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US20130153114A1 - Method of producing spalted wood veneers and method of producing spalted wood products - Google Patents

Method of producing spalted wood veneers and method of producing spalted wood products Download PDF

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Publication number
US20130153114A1
US20130153114A1 US13/768,390 US201313768390A US2013153114A1 US 20130153114 A1 US20130153114 A1 US 20130153114A1 US 201313768390 A US201313768390 A US 201313768390A US 2013153114 A1 US2013153114 A1 US 2013153114A1
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United States
Prior art keywords
wood
wood veneer
spalted
spores
chamber
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/768,390
Inventor
Brian W. Beakler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Armstrong World Industries Inc
AWI Licensing LLC
Original Assignee
Armstrong World Industries Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Armstrong World Industries Inc filed Critical Armstrong World Industries Inc
Priority to US13/768,390 priority Critical patent/US20130153114A1/en
Publication of US20130153114A1 publication Critical patent/US20130153114A1/en
Assigned to ARMSTRONG WORLD INDUSTRIES, INC. reassignment ARMSTRONG WORLD INDUSTRIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BEAKLER, BRIAN W.
Assigned to AWI LICENSING COMPANY reassignment AWI LICENSING COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ARMSTRONG WORLD INDUSTRIES, INC.
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24777—Edge feature
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31975—Of cellulosic next to another carbohydrate
    • Y10T428/31978—Cellulosic next to another cellulosic
    • Y10T428/31982—Wood or paper

Definitions

  • the present invention is related to spalted wood veneers, spalted engineered wood flooring and the method of making the veneers and flooring.
  • spalted wood occurs naturally in forests in felled logs and trees which have been infected with spalt fungus (a combination of white rot and blue stain). The spalting makes the wood brittle and difficult to cut into lumber. Therefore, it has not been possible to cut the spalted wood into veneers.
  • a veneer is a thin sheet of wood, rotary cut, sliced, or sawed from a log, bolt or flitch.
  • a veneer is referred to as a ply when assembled.
  • the formation of spalted veneers would permit the manufacture of spalted engineered wood flooring having a spalted wood veneer decorative layer.
  • Naturally occurring spalted maple is traditionally used by artisans in lathe produced turnings, e.g. bowls and vases. While spalted solid wood floors have been made from lumber pieces cut from spalted logs, it has not been possible to cut the spalted logs into veneers for use in making engineered wood and engineered wood floors. If the decay progresses too far, the wood becomes punky, soft and spongy, stringy, ringshaked, pitted or crumbly.
  • White rot is a decay mechanism that yields thin distinctive lines with broad lighter colored areas in between the lines.
  • White rot is caused by white rot decay fungi. The white rot attacks the cellulose and lignin giving the wood a whitish appearance and multicolored streaks of black, pink and gray.
  • the white rot spores are typically airborne.
  • Blue stain does not contribute to the decay of the wood but does yield a yellow, orange, red, blue, black or brown coloration. It is caused by microscopic fungi that infect only the sapwood. The blue stain fungi are normally spread by spores that are carried into the wood by insects.
  • a method of production of a spalted wood veneer includes comprising forming a wood veneer, sterilizing a chamber, and inoculating the wood veneer with spalting spores.
  • the inoculated wood veneer is positioned in the chamber.
  • a method of production of a spalted wood product includes sterilizing a chamber and inoculating a wood product with spalting spores.
  • the inoculated wood product is positioned in the chamber.
  • a method of production of a spalted wood veneer includes forming a wood veneer and inoculating the wood veneer with spalting spores.
  • the inoculated wood veneer is positioned in the chamber.
  • green (wet) wood is cut into veneers and then inoculated with the white rot (e.g. Phanerochaete chyrsosporium) and/or blue stain (e.g. Ceratocystis tenella) spores by coating the surfaces of the veneer with a solution containing the spores. Both of the major surfaces of the veneers can be efficiently coated with a roll coat system.
  • Other means of inoculating the cut veneers is to spray the major surfaces of the veneers with a solution containing the white rot and/or blue stain spores.
  • the environment of the impregnated veneers can be controlled to promote the rapid growth of the spalting and then stopped when the desired degree of spalting is achieved.
  • the invention is directed to any species of wood which can be cut into veneers and spalted.
  • the wood species that can be used include maple, elm, beech, birch, buckeye, basswood, sycamore, apple, and the hickories. Red oak and white oak will also spalt. While walnut will spalt, it is dark in color and more difficult to observe.
  • White rot grows best at temperatures of from about 70° degree F. to about 90° degree F. and a wood moisture content of about 30% in an oxygen rich atmosphere.
  • the best conditions for blue stain are temperatures between about 60° degree F. and about 150° degree F. and a wood moisture content of about 20% to about 30% in an oxygen rich atmosphere.
  • the wood veneer should have a moisture content of about 20% to about 40% during the spalting process.
  • the inoculated veneers can be stacked into a chamber in which a preferred environment for spalting the veneer of about 50° degree F. to about 100° degree F. with about 50% RH to about 90% RH is maintained. No growth of the white rot is seen below about 50° degree F.
  • a more preferred environment for processing the spalted veneers is a temperature of from about 70° degree F. to about 90° degree F. and about 70% RH to about 90% RH in an oxygen rich atmosphere.
  • the chamber Prior to loading the inoculated veneers into the chamber, the chamber could be sterilized with an ultraviolet light treatment to kill any other spores.
  • the invention is not limited to ultraviolet light sterilization. Other sterilization techniques, such as using alcohol, may be used.
  • the spalting process may take days, weeks or months, depending upon the type and condition of the wood and the environmental conditions. Samples are removed frequently and inspected to determine when the spalting process should be stopped. It is desired to allow the spalting to proceed to a point where the appearance is pleasing, but the structure of the veneer has not been overly weakened.
  • the spalting process can be halted by drying the veneers at a temperature of at least 130° degree F.
  • the spalted veneers can be stabilized and/or stiffened by filling the spalted areas with waxes, oils, glues or impregnation chemicals, such as acrylics.
  • the veneers are then glued to the engineered platform or base, and then tongue and groove edges, including locking tongue and groove edges or other locking or interlocking designs, are typically machined into the engineered wood piece.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical And Physical Treatments For Wood And The Like (AREA)
  • Finished Plywoods (AREA)

Abstract

Methods of production of spalted wood veneer and spalted wood products are disclosed. The method of production of the spalted wood veneer includes comprising forming a wood veneer, and inoculating the wood veneer with spalting spores. The inoculated wood veneer is positioned in the chamber, which may be sterilized. The method of production of the spalted wood product includes sterilizing a chamber and inoculating a wood product with spalting spores. The inoculated wood product is positioned in the chamber.

Description

    CROSS REFERENCE TO RELATED APPLICATIONS
  • This application is a continuation of U.S. patent application Ser. No. 13/611,028, filed Sep. 19, 2012, entitled “Spalted Wood Veneers and Spalted Engineered Wood Flooring”, which is a continuation of U.S. patent application Ser. No. 11/901,361, filed on Sep. 17, 2007, entitled “Spalted Wood Veneers, Spalted Engineered Wood Flooring and Method of Making”, the disclosures of which are hereby incorporated by reference in their entirety.
    • FIELD OF THE INVENTION
  • The present invention is related to spalted wood veneers, spalted engineered wood flooring and the method of making the veneers and flooring.
    • BACKGROUND OF THE INVENTION
  • Spalted wood occurs naturally in forests in felled logs and trees which have been infected with spalt fungus (a combination of white rot and blue stain). The spalting makes the wood brittle and difficult to cut into lumber. Therefore, it has not been possible to cut the spalted wood into veneers.
  • According to the American National Standards Institute, a veneer is a thin sheet of wood, rotary cut, sliced, or sawed from a log, bolt or flitch. A veneer is referred to as a ply when assembled. The formation of spalted veneers would permit the manufacture of spalted engineered wood flooring having a spalted wood veneer decorative layer.
  • Naturally occurring spalted maple is traditionally used by artisans in lathe produced turnings, e.g. bowls and vases. While spalted solid wood floors have been made from lumber pieces cut from spalted logs, it has not been possible to cut the spalted logs into veneers for use in making engineered wood and engineered wood floors. If the decay progresses too far, the wood becomes punky, soft and spongy, stringy, ringshaked, pitted or crumbly.
  • Spalting is a decay process in certain wood species that gives the wood a unique blotchy appearance having dark lines. White rot is a decay mechanism that yields thin distinctive lines with broad lighter colored areas in between the lines. White rot is caused by white rot decay fungi. The white rot attacks the cellulose and lignin giving the wood a whitish appearance and multicolored streaks of black, pink and gray. The white rot spores are typically airborne.
  • Blue stain does not contribute to the decay of the wood but does yield a yellow, orange, red, blue, black or brown coloration. It is caused by microscopic fungi that infect only the sapwood. The blue stain fungi are normally spread by spores that are carried into the wood by insects.
    • SUMMARY OF THE INVENTION
  • In an exemplary embodiment, a method of production of a spalted wood veneer includes comprising forming a wood veneer, sterilizing a chamber, and inoculating the wood veneer with spalting spores. The inoculated wood veneer is positioned in the chamber.
  • In another exemplary embodiment, a method of production of a spalted wood product includes sterilizing a chamber and inoculating a wood product with spalting spores. The inoculated wood product is positioned in the chamber.
  • In another exemplary embodiment, a method of production of a spalted wood veneer includes forming a wood veneer and inoculating the wood veneer with spalting spores. The inoculated wood veneer is positioned in the chamber.
    • DETAILED DESCRIPTION OF THE INVENTION
  • To form the spalted veneer, green (wet) wood is cut into veneers and then inoculated with the white rot (e.g. Phanerochaete chyrsosporium) and/or blue stain (e.g. Ceratocystis tenella) spores by coating the surfaces of the veneer with a solution containing the spores. Both of the major surfaces of the veneers can be efficiently coated with a roll coat system. Other means of inoculating the cut veneers is to spray the major surfaces of the veneers with a solution containing the white rot and/or blue stain spores. The environment of the impregnated veneers can be controlled to promote the rapid growth of the spalting and then stopped when the desired degree of spalting is achieved.
  • The invention is directed to any species of wood which can be cut into veneers and spalted. The wood species that can be used include maple, elm, beech, birch, buckeye, basswood, sycamore, apple, and the hickories. Red oak and white oak will also spalt. While walnut will spalt, it is dark in color and more difficult to observe.
  • White rot grows best at temperatures of from about 70° degree F. to about 90° degree F. and a wood moisture content of about 30% in an oxygen rich atmosphere. The best conditions for blue stain are temperatures between about 60° degree F. and about 150° degree F. and a wood moisture content of about 20% to about 30% in an oxygen rich atmosphere. For efficient growth of the white rot and blue stain spores, the wood veneer should have a moisture content of about 20% to about 40% during the spalting process.
  • Therefore, the inoculated veneers can be stacked into a chamber in which a preferred environment for spalting the veneer of about 50° degree F. to about 100° degree F. with about 50% RH to about 90% RH is maintained. No growth of the white rot is seen below about 50° degree F. A more preferred environment for processing the spalted veneers is a temperature of from about 70° degree F. to about 90° degree F. and about 70% RH to about 90% RH in an oxygen rich atmosphere.
  • Prior to loading the inoculated veneers into the chamber, the chamber could be sterilized with an ultraviolet light treatment to kill any other spores. The invention is not limited to ultraviolet light sterilization. Other sterilization techniques, such as using alcohol, may be used. The spalting process may take days, weeks or months, depending upon the type and condition of the wood and the environmental conditions. Samples are removed frequently and inspected to determine when the spalting process should be stopped. It is desired to allow the spalting to proceed to a point where the appearance is pleasing, but the structure of the veneer has not been overly weakened.
  • The spalting process can be halted by drying the veneers at a temperature of at least 130° degree F. After the spalting process has been stopped, the spalted veneers can be stabilized and/or stiffened by filling the spalted areas with waxes, oils, glues or impregnation chemicals, such as acrylics. The veneers are then glued to the engineered platform or base, and then tongue and groove edges, including locking tongue and groove edges or other locking or interlocking designs, are typically machined into the engineered wood piece.

Claims (20)

What is claimed is:
1. A method of production of a spalted wood veneer, comprising:
forming a wood veneer;
sterilizing a chamber; and
inoculating the wood veneer with spalting spores,
wherein the inoculated wood veneer is positioned in the chamber.
2. The method of claim 1, wherein the spalting spores are selected from the group consisting of white rot spores, blue stain spores and a combination of white rot spores and blue stain spores.
3. The method of claim 1, wherein the spalting spores are in a solution.
4. The method of claim 3, wherein the inoculating is by applying the solution with a roll coater.
5. The method of claim 3, wherein the inoculating is by spraying the solution.
6. The method of claim 1, wherein the inoculated wood veneer is stacked within a plurality of inoculated wood veneers in the chamber.
7. The method of claim 1, wherein the sterilizing by subjecting the chamber to ultraviolet light.
8. The method of claim 1, wherein the inoculated wood veneer is subjected to a predetermined environment having an average temperature of from about 50° F. to about 100° F. and a relative humidity of from about 50% RH to about 90% RH.
9. The method of claim 8, wherein the predetermined environment has an average temperature of from about 70° F. and about 90° F. and a relative humidity of from about 70% RH to about 50% RH.
10. The method of claim 1, wherein the chamber is oxygen rich.
11. The method of claim 1, wherein the wood veneer has a moisture content of about 20% to about 40% during the spalting.
12. The method of claim 1, wherein continued spalting is deterred by raising the temperature of the wood veneer to at least 130° F.
13. The method of claim 1, wherein the spalted wood veneer is coated.
14. The method of claim 1, wherein the spalted wood veneer is coated with a wax, an oil, a glue or an impregnation chemical.
15. The method of claim 14, wherein the impregnation chemical is an acrylic.
16. The method of claim 1, further comprising gluing the inoculated wood veneer to a base to form a spalted engineered wood flooring.
17. The method of claim 1, wherein the wood veneer is a species of wood selected from the group consisting of maple, elm, beech, birch, buckeye, basswood, sycamore, apple, hickory, red oak, white oak, and walnut.
18. The method of claim 1, wherein the wood veneer is formed from a log, bolt, or flitch.
19. A method of production of a spalted wood product, comprising:
sterilizing a chamber;
inoculating a wood product with spalting spores,
wherein the inoculated wood product is positioned in the chamber.
20. A method of production of a spalted wood veneer, comprising:
forming a wood veneer,
inoculating the wood veneer with spalting spores,
wherein the inoculated wood veneer is positioned in the chamber.
US13/768,390 2007-03-16 2013-02-15 Method of producing spalted wood veneers and method of producing spalted wood products Abandoned US20130153114A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US13/768,390 US20130153114A1 (en) 2007-03-16 2013-02-15 Method of producing spalted wood veneers and method of producing spalted wood products

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US91860507P 2007-03-16 2007-03-16
US11/901,361 US8287971B2 (en) 2007-03-16 2007-09-17 Spalted wood veneers, spalted engineered wood flooring and method of making
US13/611,028 US8399075B2 (en) 2007-03-16 2012-09-12 Spalted wood veneers and spalted engineered wood flooring
US13/768,390 US20130153114A1 (en) 2007-03-16 2013-02-15 Method of producing spalted wood veneers and method of producing spalted wood products

Related Parent Applications (1)

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US13/611,028 Continuation US8399075B2 (en) 2007-03-16 2012-09-12 Spalted wood veneers and spalted engineered wood flooring

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US13/611,028 Expired - Fee Related US8399075B2 (en) 2007-03-16 2012-09-12 Spalted wood veneers and spalted engineered wood flooring
US13/768,390 Abandoned US20130153114A1 (en) 2007-03-16 2013-02-15 Method of producing spalted wood veneers and method of producing spalted wood products

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US13/611,028 Expired - Fee Related US8399075B2 (en) 2007-03-16 2012-09-12 Spalted wood veneers and spalted engineered wood flooring

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US12251852B2 (en) 2022-11-11 2025-03-18 Vermont Wildwoods Spalted wood products and devices, systems, compositions, and methods for production

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8287971B2 (en) * 2007-03-16 2012-10-16 Armstrong World Industries, Inc. Spalted wood veneers, spalted engineered wood flooring and method of making
WO2012119228A1 (en) * 2011-03-04 2012-09-13 Fpinnovations Wood coloring with fungi and the treating process
CN103182726B (en) * 2011-12-28 2016-11-09 西南林业大学 A kind of decorative wood material and preparation method thereof
CN103497897B (en) * 2013-04-19 2016-02-03 西南林业大学 One strain Phomopsis fungi and the application in preparation bacterium line wood thereof
US12426601B2 (en) 2019-09-23 2025-09-30 Biofinish International B.V. Functional microbiological coating

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US4346175A (en) * 1977-10-04 1982-08-24 Sven-Olof Enfors Process for the microbiological modification of hardwood by the action of microorganisms
US4698305A (en) * 1983-09-20 1987-10-06 Hansson Goeran Method of treating wood
US5097623A (en) * 1988-03-07 1992-03-24 Saishin Co., Ltd. Apparatus for cultivating mushrooms
JPH04190716A (en) * 1990-11-26 1992-07-09 Koujiyouen:Kk Intermediate cap of culture vessel for fomes japonicus
US5976689A (en) * 1995-03-20 1999-11-02 Permagrain Products, Inc. Coated synthetic resin board tiles
KR20060110435A (en) * 2005-04-20 2006-10-25 김정석 Artificial Cultivation Method of Blossom Mushroom Using Sawdust and Solid Wood
US8287971B2 (en) * 2007-03-16 2012-10-16 Armstrong World Industries, Inc. Spalted wood veneers, spalted engineered wood flooring and method of making

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US3542641A (en) * 1967-12-01 1970-11-24 Armstrong Cork Co Method of making water laid,stained wood sheet
US9969633B2 (en) * 1999-12-16 2018-05-15 Robert Whiteman Systems and methods for treating oil, fat and grease in collection systems

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4346175A (en) * 1977-10-04 1982-08-24 Sven-Olof Enfors Process for the microbiological modification of hardwood by the action of microorganisms
US4698305A (en) * 1983-09-20 1987-10-06 Hansson Goeran Method of treating wood
US5097623A (en) * 1988-03-07 1992-03-24 Saishin Co., Ltd. Apparatus for cultivating mushrooms
JPH04190716A (en) * 1990-11-26 1992-07-09 Koujiyouen:Kk Intermediate cap of culture vessel for fomes japonicus
US5976689A (en) * 1995-03-20 1999-11-02 Permagrain Products, Inc. Coated synthetic resin board tiles
KR20060110435A (en) * 2005-04-20 2006-10-25 김정석 Artificial Cultivation Method of Blossom Mushroom Using Sawdust and Solid Wood
US8287971B2 (en) * 2007-03-16 2012-10-16 Armstrong World Industries, Inc. Spalted wood veneers, spalted engineered wood flooring and method of making

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US12251852B2 (en) 2022-11-11 2025-03-18 Vermont Wildwoods Spalted wood products and devices, systems, compositions, and methods for production

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US20080226847A1 (en) 2008-09-18
US8287971B2 (en) 2012-10-16
US20130004734A1 (en) 2013-01-03
US8399075B2 (en) 2013-03-19

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Owner name: ARMSTRONG WORLD INDUSTRIES, INC., PENNSYLVANIA

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Effective date: 20140116

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