processed into bundles using mechanical cutting devices. The bundles thus produced were stored in a humidity cabinet before drying. Once dried to a consistent moisture content, the bundle is typically screened to reduce the amount of particulates present. The bundle, sometimes referred to as filler material, is then mixed in a mixing operation, adding resin binder, wax, and any desired function-enhancing additives to form a composite raw material, sometimes referred to as a furnish. The resin-coated or resin-jetted bundles are then deposited onto a forming wire that aligns the bundles to form a loose felt-like mat, which may also be referred to as a bundle array. A mat comprising one or more layers of bundles arranged in a selectable orientation (eg, including random orientation) is then conveyed into a press. The press consolidates the mat under heat and pressure with other additives including binders to polymerize the resin and bond the strands together so as to form a consolidated array of strands. The board then exits the press into a sawing operation which trims the board to size.

Summary of the invention

It is an object of the present invention to overcome one or more of the above mentioned problems.

Accordingly, one aspect of the present invention is a composite building element comprising: a non-planar molded composite web having two outer regions and two angled regions, wherein the thickness of the angled regions is different from that of the outer the thickness of at least one of the zones; and a flange on an outer surface of said one outer zone.

Another aspect of the present invention is a composite building element comprising: a web having at least one channel defined by a first outer region, a second outer region and at least two angled regions a groove, each said region having a thickness, and each said region having an inner surface and an outer surface; a first flange connected to said web at a first outer region outer surface; and a second outer region outer surface at the second flange connected to said web; wherein the width of the building element, determined parallel to the direction of the groove, is not greater than the thickness of the building element, said thickness being determined between the parallel outer surfaces of the flanges distance.

Another aspect of the present invention is a composite building element comprising: a non-planar array of molded wood strands defining a web panel having a thickness and having a web panel one and second corrugated base surfaces providing an alternating pattern of first and second sets of ridges extending parallel to each other and oppositely positioned with respect to the centerline of the web plate ; adjacent ridges in the first set are connected to intermediate ridges in the second set by sloping walls; The thickness of said web plates differs between at least one set of adjacent said first and second corrugated base surfaces.

Another aspect of the invention is a method of producing a composite building element, the method comprising the steps of: (a) forming a mat comprising a wood-based material; (b) placing the mat in a module, the module having a non-planar structure with at least two outer regions and at least two angled regions; (c) closing the mold to form a mold gap, wherein the mold gap at the at least one outer region is different than the mold gap at the angled region; (d) consolidating the mat under pressure and heat to form a molded composite web panel; and (e) joining the web to at least one flange to form a composite building element.

Another aspect of the invention is a method of producing a building element, the method comprising the steps of: (a) forming a mat comprising an array of wood strands; (b) placing the mat in a mold, the mold set has a non-planar structure with first and second mold surfaces; (c) closing the mold to form a mold gap, wherein the mold gap provides alternating patterns of first and second sets of ridges, said first and second sets the ridges extend parallel to each other and are oppositely opposed with respect to the centerline of the module, wherein adjacent ridges of the first set are connected to intermediate ridges of the second set by inclined walls, and wherein the mold gap between the first and second mold surfaces near at least one ridge is different compared to the sloped wall; (d) consolidating the mat under pressure and heat to form a molded composite a web panel; and (e) connecting the web to at least one flange to form a composite building element.

Other objects and advantages of the present invention will become apparent to those of ordinary skill in the art from a review of the following detailed description in conjunction with the accompanying drawings and claims. Although the present invention may have embodiments in various forms, the following describe specific embodiments of the present invention, and it should be understood that the described embodiments are illustrative and should not limit the present invention to those described herein. The specific examples described.

Brief description of the drawings

Figure 1 is an isometric view of a composite building element according to the invention, which can be used as a wall or floor system and which can be divided to provide a plurality of timber or column elements;

Figure 2 is a cross-sectional view of a mold used to mold a web panel embodiment of the present invention;

Figure 3 is a cross-sectional view of a web plate embodiment of the present invention;

Figure 4 is an isometric view of a web plate embodiment of the present invention;

Figure 5 is a side view with portions of the web and flange plates used in one embodiment of the invention removed and with structured surfaces.

Figure 6 is a side view of a region of a web plate used in one embodiment of the invention.

Figure 7 is a cutaway isometric view of a portion of a composite nominally 2x4 lumber member embodiment of the present invention.

Figure 8 is an exploded isometric view of a composite strut embodiment of the present invention.

Figure 9 is an exploded isometric view of an embodiment of a composite nominally 2x4 lumber member of the present invention.

Figure 10 is an exploded isometric view of a composite nominally 2x6 lumber member embodiment of the present invention.

Figure 11 is a cut-away isometric view of a composite trim member embodiment of the present invention showing a conventional joist or frame.

Figure 12 is a top plan view of a molded element used in an embodiment of the composite trim member of the present invention.

Figure 13 is a side view of a molded element used in an embodiment of the composite trim member of the present invention.

Figure 14 is a cutaway isometric view of a flooring member of the present invention.

Figure 15 is a side view of a web wedge region used in one embodiment of the invention.

Detailed description of the preferred embodiment

According to the present invention, there is provided a method and apparatus for producing multi-layer composite building elements from wood-based materials. The wood-based material may be, for example, flakes, discs, granules, fibers and/or bundles including mixtures thereof. Typically, building elements are provided by coating or spraying one or more wood-based materials, such as flakes or fibers, with a resinous binder and optionally with waxes and other reinforcing functional fillers to form a composite raw material or furnish. Composite raw materials or furnishes are formed into mats of generally uniform basis weight. The mat is fed into a die set having the desired geometry and consolidated in a hot press to form a composite panel. The modules for producing molded or corrugated composite panels are described in detail below. One or more of these panels are bonded to a second non-planar or planar flange, and optionally to one or more end blocks or other framing members, so as to form the multi-layer wood of the present invention. Composite products. In a preferred embodiment of the invention, the bonded element is subsequently cut into a plurality of multilayer wood composite building elements.

The multilayer wood composite building elements of the present invention preferably comprise OSB elements made from raw material obtained by breaking down logs or other wood sources into bundles as described above. Various methods of producing such bundles are known in the art. The bundles are preferably produced by mechanical slicing and flaking. Exemplary sources of woody material are: aspen, balsam fir, beech, birch, cedar, elm, locust tree, maple, oak, pine, poplar, spruce, or mixtures thereof. Poplar or pine are preferred, but should depend on availability, cost and specific requirements. The type of wood-based material used will define the type and characteristics of the board produced. For example, the invention may include members defined as compression board, thin sheet board, bundle board, OSB, and/or fiberboard. Oriented beam plates are preferred.

Example ranges and bundle sizes for preferred composite panels are depicted in Table 1 below.

Table I - Preferred bundle sizes length width thickness range of examples About 2 to 10 inches (about 5 to 25.4cm) About  to 3 inches (about 6 to 76mm) About 0.007 to 0.05 inches (about 0.18 to 1.27mm) preferred range About 4 to 6 inches (about 10 to 15cm) About  to 1 inches (about 12.7 to 38mm) About 0.015 to 0.03 inches (about 0.38 to 0.76mm)

Once the bundles are produced as described above, the bundles are preferably processed to reduce the level of particulates and dust. This is preferably accomplished by passing the strand through a rotating sifter or by other suitable means. Typically, the level of particulates can be as high as 60 weight percent (wt.%) (based on the total weight of the wood-based material) at a mesh size of about 1/8 inch (about 3.2mm) or smaller, and preferably is in the range of about 20wt.% to 30wt.%. (Percentages expressed herein are on a weight basis unless otherwise indicated). Mixtures of wood-based materials are sometimes simply referred to as wood bundles.

The moisture content of the processed bundles is preferably in the range of about 2 wt.% to 9 wt.%, more preferably in the range of about 4 wt.% to 6 wt.%, based on the weight of the wood-based material.

The strands (and accompanying particles and dust) are then mixed in a mixing operation, preferably with the addition of resinous binders, waxes, and other desired functional enhancing additives, in order to form the composite used to produce the panels of the present invention. raw materials. While any suitable resin may be used, preferred resin binders include: phenolic resins, resorcinol formaldehyde resins, and MDI resins. The fat content is preferably in the range of about 1 wt.% to 10 wt.% by weight of the wood-based material. More preferably in the range of about 3.5 wt.% to 5.5 wt.%. When using MDI resins, generally less resin is required than when using phenolic, resorcinol formaldehyde resins. In addition to being used to reduce resin usage, the use of MDI resins also lowers press temperatures (due to reduced energy input) and allows the use of raw materials with higher moisture content

Ingredients can be added to the raw materials to impart various beneficial properties to the composite building elements of the present invention. For example, flame retardants, biocides, fungicides, water repellents, ultraviolet (UV) blockers, pigments, and combinations thereof may be used in alternative embodiments of the present invention. Chemical Specialties Inc. of Charlotte, N.C. sells an exemplary flame retardant under the trademark D-BLAZE. Waxes are preferably added in order to improve moisture resistance, preferably in the range of about wt.% to 2 wt.%, for example about 1 wt.%, of the weight of the wood bundle. Borden of Diboll.TX sells an exemplary wax under the trade mark EW 58 LV.

Next, the raw material is continuously deposited on a forming line to form a mat of generally uniform basis weight. In another embodiment of the invention, the mats may be formed individually in a batch production process. The basis weight of the mat is calculated as the volume of the molded panel times the target density of the molded panel divided by the surface area of the resulting mat in lb/ ^ft2 or kg/ ^m2 .

The individual bundles in the mat can be given a selected orientation (as is often the case with OSBs), or the mat can be assembled with randomly oriented bundles. OSB generally refers to boards produced from mats in which the beams are given a selected orientation, but may also refer to boards produced from mats in which the beams are given or have random orientation. Individual bundle layers in individual mats may, but do not have to, have different orientations. The beam orientation affects the mechanical performance characteristics of the consolidated composite panel, so the preferred beam orientation varies from application to application.

The continuously formed mat is then cut to dimensions having a length and width approximately equal to or slightly greater than the expected panel length and width produced by the appropriate die set. In this way, the consolidated panels are limited in length and width only by the dimensions of the equipment used to produce said panels.

The mats are then placed into a mold with the desired geometry. During mat consolidation using phenolic resin, the temperature of the press platen and die stack is preferably in the range of about 420°F to 480°F (about 215°C to 249°C), more preferably about 450° F (about 232°C). As will be appreciated by those of ordinary skill in the art, the desired pressing temperature and pressure may vary depending on various factors including: mold geometry; type of wood to be pressed; moisture content of raw material; pressing time; The type of resin used. The moisture content of the raw material is an important factor which controls the core temperature of the mat obtainable under given pressing conditions, which in turn controls the pressing cycle. Press times can generally be reduced by increasing the press temperature, with certain limitations known in the art.

For example, steam jet pressing is a useful consolidation step in some cases in the production of consolidated cellulosic composites. In steam jet pressing, steam is injected through the perforated heated press platen(s) and/or die, which then enters, passes through and exits the mat. The steam condenses on the surface of the raw material and heats the mat. The heat transferred to the mat by the steam and from the press platen and/or die set to the mat causes the resin to cure. When compared to conventional pressing operations, steam injection pressing can in some cases offer a number of advantages, namely, for example, shorter pressing times, more rapid and satisfactory handling of thicker plates, and products with more uniform density.

According to one embodiment of the method of the present invention, the first mat is consolidated under heat and pressure in an apparatus configured to produce features having one or more undulations (e.g., features as ridges , ribs, grooves, protrusions, flat areas, upper areas, outer areas, raised areas, or sloped walls), as described in more detail below, the first cushion includes Or features whose principal planes are set up and/or down. The compressed panels may be a molded array of raw material, such as a molded array of wood bundles. It is best to have the protrusions evenly spaced. When pressed, the board maintains its integrity and does not break. The panel edges are then trimmed to size.

Preferred embodiments of the present invention generally include multiple layers of OSB components that may or may not have identical structures and components. In this way, one or more additional mats are respectively consolidated under heat and pressure in an apparatus configured to produce panels of the desired configuration. These additional composite panels may be flat or may have molded or corrugated features, with the panel edges trimmed to size as well. These additional composite panels are also described in more detail below.

One or more additional composite panels are aligned and bonded to the first panel, and optionally to end blocks or other framing members, so as to form the wood composite building element of the present invention. The panels and optional end blocks may be bonded to each other with a suitable adhesive. Preferred adhesives applied to the contact surfaces and/or intersections between the panels will provide a shear strength at least equal to the shear strength of the composite panels themselves. Preferred adhesives may be selected from the group consisting of heat-melt polyurethanes, moisture-cure heat-melt polyurethanes, moisture-cure polyurethane adhesives, and mixtures thereof. The adhesive is preferably applied at a rate in the range of about 76 g/m ² (about 7.4 ml/cm ² ) to 229 g/m ² (about 22 ml/cm ² ) of the contact area, for example about 153 g/m ² ( about 14ml/cm ² ). In an alternative embodiment of the invention, a water resistant resorcinol adhesive or an isocyanate or MDI based adhesive may be used. In another alternative embodiment of the invention, mechanical fasteners, such as staples, may be used in place of or in addition to the adhesive.

In a preferred embodiment of the invention, the bonded assembly is subsequently cut into a plurality of wood composite building elements, as described below.

The advantageous properties of the products of the present invention make them excellent members in construction applications such as timber components, floors, walls, roofs and framing members. The method according to the invention produces a composite member that combines various useful desirable properties in building elements such as compressive and flexural strength, flexural stiffness, impact deflection, and increased resistance to water, insects, , bacteria and fire resistance) design combination.

Various preferred embodiments of the present invention will be described in more detail below.

composite wood

The method of the invention can be used to produce an embodiment of the composite wood product of the invention suitable for use as a substitute for conventional wood, or for a special application with size and strength characteristics that are not suitable for conventional wood. Referring first to Figure 1 for an overview of a product produced according to the invention, the multilayer composite of the invention comprises a bonded assembly 20 as an intermediate member. The member 20 comprises one or more web plates 21 (one shown), and one or more end blocks 22 (two shown) sandwiched between two flanges 23 (two shown) . The flange 23 in Figure 1 is a flat plate, but this is not required in this case. Preferably, the bonded assembly 20 is cut along a line 25 in a direction perpendicular to the groove 24 in the web panel 21 to facilitate the production of individual multilayer wood composite lumber members of the present invention (see FIGS. 9 and 10 ), each The composite timber member has one or more webs 21 , flanges 23 and optionally end pieces 22 .

It should be understood that the words "webs, flanges, and end blocks" are used to denote these individual members, either as plates or bundles in bonded assemblies 20, or as Parts of a single timber member produced by separating the bonding assembly 20 along a line 25 . Thus, for example, although the words web and web panel are interchangeable, the word web panel can be used to emphasize larger sized components, such as the one in Figure 1 here The part 21 before being separated.

The production method of one embodiment of the web plate 21 will be described below in conjunction with the composite wood member of the present invention. However, it should be understood that the features of the web plate 21 and its method of manufacture are equally applicable to the web plate 21 used alone in certain applications and with additional components, including other implementations of the invention described below. For example, such as decorative components.

In a preferred embodiment of producing the composite wood product of the present invention, the mat to become the web panel 21 consists of up to 3 layers of resin-covered, loosely bonded and oriented bundles in the above-described sequential procedure. The mat may be represented as comprising an array of wood strands. For example, the first or bottom layer is formed in a direction parallel to the longitudinal axis of the finished timber element. The first layer preferably comprises 1/3 to 100% of the total mat weight. A second or intermediate layer may be formed perpendicular to the direction of the first layer and may comprise up to 1/3 of the total mat weight. A third or top layer can be formed parallel to the direction of the first layer and can account for up to 1/2 of the total mat weight. In other words, preferably one to three layers are included in the mat, where typically each layer has bundles oriented perpendicular to the bundles in the adjacent layer. In a preferred embodiment, each layer comprises about 1/3 of the total weight of the pad.

In another preferred embodiment, about 80% to 100% of the bundles, eg about 90% of the bundles, are oriented in a direction parallel to the longitudinal axis of the wood member. In one version of that embodiment having three layers, the bundles oriented in a direction parallel to the longitudinal axis of the timber member are, for example, approximately evenly distributed in weight between the top and bottom layers of the mat. In another version of the embodiment having multiple layers, the bundles oriented in a direction parallel to the longitudinal axis of the wood member are approximately evenly distributed in weight over all layers of the mat.

In a preferred embodiment, the dimension of the web plate 21 in a direction perpendicular to the groove 24 corresponds approximately to the desired length of the finished composite wood product of the present invention. In another preferred embodiment, the dimension of the web plate 21 in the direction perpendicular to the groove 24 is less than the desired length of the finished composite wood product of the present invention, so as to assemble the beam for the end blocks as in the embodiment of Fig. 1 22 provides space. In such cases, it is preferable to bond the web plate 21 to the flange 23 so as to leave an approximately equal gap along line 25 at opposite ends of the bonded assembly 20 . These embodiments are described in more detail below in connection with end block 22 .

In order to maximize the efficiency of producing composite wood members from a bonded assembly 20, the width of the web plate 21 (i.e., along the direction perpendicular to the line 25) and the width of the mat used to produce the web plate 21 are preferably as large as possible. Possibly large. For example, in a 4 foot (about 1.2m) x 8 foot (about 2.4m) heated press for producing composite lumber about 8 feet (about 2.4m) long, the web plate 21 is preferably 4 feet ( About 1.2m) wide. Preferably, a heated press of 8 feet (about 2.4m) x 24 feet (about 7.3m) is used to produce composite lumber about 8 feet (about 2.4m) long, wherein the web panels 21 are preferably 24 feet (about 7.3 m) wide (ie, in a direction perpendicular to line 25).

A preferred process for producing the composite wood product of the present invention will be described below. Referring to Figure 2, the loosely bonded web plate mat produced as described above is placed into a die set 26 having a preferred unique structure. A die set 26 comprising a first (upper) die 27 and a second (lower) die 28 determines the contour geometry of the consolidated web plate 21 .

When the mold set 26 is placed against the mat, the wooden bundles of the mat preferably move or slide within the matrix of the mat (or, in one embodiment of the invention, within groups of wooden bundles) to generally conform to the shape of the mold . It can be found that the surface area of the mat can be increased by 75%, preferably by 15% to 25%, and more due to the compressive and shear forces on the mat due to the interaction between the upper mold 27 and the lower mold 28. It is better to increase it to 20%. Due to the loose state of the bundles in a loosely bonded mat, they generally tend to move in a certain area of the mat during the compression operation. Factors that affect the amount that the mat surface area can increase during pressing using the process of the present invention include: the geometry or shape of the web plate 21 (or, in other words, the shape or profile of the web plate 21); Variations in thickness in different locations (or, in other words, variations in die gap in different locations of die set 26); mat basis weight and bundle orientation prior to press closure; and bundle geometry (including physical length, width and thickness). These factors affect the ability of the bundles to move or slide within the mat matrix before skimming, fracturing, or breaking the continuity of the composite mat during press closure. The process and unique die shape used in accordance with the present invention facilitates an optimal combination of these factors so that the surface area of the mat can be increased without fracturing the mat, particularly in the outer region 33 . At the same time, the process preferably provides a product with an at least substantially uniform density, resulting in increased strength of the molded panels and articles made of said molded panels. In contrast, the compressed products of the prior methods are characterized by poor density deviations, leading to reduced strength of the molded panels and of the articles made of said molded panels.

During mat consolidation using phenolic resin, the temperature of the press platen and/or die set is preferably in the range of about 420°F to 480°F (about 215°C to 249°C), more preferably about 450° F (about 232°C). The pressing time depends on the thickness of the finished product as well as the other factors listed above, but is preferably in the range of 1 to 5 minutes in the preferred embodiment of the invention.

The distance or gap between the first die 27 and the second die 28 during pressing and mat consolidation defines the thickness of the consolidated web at any particular point. For example, points 29 and 30 in FIG. 2 define a die gap at one location of die set 26 . Another measurement of die gap can also be made, for example at points 31 and 32 . Due to specific deviations in the mold gap, die set 26 of the present invention preferably produces a web plate 21 having a thickness that varies from one point to another (for example, at position 29/30 of the web relative to die set 26 of FIG. 2 and 31/32) in order to obtain an at least substantially uniform density throughout the web plate 21. This aspect of the invention not only maximizes the stiffness of the web 25, but also maintains the integrity of the mat during compression.

FIG. 3 shows the cross-sectional geometry of the web plate 21 of the invention produced by the die set 26 of FIG. 2 . FIG. 4 provides an isometric view of web panel 21 produced by die set 26 of FIG. 2 . (Like reference numerals in the figures denote like elements.) The web panel 21 shown in FIGS. 3 and 4 has (a) a generally flat plurality of longitudinally extending outer regions 33 and (b) a plurality of longitudinally extending An inner or angled region 34 located between, adjoining and integral with the outer regions 33 . Outer regions 33 are located above (e.g., elements 33a, 33b, and 33c in FIG. 3 ) and below (e.g., elements 33d, 33e, and 33f in FIG. 3 ) angled regions 34 that are angled to the angled region 34. The region 34 is adjacent to and integral with it. Preferably, the intersection of the outer region 33 and the angled region 34 is rounded. The upper surface of the web plate is formed by contact with the first mold 27 and the lower surface of the web plate is formed by contact with the second mold 28 . When the web plate 21 includes a group of upper outer regions (such as regions 33a, 33b and 33c) and a group of lower outer regions (such as regions 33d, 33e and 33f), it is preferable that adjacent outer regions ( For example, the lateral directions of the regions 33a and 33d) are separated by a predetermined distance and the vertical directions are also separated by a predetermined distance.

The thickness of the web 21 at the upper outer regions 33a, 33b and 33c (as shown in FIG. 3 ) is preferably smaller (thinner) than the thickness of the web 21 at the angled region 34 . The thickness of the web 21 at the lower outer regions 33d, 33e and 33f is preferably greater than the thickness of the web 21 at the upper outer regions 33a, 33b and 33c and at least equal to the thickness of the web 21 at the angled region 34 thickness of. The thickness of the web 21 at the intersection of the outer zone 33 and the angled zone 34 preferably transitions gradually between the thicknesses of the web 21 at the respective zones 33 and 34, preferably via rounded intersections. These thicknesses are provided by setting the die gap as described above. More specifically, the ratio of the thickness of the web 21 at the upper outer regions 33a, 33b and 33c to the thickness of the angled region 34 and the thickness of the lower outer regions 33d, 33e and 33f is preferably in the range of about 0.75 to 1.0. In the range, more preferably in the range of about 0.8 to 0.9, such as 0.85. The different thicknesses provide substantial unexpected advantages in the production and use of the web 21 in the building elements of the present invention.

In a preferred embodiment, the thickness of the web goes from a thicker lower outer region (e.g., 33d in FIG. 3), via an angled region (e.g., region 34), to a thinner upper outer region (e.g., region 33b) tapers off (eg, through a straight drop in thickness), where the taper runs through the intersections between regions. Adjusting the mold gap at each zone is responsible for the redistribution of raw material in the mat caused by gravity and closing of the die set 26 so that the web 21 has a substantially uniform density after forming. Therefore, comparatively speaking, the thickness of the web 21 where more raw material is allocated in the mold gap (such as around position 29/30 in FIG. /32 near) the thickness of the web 21.

In one composite wood embodiment of the present invention, the thickness of the web 21 is preferably in the range of about 1/8 inch to 1 inch (about 3.18 mm to 25.4 mm), more preferably about  inch to  inch (about 6.35mm to 12.7mm). The thickness of the outer regions 33a, 33b and 33c is preferably in the range of about 0.215 inches to 0.465 inches (about 5.5mm to 11.8mm), while the thickness of the outer regions 33d, 33e and 33f is preferably about 0.250 inches to 0.50 inches. (about 6.35mm to 12.7mm).

When using American longleaf pine as the cellulose member in the raw material, the web panel 21 according to the present invention preferably has a specific gravity in the range of about 0.6 to 0.9, more preferably in the range of about 0.65 to 0.75, at any position of the panel. The specific gravity is preferably about 0.75. When using American longleaf pine as the cellulose member in the raw material, the total specific gravity of the board is in the range of about 0.6 to 0.9, more preferably in the range of about 0.65 to 0.75, most preferably about 0.75, making it a high density wood composite. A variable die gap is preferably available to produce a web panel 21 having at least a substantially uniform density along its contour. Preferably, the density of the webs 21 at the outer region 33 is at least 75%, more preferably at least 90%, eg 95%, of the density of the webs 21 at the angled region 34. Likewise, the density of the webs 21 in the upper outer region (for example, 33a) is at least 75%, more preferably at least 80%, and most preferably 90% of the density of the webs 21 in the lower outer region (for example, 33d) , for example 95%.

While the outer region 33 of the web plate 21 shown in FIGS. 3 and 4 is generally flat (planar), in an alternative embodiment the outer region 33 may be curved, or may have both curved and planar surfaces. Combinations or surfaces that may have other shapes and/or configurations. For example, some structure, profile or other surface may be provided on the outer surface of the outer region 33 of the web 21 in order to provide a modification with other components of the final wood product such as the flange 23, the end piece 22 or the auxiliary web 21. connection or bonding. For example, Figure 5 shows a portion of web 21 with structured surfaces 123a, 123b and flanges 23a and 23b. In addition, the lower surface 133d of the outer region 33d has an alternating rib and groove structure that provides mechanical interweaving and/or gripping with the ribs and grooves of the surface 123b of the flange 23b. In a preferred embodiment, the lower surface 133d of the outer region 33d has the same structure as the upper surface 123b of the flange 23b, but in other embodiments the structure may be slightly or completely different. The structure may include any feature that, when located on one or more surfaces of the web 21, end block 22, and flange 23, with or without the use of adhesives, provides Improved engagement (for example, gripping, frictional resistance, adhesion, or interweaving) of the surface of any other component. The surfaces 123a, 133a, 133b may also be configured to provide the improved engagement described above.

Accordingly, it should be understood that the use of the word "flat" herein refers to generally planar portions. In another alternative embodiment, the outer zone 33 may be the apex of the curved portion of the web 21 . In another embodiment, the outer zone 33 may have a thickness that increases or decreases from the center of the zone 33 to the ends of the zone 33 that adjoins and is integral with the angled region 34 .

Likewise, the angled region 34 shown in Figure 3 is generally flat (planar) (as also shown in Figures 5 and 6), but may also be contoured. For example, the web 21 may have a sinusoidally shaped cross-section. In another embodiment, the angled region 34 shown in FIG. 3 may comprise one or more flat (planar) regions, such as a flat region generally perpendicular to the outer region 33 of the web 21 .

Angled region 34 may form various angles with outer region 33 . These angles may be referred to as rake angles. For example, referring to FIG. 6 , the angle α between the lower surface 133d of the outer region (eg, 33d ) and the centerline 49 of the angled region 34 is the slope angle of the web segment 36 . Referring to FIG. 15 , which features an embodiment of the web 21 of tapered thickness in the angled region 34, the preferred design has a lower surface 133d of the outer region (e.g., 33d) and an upper surface 134a of the angled region 34. The slope angle β between. In this case, the angle between the lower surface 133d of the outer region (eg 33d ) and the lower surface 134b of the angled region 34 is determined by the selected tapered angle of that portion of the web 21 .

The slope angles α and β of the web 21 are preferably in the range of about 30° to 60°, more preferably in the range of about 35° to 55°, most preferably in the range of about 40° to 50° , eg about 45 degrees in a preferred composite wood product. In another embodiment of the invention, the slope angles α and β of the web 21 are greater than 45 degrees. Increased rake angles, particularly rake angles greater than 45 degrees, provide substantial advantages in the web plate 21 of the present invention, such as the ability to span greater distances with reduced material cost and increased strength.

Referring to Figure 7, there is shown an embodiment of a composite timber 38 of the present invention having an upper flange 23a and a lower flange 23b, respectively, a web 21 clamped between flanges 23a and 23b, and an optional Selected end block 22. The surface with the outer rounding 35 is defined at the intersection of the outer zone 33 and the angled zone 34 (i.e. the intersection of the roundings), which is shown in detail in FIG. 15, where the upper surface of the web 21 is at The intersection of the upper outer region 33a and the angled region 34 forms a rounding 35a. Such a rounding at the outer surface of the web 21 (i.e., near the upper surface of an upper outer region such as 33a, or near the lower surface of a lower outer region such as 33d) may be referred to as an outer rounding Round or shoulder shaped. FIG. 15 shows the rounding 35 b formed by the lower surface of the web 21 at the intersection of the upper outer region 33 a and the angled region 34 . Likewise, FIG. 15 shows the rounding 35 c formed by the upper surface of the web 21 at the intersection of the lower outer zone 33 d and the angled zone 34 . A rounding such as roundings 35b and 35c at the inner surface of the web 21 (i.e., near the lower surface of the upper outer region such as 33a, or near the upper surface of the lower outer region such as 33d), may Known as inner rounding. The inner rounding (such as rounding 35b and 35c) is preferably smaller than the outer rounding (such as rounding 35a). When the web 21 tapers as in FIG. 15, the rounding 35b is preferably smaller than the rounding 35c.

The rounding of the web 21 generally varies with the overall thickness of the web 21 . For example, the rounding 35a of the web 21 at the intersection between the angled region 34 and the upper outer region (eg 33a) generally varies with the thickness of the upper outer region (eg 33a). The size of the rounding 35a is preferably equal to about 1 to 3 times the thickness of the web 21 in the vicinity. In one particular embodiment, this dimension is approximately 1.5 times the thickness of the web 21 adjacent the outer region.

Exemplary rounding radii 35a for various thicknesses of the upper outer region 33 are listed in Table 2 below.

Diagram II - Exemplary web fillet radius 35a (approx.) The thickness of the upper outer zone 33 Radius 35a 0.125 inches (3.175mm) 0.1875 inches (4.76mm) 0.25 inches (6.35mm) 0.3125 inches (7.93mm) 0.375 inches (9.525mm) 0.4375 inches (11.1mm) 0.5 inches (12.7mm) 0.5625 inches (14.3mm) 0.625 inches (15.875mm) 0.6875 inches (17.5mm) 0.75 inches (19.05mm) 0.8125 inches (20.6mm)

The profile thickness or profile depth of the web 21 (determined by the maximum depth of the web, for example, referring to FIG. 5, the distance from the upper surface 133a of the region 33a to the lower surface 133d of the region 33d) is preferably about ? inches to 8 inches (about 6.35mm to 20.32cm), preferably around? inches to 4 inches (approximately 6.35mm to 10.16cm).

The stretching depth of the web 21 is measured as the vertical distance between the centerlines of adjacent outer regions (eg, regions 33a and 33d ) through which the angled region 34 passes. While the depth of draw across the web 21 may be uniform, this is not required. Thus, for example, the top surfaces of the outer regions 33a, 33b and 33c are preferably, but alternatively lie in one plane. The web 21 preferably has a compression depth of about 6 inches (about 15.24 cm) or less, more preferably in the range of about 1/4 inch to 3 1/2 inches (about 6.35 mm to 88.9 mm). In a preferred embodiment of the invention, the web 21 has a draw depth greater than the thickness of any one zone.

The web segment 36 shown in FIG. 6 is said to be located between the longitudinal midpoint of the lower outer zone 33 and the longitudinal midpoint of the adjacent upper outer zone 33 (midpoint of 33d to midpoint of 33b ) part of the web 21. This distance, the length of the web section 36 (measured along the line A-B shown in Figure 6), depends on the inclination angle of the angled region 34, the depth of compression in the web section and the lower outer zone 33d and The length of the upper outer zone 33b. In a web 21 in which all web segments 36 are identical, the frequency with which the web segments repeat is defined by the reciprocal of the web segment 36 length.

The strength of a composite wood product depends in part on how frequently the web segments are repeated. In general, the flexural strength of the wood product increases as the frequency with which the web segments are repeated increases. The following design factors are relevant to provide the bending resistance of the web, and thus the article comprising the web: (a) the desired length of the lumber; (b) the width of the end pieces used (if any); (c) The slope angle of the angled region 34 (which itself depends on the raw material used and the depth of draw); (d) web thickness at each zone and zone intersection; (e) web 21 density; (f) web 21 and the flange 23; and (g) the type and amount of adhesive between the web 21, the flange(s) 23 and the end block(s) 22. These factors can be chosen such that the desired resistance to bending can be achieved.

Figure 15 shows another preferred feature of the web 21, wherein a portion 51 of the lower surface of the web 21 near the intersection of the angled region 34 and the lower outer region (eg 33d) is substantially flat (planar ) and form an angle γ with respect to the lower surface 133d of the lower outer region 33d. This feature may be referred to as a crushed shoulder 51 . This feature allows the thickness of the web 21 to be controlled or determined at the intersection of the angled region 34 and the lower outer region (eg 33d). When this feature is included, the flattened shoulder 51 intersects the angled region 34 at one end (e.g., the lower surface) and the surface of the outer region (e.g., the lower outer region 33d) at the other end. The intersection of the lower surface) is preferably rounded.

The angle γ and the length of the flattened shoulder 51 are preferably selected to provide a thickness of the web 21 near the intersection between the angled region 34 and the outer region (e.g., the lower outer region 33d), so The thicknesses alternate between the thickness of the outer region and the thickness of the angled region 34 . Preferably, the angle γ and the length of the portion 51 are chosen to provide a thickness of the web 21 near the intersection between the angled region 34 and the outer region (e.g., the lower outer region 33d) that is The distribution of raw material in the die set 26 near the intersection between the angled region 34 and the outer region (eg 33d ) conforms after the group is closed so as to provide a substantially uniform density of the webs 21 . Therefore, it is preferable to use the feature of the crushed shoulder 51 at the intersection between the angled region 34 and the lower outer region (eg, 33d).

Angle γ is preferably in the range of about 20° to 50°, more preferably in the range of about 25° to 35°. In an exemplary embodiment, angle γ is substantially equal to 31 degrees.

In another embodiment of the invention, the consolidated web plate 21 has first and second corrugated base surfaces formed by a first (upper) mold 27 and a second (lower) mold 28, respectively. The first and second corrugated base surfaces provide alternating patterns of first and second sets of ridges extending parallel to each other and about the centerline of the web plate 21 (eg element 33 in FIG. 3 ) relatively placed. The sloping walls (such as elements 34 in FIG. 3 ) are such that adjacent ridges in the first set (such as elements 33a, 33b, 33c in FIG. 3 ) are aligned with intermediate ridges in the second set (such as elements 33d, 33c in FIG. 33e) Connection. Preferably, at least one base surface is rounded in the vicinity of the intersection of the ridge and the inclined wall. Web plate 21 between at least one adjacent first and second base surfaces in at least one of the first and second sets of ridges (eg, elements 33a, 33b, 33c, and elements 33d, 33e, 33f, respectively, in FIG. 3 ) The thickness of is different compared with the inclined wall (such as the element 34 in Fig. 3).

The features of this embodiment of the web plate 21 of the invention may be the same as those of the web plate 21 previously described. For example, in a preferred embodiment, the thickness of the web 21 gradually increases or decreases from the sloping wall to the ridge via rounded intersections.

Referring to FIG. 1 , to manufacture a composite timber member, one or more consolidation web panels 21 are bonded to two flange panels 23 and optionally to two end block beams 22 so as to form the bond of FIG. 1 Component 20. In general, any material may be used to form the flange panels 23 of the composite wood product of the present invention. Exemplary flange materials are: Laminated Veneer Lumber (LVL), Regular Solid Lumber, Plywood, Laminated Strand Lumber (LSL), Parallel Strand Lumber (PSL), Particle Board, OSB, Strand Board (Laminar), Fibreboard, corrugated cardboard, kraft paper, plastic, fiberglass and metal. Alternative flange materials may include enhanced function materials such as those described above in relation to web 21 .

The flange 23 also contributes to the deflection resistance of the composite wood product. Accordingly, the flanges are preferably made of a material that, in combination with the web, provides the desired resistance to deflection for the particular application. In a preferred embodiment of the invention, the flange is OSB made of the same raw material as the web 21 according to the method described above. In such an embodiment, the bundle of flanges 23 is preferably oriented in a direction perpendicular to the groove 24 of the web 21, and the thickness of the flanges 23 is preferably between about 1/8 inch and 1 inch (about 3.2 mm to 25.4mm). The opposing flanges are preferably of equal thickness, however, in some applications the product of the invention may be used with two completely different flanges (different both with respect to thickness and material).

The flange 23 of the wood product is preferably flat throughout and of uniform cross-sectional dimension (or thickness). However, it should be understood that other flange shapes may be used with the present invention. For example, in an alternative embodiment, the flange 23 itself is a web plate 21 having one or more of the features described above. When the flange 23 is itself a web 21, the term "nominal flange" 23 is used to refer to its specific web-like character. Alternatively, such a multilayer assembly may simply refer to one or more webs 21 . Such "nominal flanges" 23 preferably have a relatively small draw depth [e.g., in the range of approximately 1/16 to 1/2 inch (approximately 1.6 mm to 12.7 mm)], repeating web segment 36 frequency, and the length of the outer zone 33 is sufficient so that the one or more outer zones 33 of the “nominal flange” 23 are in contact with the one or more outer zones 33 of the web 21 .

The flange plate 23 preferably has a dimension (here length) approximately equal to the desired length of the composite wood product. Referring to FIG. 1 which depicts bonded assembly 20 , the length of flange plate 23 is measured along line 25 . The size of the flange plate 23 in the plane perpendicular (width) direction can be any practical size and is preferably equal to the width of the web 21 in the bonded assembly 20.

In general, any material or combination of materials can be used to make the optional end blocks 22 of the composite wood products of the present invention, including: laminated veneer lumber (LVL), conventional solid wood, plywood, laminated strand lumber (LSL) ), Parallel Strand Lumber (PSL), Particle Board, OSB, Strand Board (Laminer Board), Fibreboard, Corrugated Board, Kraft Paper, Plastic, Fiberglass and Metal. The end block 22 is preferably formed of a material of sufficient strength to maintain mechanical attachment, and more preferably is formed of a nailable material. In a preferred embodiment of the invention, end block 22 is formed from particle board. In another preferred embodiment of the invention, the end block 22 is made from off-cuts from the production of the flange 23 . The opposing end pieces 22 are preferably made of the same material, however, the present invention may also include end pieces 22 made of two different materials, or two end pieces each made of a different material.

The optional end block beam preferably has a length approximately equal to the width of the flange plate 23 (approximately equal to the width of the web plate 21).

Referring to FIG. 1, the optional end block beam preferably has sufficient spanning distance between the outer edges 223a and 223b of the flange plates 23a and 23b on each end of the bonded assembly 20 and the end of the web plate 21 (not shown). The width of the predetermined gap between. The end blocks 22 are preferably large enough to provide sufficient volume for solid material to remain mechanically secured when the timber is positioned.

Referring to FIGS. 1 and 5, the optional end block beam is preferably large enough to span the gap formed in the bonded assembly 20 between the inner surfaces 123a and 123b of the opposing flanges 23a and 23b. In the composite lumber product of FIG. 1, wherein the length of the web plate 21 perpendicular to the groove 24 along the line 25 is less than the length of the flange 23 along the line 25, the end block beam thickness is preferably approximately equal to that of the web plate 21. Bracket depth. In another embodiment, the length of the web plate 21 along the line 25 is substantially equal to the length of the flange plate 23 (wherein the outer region of the web 21 extends to the outer edges 223a and 223b of the flange 23). In such an embodiment, the preferred end block 22 has a thickness approximately equal to the web 21 draw depth and less than the thickness of the terminal outer region 33 . In other words, in such an embodiment, the thickness of the end piece 22 is no greater than the gap formed between the inner surface of the outer region 33 of the web 21 and the inner surface of the opposing flange 23 (eg, 123a ).

To assemble the preferred intermediate bonded assembly 20, adhesive is applied to the interface between the components and the components are aligned. For example, an adhesive may be applied to the outer surfaces 133a, 133b, and 133d ( FIG. 5 ) of the outer region 33 of the one or more web panels 21 . In cases where two or more web plates are used, it is preferred that the outer regions 33 are aligned such that the grooves 24 are parallel and the outer surfaces of the outer regions 33 coincide, for example as shown in FIG. 10 . One or more web panels 21 may be stacked to form a web core which may be aligned with and bonded to one or more flange panels 23 . An optional end block 22 may be bonded to the flange plate 23 and the single or multiple web plates 21 at the ends of the single or multiple web plates 21 , parallel to the groove 24 . The second flange plate may be aligned with and bonded to the web 21 and optional end block 22 struts.

After applying the adhesive and aligning the components, the entire bonded assembly 20 is conveyed into a press (preferably a continuous clip press or press) for a predetermined period of time and subjected to sufficient curing and/or drying of the bond high pressure and/or temperature of the agent.

To produce composite wood products, the bonded assembly 20 is then conveyed to a multi-spindle sawing machine. The sawing machine cuts the bonded assembly 20 along a straight line 25 in a direction perpendicular to the groove 24 . The width between the knife shafts is approximately equal to the width of the desired composite wood article, eg, about 1 1/2 inches (about 3.81 cm), a nominal 2x4 width. In this way, many wood-composite lumber embodiments of the present invention can be produced from one bonded assembly 20 .

By only cutting thicker sections, such as 1 foot thick (about 30.5 cm) sections, from the bonded assembly 20, preferably in a direction parallel to the groove 24, the same intermediate bonded assembly 20 for composite wood can be cut. Props 37 (an example depicted in FIG. 8 ) are produced. In this manner, a 1 foot thick (approximately 30.5 cm) strut 37 can be produced with the same performance as composite lumber. This is an advantage over known methods where, for example, 8 conventional 2x4 nominal lumbers are glued together to produce a stanchion of the same size.

Additional functions such as coloring, fire protection, insect resistance, fungus resistance, and water resistance can be obtained by adding suitable function-enhancing additives, or by applying suitable special coatings to the surface of the composite wood products of the present invention.

Composite lumber embodiments of the present invention can be designed to have the same external dimensions as conventional lumber and sufficient modulus of elasticity and moment of inertia to meet the structural requirements of standard applications. However, the invention is also applicable to the production of timber elements having alternative cross-sectional dimensions and whose length is limited only by the size of the equipment used to produce the individual elements of the bonded assembly 20 .

In addition, the present invention may also provide composite wood products having functional properties different from their conventional wood counterparts. For example, regular 2×6 (nominal) lumber is often used in house construction to provide a 5” (approximately 14 cm) deep space for R-19 insulation between decking, but it is usually more than sufficient to meet Building regulations require the required strength, thereby adding to the cost of the building project. A nominally 2x6 multi-ply wood-based composite lumber member of the present invention may have the same cross-sectional dimensions as a conventional 2x6, but may be engineered for special (eg, increased or decreased compared to conventional lumber) strength Require. Accordingly, one advantage of the present invention is the ability to provide a building element that meets or exceeds building code requirements and, among other advantages, uses less virgin material than conventional products such as conventional 2×6 , lighter weight and less costly to produce.

A nominal 2 x 4 embodiment of the invention

One embodiment of a preferred composite article of the present invention (shown in isometric view in Figure 9) suitable for use as a conventional lumber replacement of conventional 2" x 4" x 8' (nominal) comprises: a web 21 and two end pieces 22 sandwiched between and bonded to two flanges 23. The preferred composite 2×4 article 38 of the present invention is designed to have the same cross-sectional dimensions as conventional 2×4 lumber, i.e. 1  inch to 3  inch (about 38.1 mm to 88.9 mm), about 8 feet (about 244 cm) Long, and have a modulus of elasticity for the manufacture of domestic buildings built in Wind Belt 1 that enables the product to comply with Housing and Urban Development (HUD) building and safety standards. However, the invention is also applicable to other multi-ply wood composites used in place of conventional wood, including for example actual and nominal 1×3s, 1×4s, 2×3s, 2×6s, 2×8s, 2× 10s, 2×12s, 4×4s, 4×6s, and 6×6s, and are limited in length only by the size of the equipment used to produce the bonded assembly 20 individual components. For example, Figure 10 is a perspective view of a multilayer composite 2x6 product 39 that can be used as a replacement for conventional nominal 2x6s. This embodiment of the invention comprises two webs 21 bonded in their outer regions 33 .

The structure of the preferred 2x4 product 38 of the present invention will be described below. The preferred web 21 can be made from bundles having a length in the range of about 4 1/2 inches to 5 1/2 inches (about 11.4 cm to 14 cm), about 3/4 inch to 1 inch (about 19 mm to 25.4 mm), and a thickness in the range of about 0.02 inches to 0.025 inches (about 0.51 mm to 0.64 mm). The bundles used in the preferred web 21 have a pre-compressed moisture content in the range of about 2% to 9% based on the weight of the bundles, preferably in the range of about 4% to 6%, for example 5%.

Mats are produced by combining the strands, resin binder, wax and other optional additives as described above. A preferred resin binder for the web 21 is resorcinol formaldehyde resin, preferably added in an amount of about 4.1% wt. based on the weight of the wood bundle. Preferably, the wax is added to the raw material in the range of about 1.2 wt.% to 2 wt.% based on the weight of the wood bundles, for example about 1.2 wt.%.

In the preferred 2x4 embodiment, the mat that will become the web 21 is formed from three layers of raw material, including bundles, according to the above-described continuous process. The first (bottom) and third (top) layer bundles are oriented in the machine direction (i.e., in a direction perpendicular to the trench 24), and the first (bottom) and third (top) layer bundles comprise About 90% of the total pad weight is divided equally between these two layers. The second (or middle) layer bundle is oriented perpendicular to the machine direction (ie, in a direction parallel to the grooves 24) and comprises the remaining about 10% of the total mat weight.

It is preferable to make the composite 2×4 product of the present invention into lengths of about 81.75 inches (about 2.08 m), about 87.75 inches (about 2.23 m), or about 96 inches (about 2.44 m), so as to be suitable for use. Standard length in the construction industry. One type of preferred web 21 used in the above products has a length of about 81.75 inches (about 2.08 m), about 87.75 inches (about 2.23 m), or about 96 inches (about 2.44 m), respectively. In an alternative web embodiment, the preferred lengths are about 75.75 inches (about 1.92m), about 81.75 inches (about 2.08m), or about 90 inches (about 2.29m), respectively, to facilitate the Provide approximately 3 inches (approximately 7.6 cm) of space.

In order to maximize the efficiency of producing composite wood members from a bonded assembly 20, the width of the web plates (and mats used to produce the web 21) is preferably as large as possible. For example, in a 4 foot by 8 foot (approximately 1.22m to 2.44m) heated press for the production of approximately 8 foot (approximately 2.44m) long composite 2x4 About 1.22m) wide. Preferably, an 8ft x 24ft heated press is used to produce composite 2x4 lumber approximately 8ft long, with web panels preferably 24ft (approximately 7.32m) wide.

The temperature of the press platen during consolidation of the mat using phenolic resin is preferably about 450°F (about 232°C). The pressing time depends on the thickness of the finished product as well as the other factors listed above, but for the preferred webs of the present invention used in 2x4 composite lumber applications, the pressing time is generally in the preferred range of about 2.5 minutes to 3 minutes.

The web plate 21 according to the present invention preferably has a specific gravity in the range of about 0.6 to 0.9, more preferably about 0.75, at any point on the plate. The overall specific gravity of the board is preferably in the range of about 0.6 to 0.9, such as about 0.75, making it a high density wood composite. A variable die gap is preferably available to produce a web panel 21 having at least a substantially uniform density along its contour. Preferably, the density of the webs 21 at the outer region 33 is at least 75%, more preferably at least 90%, eg 95%, of the density of the webs 21 at the angled region 34. Likewise, the density of the webs 21 in the upper outer region (for example, 33a) is at least 75%, more preferably at least 80%, and most preferably 90% of the density of the webs 21 in the lower outer region (for example, 33d) , for example 95%.

The web 21 of article 38 preferably has a thickness in the range of about 1/4 inch to 1/2 inch (about 6.35 mm to 12.7 mm). The thickness of the angled region 34 is preferably greater than the thickness of the upper outer regions 33a, 33b and 33c. The thickness of the underlying outer regions 33d, 33e and 33f is preferably at least equal to the thickness of the angled region 34. For example, in the article 38 of FIG. 9, the thickness of the lower outer regions 33d, 33e and 33f and the angled region 34 is about 0.375 inches (about 9.52 mm), while the thickness of the upper outer regions 33a, 33b and 33c is about 0.375 inches (about 9.52 mm). is 0.340 inches (about 8.64mm). In another embodiment, the thickness of the lower outer regions 33d, 33e, and 33f is about 0.352 inches (about 8.94mm), and the thickness of the upper outer regions 33a, 33b and 33c is about 0.3 inches (about 7.62mm), and The angled region 34 tapers from 0.352 inches between the lower outer zone and the upper outer zone to 0.3 inches.

The outer region 33 of the web 21 preferably has a length of about 6 inches (about 15.24 cm) or less, or about 2 inches (about 5.08 cm) or less, such as about 1.1688 inches (about 2.97 cm). In special applications, the outer region 33 of the web 21 may be longer than 2 inches. The slope angle of the web 21 of the article 38 is preferably 45 degrees.

Exhibit III below summarizes preferred dimensions for tapered composite timber webs 21 for use as nominal 2×4 members, wherein the webs 21 have a section thickness equal to approximately 2 inches (approximately 5.08 cm), approximately equal to 3.175 Inch (approximately 8.06cm) length of web segment 36, a taper angle β equal to approximately 45 degrees, an angle γ in the range of approximately 25 degrees to 35 degrees, respectively located at 0.15 inches (3.81 mm) and 0.35 inches (8.89 mm ), such as 0.25 inches (6.35mm). The thickness of the angled region 34 at three different locations is indicated in FIG. 15 by elements 34a, 34b and 34c.

Chart III - Preferred Web Thickness and Rounding Radius, Approximate Values* The thickness of the web 21 at different positions The preferred range of rounding radius 35a Preferred rounding radius 35a 33a 34a 34b 34c 33d 0.125(3.18) 0.127(3.23) 0.135(3.43) 0.143(3.63) 0.147(3.73) 0.234 to 0.360 (5.94 to 9.14) 0.297(7.54) 0.25(6.35) 0.253(6.43) 0.269(6.83) 0.285(7.24) 0.293(7.44) 0.469 to 0.719 (11.91 to 18.27) 0.597(15.09) 0.375(9.53) 0.380(9.65) 0.404(10.26) 0.428(10.87) 0.440(11.18) 0.703 to 1.079 (17.85 to 27.41) 0.891(22.63) 0.500(12.7) 0.507(12.88) 0.539 (13.69) 0.570(14.48) 0.587(14.91) 0.938 to 1.438 (23.83 to 36.53) 1.188 (30.18) 0.625(15.88) 0.633(16.08) 0.673(17.09) 0.713(18.11) 0.733(18.62) 1.172 to 1.796 (29.77 to 45.61) 1.484 (37.69) 0.750(19.05) 0.760(19.30) 0.808(20.52) 0.855(21.72) 0.880(22.35) 1.406 to 2.156 (35.71 to 54.77) 1.781 (45.24)

*All dimensions are in inches (mm) in parentheses

Flanges 23a and 23b of article 38 are preferably OSB of the same material as web 21 and are oriented with bundles perpendicular to grooves 24 of web 21 (ie, parallel to the longitudinal axis of article 38). Flange 23 is preferably about 8 feet (about 2.43m) long. The thickness of flange 23 is preferably in the range of about 1/8 inch to 1 inch (about 3.18mm to 25.4mm), more preferably in the range of about ½ inch to 1 inch (about 1.27cm to 2.54cm) , for example about 0.75 inches (about 1.9 cm) in the preferred flange 23 embodiment for use in the nominal 2x4 embodiment of the invention.

In a preferred embodiment of the present invention, the width of end piece 22 (measured along line 25 parallel to line 25 in FIG. 1) is preferably in the range of about 1 inch to 5 inches (about 2.54 cm to 12.7 cm), Preferably about 1  inches (about 3.8 cm), more preferably about 3 inches (about 7.62 cm). The end block 22 can be made from off-cuts from the flange 23 manufacture. For example, as shown in FIG. 9, an end piece having a width of about 1 1/2 inches (about 3.8 cm) can be obtained by bonding two portions of an inch (1.9 cm) flange 23 stock or trim. End piece 22 preferably has a thickness of 2 inches (about 5.08 cm), approximately equal to the cross-sectional depth of web 21.

Then, as shown in FIG. 1 , the web plate 21 , flange plate 23 and end piece 22 are assembled and bonded according to the method described above so as to form the bonded assembly 20 . In a preferred 2x4 article of the invention produced as described above, the adhesive has a minimum shear strength of about 400 lb/ ⁱⁿ² (about 28.1 kg/ ^cm2 ).

The bonded assembly 20 is then transported to a plurality of arbor sawing machines. As noted above, the sawing machine cuts bonded assembly 20 along line 25 of FIG. 1 in a direction perpendicular to groove 24 .

The composite 2x4 of this example is designed to meet the technical requirements of construction in applications where conventional 2x4s are used as pillars. In the preferred 2x4 embodiment, flange 23 has a minimum spring rate of about 900,000 lb/ ⁱⁿ² . For example, in the test method described by Fleetwood Enterprises. Inc. of Riverside (USA City), CA and HUD standards, such that the nominal 2×4 supports are at the top and bottom (and side out 1  inch (about 3.8 cm) side contact) with an evenly distributed load applied over the length of the member. In order to pass the "Dynamic Load" test, the 2×4 does not break immediately after 2 times of "Dynamic Load" is applied. In order to pass the flex test, the 2x4 must not move at the midpoint greater than the maximum allowable deflection. The dynamic load is determined from the wind load, which is approximately 15 lb/ft ² (73 kg/m ² ) times the length of the timber member and times the distance between the posts in the wall. The allowable deflection is determined by dividing the length of 2x4 by 180. For example, for 2×4s that are 81.75 inches (about 2.08m) and spaced 16 inches (about 40.64cm) apart, the dynamic load is about 136 pounds (61.7kg), and the allowable deflection is about 0.45 inches (about 11.43mm) ); for 2×4s that are 87.75 inches (about 2.23m) and spaced 16 inches (about 40.64cm) apart, the dynamic load is about 146 pounds (66.3kg), and the allowable deflection is about 0.49 inches (about 12.45mm ); for 96 inches (about 2.44m) and 16 inches (about 40.64cm) apart for 2×4, the dynamic load is about 160 pounds (72.6kg), and the allowable deflection is about 0.53 inches (about 13.46mm ).

decorate

The process of the present invention can be used to produce integral composite decorative component products of the present invention suitable for use as conventional trim, or the process of the present invention can vary the dimensional and strength characteristics for a particular application. FIG. 11 is a cut-away isometric view of a two-ply composite trim member 40 of the present invention showing a conventional joist or frame 41 . The trim member 40 preferably has a first (lower) molded trim panel 42 bonded to a second (upper) cover panel 43 . The trim panel 42 is an embodiment of the web panel 21 described above, and thus the trim panel 42 may have the features and properties of the web panel 21 described above. A preferred trim panel 42 is shown in top plan view in FIG. 12 and in side view in FIG. 13 . The portion of the trim panel 42 lying in the main plane of the panel is referred to as grid 46 .

The trim panel 42 preferably includes at least one cavity 44, preferably including one or more rows and/or rows of cavities 44 depending from the grid 46 of the wood composite panel, contiguous to the grid 46 and integrally formed therewith or one or more columns (seen in side view of FIG. 13 ) of cavities 44 . In a preferred embodiment, as shown in Figures 11, 12 and 13, the cavity 44 is arranged downwardly as a right rectangular pyramidal frustum. A frustum is what is left after truncating a pyramid or cone along a plane parallel to the base of said pyramid or cone. The cavity 44 of the preferred embodiment has angled (or sloped) spacer sidewalls 45 extending downwardly from the grid 46 and terminating in a substantially flat cavity bottom or base 47, wherein the plane of the cavity base 47 The major planes of the mesh 46 of the trim panel 42 are generally parallel. Trim members 40 are supported by and/or are connected to joists and/or frames 41 by grids 46 between parallel, substantially planar rows and/or columns of cavities 44 of trim panels 42 The flat belts 46a, 46b and 46c. Decorative member 40 may be attached to joists and/or frame 41 by any suitable method, including adhesives and mechanical fastening, such as staples.

The decorative panel 42 of the present invention is preferably a bundled panel, wherein its raw material is constructed according to the process described above. The mat that becomes the consolidated trim panel 42 is preferably formed from up to three layers of raw material in the above-described continuous process and then cut to size. The beams in the trim panel 42 can be oriented arbitrarily or can be given a special orientation. In addition, the trim material may optionally include enhanced function materials such as those described above.

In a preferred embodiment, the thickness of the decorative plate 42 at the cavity base 47 and the cavity sidewall 45 is greater (thicker) than the thickness of the decorative plate 42 at the grid 46 . In a preferred trim panel 42, the thickness of the cavity base 47 is at least approximately equal to the thickness of the cavity sidewall 45, and the ratio of the thickness of the mesh 46 to the thickness of the cavity sidewall 45 is at least about 0.75, and more preferably In the range of about 0.8 to 0.9, for example about 0.85.

In another preferred embodiment, the thickness of the decorative panel 42 at the cavity base 47 is smaller (thinner) than the thickness of the decorative panel 42 at the cavity sidewall 45 and the grid 46 . In such a trim panel, the thickness of the grid 46 is at least approximately equal to the thickness of the cavity sidewall 45, and the ratio of the thickness of the cavity base 47 to the thickness of the cavity sidewall 45 is at least about 0.75, preferably at least about 0.75. In the range of about 0.8 to 0.9, for example about 0.85.

Generally, the slope angle formed by the cavity side wall 45 and the grid 46 of the decorative panel 42 is in the range of about 30 degrees to 60 degrees, preferably in the range of about 35 degrees to 55 degrees, and more preferably In the range of about 40 degrees to 50 degrees, for example about 45 degrees. In another embodiment of the present invention, the slope angle formed by the cavity side wall 45 and the grid 46 of the decorative panel 42 is greater than 45 degrees. Increased rake angles, especially rake angles greater than 45 degrees, provide major advantages of the trim member 40 of the present invention, such as at reduced material cost and increased strength capability over greater distances.

The profile thickness of the trim panel 42 (determined by the maximum depth of the trim panel 42, e.g., the distance from the upper surface 146 of the mesh 46 to the lower surface 147 of the cavity base 47) is preferably between? inches (about 6.35mm) to 8 inches (about 20.32cm), preferably in the ? inches (about 6.35mm) to 4 inches (about 10.16cm).

Stretch depth is determined as the vertical distance traveled by sidewall 45 between the centerline of cavity base 47 and the centerline of grid 46 . While the draw depth is uniform throughout the trim panel 42, it may alternatively lie on a single plane. The burring depth is preferably at most 6 inches (approximately 15.24 cm), preferably at? inches (about 6.35mm) to 3  inches (about 8.89cm). In one decorative embodiment of the present invention, the draw depth is greater than the thickness of any one of the grid 46 , the sidewall 45 and the cavity base 47 .

The length of cavity 44, eg, the distance between parallel flat regions 46a and 46b, is preferably in the range of about 6 inches (about 15.24 cm) to 90 inches (about 228.6 cm). The width of cavity 44, measured perpendicular to the length, is preferably in the range of about 4 inches (about 10.1 cm) to 24 inches (about 60.9 cm).

Although the grid 46 shown in Figures 11, 12 and 13 is substantially planar (flat), in alternative embodiments the grid 46 may have contours or other structures other than planar. For example, structure may be added to the upper surface 146 of the mesh 46, and optionally to the mating face of the cover panel 43, in order to provide enhanced adhesion, as described above with respect to the composite wood. Structure may also be added to the lower surface of the grid 46 (i.e., the surface relative to the upper surface 146), and optionally to the mating faces of the joists and/or frame 41 in order to provide improved adhesion, as described with respect to Composite wood described above.

In a preferred embodiment of the present invention, a consolidated trim panel 42 is bonded to a cover panel 43 so as to form the trim member 40 shown in FIG. 11 . In general, any material can be used to form the cover panel 43 of the trim member 40 of the present invention. The cover plate 43 contributes to the deflection resistance of the composite trim member 40 . Accordingly, cover panel 43 is preferably made of the material associated with trim panel 42 to provide the desired deflection resistance for the particular application. In a preferred embodiment of the present invention, the cover panel 43 is a beam panel made of the same raw material as the trim panel 42 . In another preferred embodiment, the cover board 43 is particle board.

Covering panel 43 of trim member 40 is preferably generally planar and of uniform cross-sectional dimension. However, it should be understood that the invention is also applicable to the use of cover panels of other shapes.

The length and width of the cover panel 43 are preferably equal to the length and width of the corresponding trim panel 42 in the trim member 40 .

floor components

The process of the present invention can be used to produce integral floor member products of the present invention suitable for use as traditional joists and decorative floors or the process of the present invention can vary in size and strength characteristics for special applications. FIG. 14 is a cut-away isometric view of a four-ply composite flooring member 48 . The floor members 48 may be manufactured by the same method used to produce the bonded assembly 20 of the composite lumber embodiment, optionally without the end blocks.

Referring to Fig. 14, the floor member 48 produced by the inventive method preferably has two webs 21, and said web 21 is bonded with two flange plates 23a and 23b, and is clamped between two flange plates 23a and 23b. Between 23b. The floor member 48 of the present invention provides significant advantages over the prior art, including reduced cost and reduced labor required for installation.

wall components

The process of the present invention can be used to produce integral wall element products of the present invention suitable for use as replacements for traditional pillars and cladding walls or for special applications of the present invention that can be modified to manipulate dimensions and strength characteristics.

The wall elements are preferably manufactured by the same method used to produce the bonded assembly 20 of the composite timber embodiment. Preferably the web section 36 of the web 21 of the wall element repeats less frequently. Additionally, the wall members preferably have webs 21 having a cross-sectional depth of 5 1/2 inches (about 14 cm) to accommodate R-19 insulation in grooves 24 between flanges 23 .

Building elements, such as timber elements, trim elements, floor elements, walls, pillars and framing elements made in accordance with the present invention exhibit a number of improved properties. First, the present invention provides consistency in the dimensional accuracy of building elements with respect to construction time and useful life of the elements and structures built therefrom. The inventive building elements also require less material input than their traditional timber and cladding counterparts. The building elements of the present invention are lightweight compared to their traditional timber and cladding counterparts. Due to their light weight compared to their traditional timber and cladding counterparts, the inventive building elements can be transported in larger sizes. Also, because the building elements of the present invention are consistent in size and can be shipped in larger sizes, less manpower is required to assemble the elements when constructing buildings. In addition, the present invention can provide a product with enhanced surface friction to facilitate installation and use.

Since the building elements of the present invention can be designed to be stronger than their traditional timber counterparts, greater distances can be spanned while using fewer support members. Composite wood embodiments of the present invention can provide built-in voids suitable for accommodating wires and tubing, which eliminates the labor involved in drilling holes in conventional lumber to accommodate wires and tubing. Furthermore, the multilayer building elements of the present invention are able to provide built-in voids that enhance the thermal and acoustic performance of the element. The present invention also provides the ability to design building elements with built-in properties such as conventional coloring as well as fire, insect, water, UV and bacteria resistance. The building elements of the invention also protect the environment as they allow for a more thorough use of wood, allow for the use of low quality wood, and can be ground up and easily disposed of or recycled. Finally, the present invention provides production efficiencies such that multiple pieces of composite lumber or fully assembled flooring systems can be produced at once in an assembly line, whereby multiple identical operations can be used to produce different building elements such as walls, columns and composite wood.

The above detailed description is given only for the purpose of clear understanding. It should be understood that the above detailed description has no unnecessary limitations, and those skilled in the art should understand that the present invention can be modified within the protection scope of the present invention.

Claims (109)

1. A composite building element comprising: (a) a molded composite web having a first outer region, a second outer region and two angled regions which are angled from the first and second outer regions, each said region having a thickness, and each of said regions has an inner surface and an outer surface, wherein the thickness of the angled region differs from the thickness of at least one of the outer regions; and (b) a flange on an outer surface of said first outer region. 2. The composite building element of claim 1, wherein an outer region has a thickness that is less than the thickness of the angled region. 3. The composite building element of claim 1, wherein an outer zone has a thickness equal to the thickness of the angled zone. 4. The composite building element of claim 1, wherein the thickness of the angled region tapers from one outer zone to the thickness of the adjacent outer zone. 5. The composite building element of claim 1, further comprising a rounded intersection between a surface of the angled region and a surface of the outer region. 6. The composite building element of claim 5, wherein the thickness of the web changes gradually from the angled region via the rounded intersection to the outer region. 7. The composite building element of claim 1, wherein the molded composite web has a depth of tension greater than the thickness of any zone, and said depth of tension is defined as being between the center points of adjacent outer zones. the vertical distance between them. 8. The composite building element of claim 1 wherein said non-planar molded composite web has a uniform density. 9. The composite building element of claim 1, wherein the density of the molded composite web at the outer region is at least 75% of the density of the molded composite web at the angled region. 10. The composite building element of claim 1, wherein the density of the molded composite web at the first outer zone is at least 75% of the density of the molded composite web at the second outer zone. %. 11. The composite building element of claim 1, wherein at least a portion of a surface of the outer region is roughened. 12. The composite building element of claim 1 wherein said non-planar molded composite web comprises oriented strand board. 13. The composite building element of claim 1, wherein the outer region and angled region define at least one groove. 14. The composite building element of claim 1, further comprising a second flange on an outer surface of the second outer region. 15. The composite building element of claim 1 including an end block connected to at least one of said web and said flange. 16. A composite building element according to claim 1, comprising: A second non-planar molded composite web having two outer regions and two angled regions, each of the regions having a thickness, and each of the regions having an inner surface and the outer surface, wherein the thickness of the angled region is different than the thickness of at least one of the outer regions. 17. The composite building element of claim 16, wherein at least one outer region of the second non-planar molded composite web is aligned with an outer region of the first non-planar molded composite web. 18. The composite building element of claim 1, wherein said web includes a shoulder between a surface of the angled region and a surface of the outer region, and said shoulder is flat . 19. The composite building element of claim 1 wherein said web includes at least one cavity depending from and connected to a major plane of said web. 20. A composite building element comprising: (a) a web having a groove defined by a first outer region, a second outer region, and two angled regions, each of said regions having a thickness, and each of said regions having an inner surface and outer surfaces; (b) a first flange connected to said web at the outer surface of the first outer region; (c) a second flange connected to said web at the outer surface of the second outer region; characterized in that, The width of the building element, determined in a direction parallel to the groove, is not greater than the thickness of the building element, said thickness being determined as the distance between the parallel outer surfaces of the flanges. 21. The composite building element of claim 20, wherein the thickness of the angled region differs from the thickness of the at least one outer region. 22. A composite building element comprising: a web panel comprising an array of molded wood strands having a thickness and having first and second corrugated base surfaces, said first and second corrugated base surfaces provide alternating patterns of first and second sets of ridges extending parallel to each other and positioned oppositely with respect to a centerline of said web plate, adjacent ridges of the first set are connected to intermediate ridges of the second set by inclined walls; and The sloped wall has a different thickness than at least one of the first and second sets of ridges. 23. The composite building element of claim 22, wherein at least one of the first and second sets of ridges has a thickness that is less than the thickness of the sloped wall. 24. The composite building element of claim 22, wherein at least one of the first and second sets of ridges has a thickness equal to the thickness of the sloped wall. 25. The composite building element of claim 22, wherein said sloped walls are tapered in thickness. 26. The composite building element of claim 22, further comprising a rounded intersection between the ridge and the sloped wall on at least one base surface. 27. The composite building element of claim 26, wherein the thickness of the web plate is gradual from the sloped wall via the rounded intersection to the ridge. 28. The composite building element of claim 22, wherein the depth of tension of the web is greater than the thickness of the web at any location, and wherein the depth of tension is defined as between the center points of adjacent outer regions the vertical distance. 29. The composite building element of claim 22, wherein the web panels have a uniform density. 30. The composite building element of claim 22 wherein the density of said web panels at the ridges is at least 75% of the density of said web panels at the sloped walls. 31. The composite building element of claim 22, wherein the density of said web plate at a first ridge is at least 75% of the density of said non-planar molded composite web at a second ridge . 32. The composite building element of claim 22, wherein at least a portion of the base surface at the ridge is roughened. 33. The composite building element of claim 22, wherein said web panel comprises oriented strand board. 34. The composite building element of claim 22, wherein the ridge and sloped walls define at least one groove. 35. The composite building element of claim 22, including a flange on a substantial surface between at least one ridge and at least one sloped wall. 36. The composite building element of claim 22, including an end block connected to the web plate. 37. The composite building element of claim 22, including a crushed shoulder between the ridge and the sloped wall. 38. The composite building element of claim 22 including a second web panel comprising a molded array of wood strands, said second web panel having a thickness and having first and second corrugated base surface, said first and second base surfaces provide alternating patterns of first and second sets of ridges extending parallel to each other and positioned oppositely with respect to a centerline of said second web plate, adjacent ridges of the first set are connected to intermediate ridges of the second set by inclined walls; and The sloped wall has a different thickness than at least one of the first and second sets of ridges. 39. The composite building element of claim 38, wherein at least one ridge of said second web panel is aligned with one ridge of said first web panel. 40. A method of producing a composite building element, said method comprising the steps of: (a) forming a mat comprising a wood-based material; (b) placing the mat in a module having at least two outer regions and at least two angled regions; (c) closing the mold to form a mold gap, wherein the mold gap at the at least one outer region is different than the mold gap at the angled region; (d) consolidating the mat under pressure and heat to form a molded composite web; and (e) connecting said web to at least one flange; to form composite building components. 41. The method of claim 40, wherein the wood-based material comprises wood strands. 42. The method of claim 40, wherein the die gap at an outer region is smaller than the die gap at the angled region. 43. The method of claim 42, wherein the die gap at an outer region is equal to the die gap at the angled region. 44. The method of claim 40, wherein the molded composite web has a surface area that is 75% greater than the surface area of the mat. 45. The method of claim 44, wherein the molded composite web has a surface area that is 15% to 25% greater than the surface area of the mat. 46. The method of claim 40, wherein the molded composite web has at least one groove defined by a first outer region, a second outer region, and at least two angled regions, wherein The flange of step (e) is attached to the outer surface of the first outer region, and the method further comprises the steps of: (f) connecting said web to a second flange at an outer surface of said second outer region; and (g) dividing the product of step (f) along a direction perpendicular to the groove; In order to facilitate the production of composite building components. 47. A composite building element produced according to the method of claim 40. 48. A method of producing a composite building element comprising the steps of: (a) forming a mat comprising an array of wood strands; (b) placing the mat in a mold set having first and second mold surfaces; (c) closing the mold to form a mold gap between the first and second mold surfaces, wherein the mold gap provides an alternating pattern of first and second sets of ridges extending parallel to each other and oppositely positioned with respect to the centerline of the die set, wherein adjacent ridges of the first set are connected to intermediate ridges of the second set by inclined walls, and wherein the mold gap of at least one ridge is different compared to the die clearance of the sloped wall; (d) consolidating the mat under pressure and heat to form a molded composite web panel; and (e) connecting said web panel with at least one flange to form a composite building element. 49. The method of claim 48, wherein the die gap at one ridge is smaller than the die gap at the sloped wall. 50. The method of claim 49, wherein the mold gap at one ridge is equal to the mold gap at the sloped wall. 51. The method of claim 48, wherein the molded composite web panel has a surface area that is 75% greater than the surface area of the mat. 52. The method of claim 51, wherein the molded composite web panel has a surface area that is 15% to 25% greater than the surface area of the mat. 53. The method of claim 48, wherein the molded composite web panel has at least one groove defined by a first ridge, a second ridge, and at least two sloped walls, wherein the step ( e) said flange is attached to a first substantial surface of said first set of ridges, and said method further comprises the steps of: (f) connecting said web plate to a second flange at a second substantial surface of said second set of ridges; and (g) dividing the product of step (f) along a direction perpendicular to the groove; In order to facilitate the production of composite building components. 54. A composite building element produced according to the method of claim 48. 55. A compressed wood composite panel comprising: a first planar portion having a first thickness and lying in a first plane; a second planar portion located in a second plane spaced from the first plane of said first planar portion; a wavy curved portion located between and adjacent to the first and second planar portions and extending upward and downward relative to a first plane of the first planar portion, the wavy portion having A second thickness that is at least 20% different than the first thickness, and the first planar portion, the second planar portion, and the wave-curved portion are integral and constructed of a wood composite. 56. The panel of claim 55, wherein the wave-like curvature includes a sloped portion. 57. The panel of claim 56, wherein the sloped portion extends at an angle between about 35[deg.] and 45[deg.] relative to the plane of the first planar portion. 58. The panel of claim 55, wherein the panel has a specific gravity in the range of 0.75 to 0.90. 59. The panel of claim 55, wherein the density of the first planar portion is at least 95% of the density of the wave-curved portion. 60. A method of forming a molded wood composite panel comprising the steps of: providing a die set having an upper mold and a lower die, the die set having a structure with a first planar portion, a second planar portion and at least one wavy curved portion; Arrange the web pad between the upper and lower moulds; compressing the mat between the die sets to form a corrugated composite panel having a first planar portion having a first thickness, a second planar portion in a plane spaced from the plane of the first planar portion, and a corrugated bend portion, the undulating curved portion is located between and adjacent to the first and second planar portions and extends upward and downward relative to the plane of the first planar portion, wherein the undulating portion has at least 20% A second thickness different from the first thickness. 61. The method of claim 40, wherein the step of compressing uses pressure and heat to form the panel. 62. The method of claim 41, wherein said step of compressing further comprises heating the mat to a temperature of 420 to 450°F. 63. The method of claim 40, wherein the plate formed by said compressing has a uniform density. 64. The method of claim 43, wherein the density of the first planar portion is at least 95% of the density of the undulating curved portion. 65. The method according to claim 40, further comprising the step of setting a predetermined gap between the upper mold and the lower mold so that the predetermined gap determines the plate thickness. 66. The method of claim 40, wherein the plate has a specific gravity in the range of about 0.75 to 0.90. 67. The method of claim 40, further comprising the step of trimming the panel to a desired size. 68. The method of claim 40, further comprising the step of bonding the panel to the frame member with an adhesive. 69. The method of claim 40, wherein said mat has first and second major surfaces, said connecting comprising joining said web to said second major surface at said first outer region first major surface. connected by a flange; the method also includes: (f) connecting said web to a second flange at a second major surface of the second outer region; and (g) dividing the product of step (f) into a plurality of composite building elements, each of said parts comprising a portion of said web, a portion of said first flange, and a portion of said second flange. 70. The method of claim 69, wherein the wood-based material comprises wood strands. 71. The method of claim 70, wherein the wood-based material comprises wood strands having a length of 10.16-15.24 centimeters. 72. The method of claim 69, wherein the die gap at an outer region is smaller than the die gap at an angled region. 73. The method of claim 72, wherein the die gap at the outer region is equal to the die gap at the angled region. 74. The method of claim 69, wherein the ratio of the die gap at the outer region to the die gap at the angled region is 0.8-0.9. 75. The method of claim 69, wherein the molded composite web has a surface area that is 75% greater than the surface area of the mat. 76. The method of claim 75, wherein the molded composite web has a surface area that is 15% to 25% greater than the surface area of the mat. 77. The method of claim 70, wherein the wood strands are altered in the mat matrix to substantially conform to the mold configuration of step (c). 78. The method of claim 69, wherein at least one groove of the molded composite web is defined by a first outer region, a second outer region, and at least two angled regions. 79. The method of claim 69, further comprising the step of attaching: prior to said separating step, the step of attaching at least one of said web and flange to an end block. 80. The method of claim 78, further comprising the step of attaching: prior to said separating step, the step of attaching at least one of said web and flange to an end block. 81. The method of claim 78, wherein the molded composite web includes a plurality of grooves. 82. The method of claim 78, wherein the separating step comprises separating the product of step (f) in a direction perpendicular to the groove. 83. The method of claim 69, wherein the molded composite web is laminated to a depth greater than the mold gap at any region. 84. The method of claim 69, wherein at least one flange comprises a wood-based material. 85. The method of claim 69, further comprising the step of providing the major surfaces of the outer region with an interlocking geometry. 86. The method of claim 85, further comprising the step of providing the flanges with an interlocking geometry at the major surfaces. 87. The method of claim 69, wherein said separating step provides a plurality of composite building elements, wherein the width of each element is equal to or less than the thickness of each element, said thickness being at said The distance measured between the parallel outer surfaces of a flange. 88. The method of claim 69, wherein said forming step includes forming a mat comprising randomly oriented lumber-based wood bundles. 89. The method of claim 69, wherein said forming step comprises depositing a first layer and depositing a second layer and depositing a third layer, the first layer comprising timber-based wood strands in the direction of the longitudinal axis of the separated composite building element, the second layer comprising wood-based wood strands oriented perpendicular to the direction of said first layer, the third layer comprising in The first layer is of parallel oriented wood-based wood strands. 90. The method of claim 89, wherein said forming step includes orienting at least 80% of said wood strands in a direction parallel to the longitudinal axis of the divided composite building elements to be formed. 91. The method of claim 69, wherein said forming step comprises continuously depositing said wood-based material on a forming line, further comprising the step of cutting said continuous The shaped mat is cut to size. 92. The method of claim 69, wherein the molded composite web has a uniform density. 93. The method of claim 92, wherein the density of the web in the outer region is at least 90% of the density of the web in the angled region. 94. The method of claim 75, wherein the cushion has a consistent basis weight. 95. A compressed wood composite panel comprising: a planar portion having a first thickness; a second planar portion at a plane spaced apart from the plane of said first planar portion; a wavy bent portion disposed between and connected to the first and second planar portions and extending upward or downward relative to the plane of the first planar portion, the second thickness of the shaped portion The difference between said first thickness is at least 20%, said first planar portion, said second planar portion and said corrugated curved portion are integral and formed of wood composite material. 96. The panel of claim 95, wherein the wave-like curvature comprises a sloped portion. 97. The panel of claim 96, wherein said sloped portion extends at an angle of 30-45 degrees relative to the plane of said first planar portion. 98. The panel of claim 95, wherein the panel has a specific gravity of 0.75-0.90. 99. The panel of claim 95, wherein the density of said first planar portion is at least 95% of the density of said wave-curved portion. 100. A method of forming a molded wood composite panel comprising the steps of: providing a die set having an upper die and a lower die, the die set shown having a first planar portion, a second planar portion, and at least one wavy curved portion; providing web cushions between the upper and lower molds; and The mat is compressed between the die sets to form a shaped composite panel having a first planar portion having a first thickness, a second planar portion lying in a plane spaced from the plane of the first planar portion, and A wave-like curved portion is disposed between and connected to first and second planar portions and extends upwardly and downwardly relative to said first planar portion, wherein said shaped portion has a second thickness that is substantially the same as that of the first thickness The difference is 20%. 101. The method of claim 100, wherein said step of compressing uses pressure and heat to form said plate. 102. The method of claim 101, wherein said compressing step further comprises heating the mat to 216-232°C. 103. The method of claim 100, wherein the plate formed by compression has a uniform density. 104. The method of claim 103, wherein the density of the first planar portion is at least 95% of the density of the wave-like curved portion. 105. The method of claim 100, further comprising the step of providing a predetermined gap between the upper and lower molds, such that the predetermined gap determines the thickness of the panel. 106. The method of claim 100, wherein the plate has a specific gravity of 0.75-0.90. 107. The method of claim 100, further comprising the step of trimming the panel to predetermined dimensions. 108. The method of claim 100, further comprising the step of bonding the panel to the frame member with an adhesive. 109. The method of claim 108, wherein the adhesive is selected from the group consisting of hot melt polyurethane, moisture cure hot melt polyurethane and moisture cure polyurethane adhesives.

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