Solid-Wood Rigid Block Assemblies

Abstract

In some embodiments, a durable solid-wood door or other rigid block assembly includes two generally-planar, mutually-parallel solid-wood boards each having a plurality of mutually-parallel dovetail-connection channels running generally along an internal surface of each of the boards, and a solid-wood central keying structure disposed between the two solid-wood boards. The central keying structure includes a plurality of two-sided sliding dovetails keys sized to slide within the dovetail-connection channels to secure the two-mutually-parallel solid-wood boards to each other via sliding dovetail connections to the central keying structure. Alternating wood grain orientations may be used to reduce warping. Each board may include multiple laterally-adjacent monolithic slabs interconnected via tongue-and-groove edge connections, with the dovetail connection channels extending across multiple slabs. An adhesive and/or fasteners secure the two boards in a fixed position relative to each other, creating a solid block structure.

Description

BACKGROUND OF THE INVENTION[0001]This invention relates to woodworking, and in particular to solid-wood rigid block structures suitable for forming doors, door jambs, table-tops and other rigid block structures.[0002]Engineered wood products such as plywood are manufactured by binding together wood strands, fibers or veneers with adhesive to form a composite material. Engineered wood products may exhibit inferior reliability and durability, but are relatively easy to manufacture. Engineered wood is increasingly commonly used to make doors, furniture, and other wood products.[0003]Solid-wood products are made from cut solid lumber. Solid-wood products are generally relatively robust and durable, and have a distinctive look which is desirable for certain applications. At the same time, solid-wood products are generally expensive and difficult to manufacture, and may exhibit significant changes in volume in the presence of temperature and humidity variations.SUMMARY OF THE INVENTION[00...

AI Technical Summary

Benefits of technology

[0005]According to another aspect, a solid-wood assembly comprises a first generally-planar solid-wood board; and a second generally-planar solid-wood board generally-parallel to the first solid-wood board. The first solid-wood board and the second solid-wood board are rigidly interlocked via a plurality of sliding dovetail connections established by a plurality of sliding dovetail keys sized to slide within a corresponding plurality of sliding dovetail channels defined in the first and second solid-wood board. The first and second solid-wood boards are secured in a fixed position relative to each other using an adhesive and / or a set of fasteners affixed to the first and second solid-wood boards to form a rigid block structure.

[0006]According to another aspect, a method of making a solid-wood assembly comprises machining, using a computer numerical control (CNC) machine, a plurality of sliding dovetail channels along at least one major surface of two generally-planar solid-wood boards; sliding a plurality of sliding dovetail keys through the plurality of sliding dovetail channels to interlock the two solid-wood boards to each other in a mutually-parallel relationship; and affixing the two interlocked solid-wood boards in a fixed position relative to each other using an adhesive and / or a set of fixed fasteners affixed to the two solid-wood boards to form a rigid block structure.

Problems solved by technology

Engineered wood products may exhibit inferior reliability and durability, but are relatively easy to manufacture.

At the same time, solid-wood products are generally expensive and difficult to manufacture, and may exhibit significant changes in volume in the presence of temperature and humidity variations.

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