Joining Wood or Other Plant Products Using Ultrasonic Energy

Abstract

A filler material is applied to a plurality of wood elements which are joined to form a composite wood product, said joining comprising applying ultrasonic energy to the plurality of wood elements, said ultrasonic energy having a frequency within a frequency range of 10 kHz to 20 MHz.

Description

[Technical field]

[0001] This specification outlines devices, systems and methods for joining wood or other plant products using ultrasonic energy. [Background technology]

[0002] Engineered wood products are made by taking lumber, veneers, wood chips, or other small wood elements and bonding them with resins into a structural product. This allows smaller or lower quality lumber or wood elements to be used to produce a replacement for larger lumber. Engineered wood products are used in structural applications such as girders, beams, joists, headers, studs, columns, etc., and are used in place of or in conjunction with wood products.

[0003] Ultrasonic energy has been used for diagnostic imaging in medical applications. In ultrasound imaging, high frequency sound pulses are sent from a probe into the body. The sound pulses propagate through the body as waves, passing through some fluids and tissues while being partially absorbed by other body tissues. This absorption causes partial reflections, or echoes, of the sound waves to return towards the probe. Sensors in the probe measure the echoes of the sound waves, and that information can be used to create a diagnostic image of the examined area of ​​the body.

[0004] Ultrasonic energy is also used for diagnostic imaging and non-destructive testing in industrial applications such as inspecting metal welds, detecting defects in concrete and assessing concrete consistency, and detecting defects in wood. In one application, a probe transmits high frequency sound pulses into the material being imaged or inspected, and a sensor in the probe measures the echoes of the sound waves that return to the probe. In another application, a high frequency sound pulse is transmitted from the probe into the material, and then a separate receiving unit on the opposite side of the material from the probe receives the sound waves that have passed through the material being imaged or inspected. Summary of the Invention

[0005] In a general aspect, a method of making a composite wood product includes applying a filler material to a plurality of wood elements and joining the plurality of wood elements into a composite wood product, the joining including applying ultrasonic energy to the plurality of wood elements, the ultrasonic energy having a frequency within a frequency range of 10 kHz to 20 MHz.

[0006] Embodiments may include one or more of the following: the ultrasonic transducer may supply ultrasonic energy; the filler material may or may not include an adhesive; the filler material may include a plastic; the filler material may include a metal; the plurality of wood elements may be positioned adjacent to one another prior to joining the plurality of wood elements; the applying of the filler material to the plurality of wood elements and the supplying of ultrasonic energy to the plurality of wood elements may occur simultaneously; the ultrasonic energy may be supplied to the plurality of wood elements prior to applying the filler material to the plurality of wood elements; or the ultrasonic energy may be supplied to the plurality of wood elements after applying the filler material to the plurality of wood elements; the method may further include applying a compressive force to the plurality of wood elements; the compressive force may be applied to the plurality of wood elements prior to supplying ultrasonic energy to the plurality of wood elements; or the compressive force may be applied to the plurality of wood elements simultaneously with supplying ultrasonic energy to the plurality of wood elements; or the compressive force may be applied to the plurality of wood elements after supplying ultrasonic energy to the plurality of wood elements. The ultrasonic energy may have a frequency within a frequency range of 15 kHz to 1 MHz. The ultrasonic energy may have a frequency in the frequency range of 20 kHz to 100 kHz. The method may further include inspecting the composite wood product for defects, the inspection including applying ultrasonic energy to the composite wood product. The method may further include pre-treating the plurality of wood elements prior to applying the filler, the pre-treating including applying ultrasonic energy to the plurality of wood elements. The pre-treating may also include applying ultrasonic energy to the plurality of wood elements to clean the plurality of wood elements. The method may further include treating the composite wood product after joining into the composite wood product, and applying ultrasonic energy to the composite wood product.

[0007] Details of one or more embodiments are provided in the associated drawings and description below. In certain embodiments, one or more advantages can be obtained. For example, in the disclosed method embodiments, the apparatus and system can be used to produce composite wood products that are stronger (e.g., have higher tensile strength, higher compressive strength, higher shear strength, or more) than composite wood products produced using conventional techniques. In another example, the disclosed method, apparatus and system embodiments can be used to produce composite wood products with improved durability compared to composite wood products produced using conventional techniques. In yet another example, the disclosed method, apparatus and system embodiments can be used to produce composite wood products with improved moisture resistance compared to composite wood products produced using conventional techniques. In yet another example, the disclosed method, apparatus and system embodiments can be used to produce composite wood products with improved heat resistance compared to composite wood products produced using conventional techniques. In yet another example, the disclosed method, apparatus and system embodiments can be used to produce composite wood products with increased hardness compared to composite wood products produced using conventional techniques. In yet another example, embodiments of the disclosed methods, apparatus, and systems can be used to improve the cure rate or reduce (e.g., accelerate or speed up) the cure time in the production of composite wood products as compared to the cure rate or cure time of composite wood products produced using conventional techniques. In yet another example, embodiments of the disclosed methods, apparatus, and systems can be used to produce composite wood products that have improved resistance to insects or pests as compared to composite wood products produced using conventional techniques.

[0008] Other features, objects, and advantages of the techniques described herein will be apparent from the description, drawings, and claims.Like reference characters in the various drawings indicate like elements. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a block diagram illustrating an environment for producing composite wood products using ultrasonic energy. [Diagram 2] FIG. 1 is a conceptual diagram of exemplary wood elements on or within an exemplary funnel to be placed on an exemplary conveyor as part of an exemplary manufacturing process for producing composite wood products using ultrasonic energy. [Figure 3A] FIG. 1 shows an example of the application of filler to multiple wood elements. [Figure 3B] FIG. 13 shows another example of the application of filler to multiple wood elements. [Figure 3C] FIG. 13 shows yet another example of the application of filler to a number of wood elements. [Figure 4] FIG. 1 is a conceptual diagram illustrating an exemplary ultrasonic transducer supplying ultrasonic energy to a plurality of exemplary wood elements for producing a composite wood product using ultrasonic energy. [Diagram 5] 5 is a conceptual diagram of the example ultrasonic transducer of FIG. 4. [Figure 6A] FIG. 1 is a conceptual diagram of an example ultrasonic transducer including an example cymbal-shaped horn that can be used to manufacture composite wood products using ultrasonic energy. [Figure 6B] 1 is a conceptual diagram of an exemplary ultrasonic transducer including an exemplary Langevin horn that can be used to manufacture composite wood products using ultrasonic energy. [Figure 6C] FIG. 1 is a conceptual diagram of an example ultrasonic transducer including an example ring-shaped horn that can be used to manufacture composite wood products using ultrasonic energy. [Figure 6D] FIG. 1 is a conceptual diagram of an example ultrasonic transducer including an example pyramidal shaped horn that can be used to manufacture composite wood products using ultrasonic energy. [Figure 6E] FIG. 1 is a conceptual diagram of an example ultrasonic transducer including an example spherical horn that can be used to manufacture composite wood products using ultrasonic energy. [Figure 6F] FIG. 1 is a conceptual diagram of an example ultrasonic transducer including an example dome-shaped horn that can be used to manufacture composite wood products using ultrasonic energy. [Figure 6G] FIG. 1 is a conceptual diagram of an example ultrasonic transducer including an example wedge-shaped horn that can be used to manufacture composite wood products using ultrasonic energy. [Figure 6H] FIG. 1 is a conceptual diagram of an example ultrasonic transducer having an example horn having a general shape, such as a tube or cylinder, and including an example chamber, that can be used to manufacture composite wood products using ultrasonic energy. [Figure 7] 1 is a flow chart of an exemplary method that can be used to manufacture a composite wood product. [Figure 8] FIG. 1 is a block diagram of an exemplary environment for producing composite wood products using ultrasonic energy. [Figure 9] FIG. 1 is a conceptual diagram of an exemplary environment for producing composite wood products using ultrasonic energy. [Figure 10A] FIG. 1 is a conceptual diagram of an exemplary press that can be used to manufacture composite wood products using ultrasonic energy and an exemplary ultrasonic transducer integrated with the press. [Figure 10B] FIG. 2 is a conceptual diagram of another exemplary press and an exemplary ultrasonic transducer integrated therewith that may be used to manufacture composite wood products using ultrasonic energy. [Figure 10C] FIG. 2 is a conceptual diagram of yet another exemplary press and an exemplary ultrasonic transducer integrated therewith that may be used to manufacture composite wood products using ultrasonic energy. [Figure 11A] FIG. 1 is a block diagram of an exemplary environment for producing composite wood products using ultrasonic energy. [Figure 11B] FIG. 1 is a block diagram of an exemplary environment for producing composite wood products using ultrasonic energy. [Figure 11C]FIG. 1 is a block diagram of an exemplary environment for producing composite wood products using ultrasonic energy. [Figure 12A] FIG. 1 is a conceptual diagram of an exemplary environment for producing a composite wood product using ultrasonic energy, the environment including an exemplary ultrasonic transducer including an exemplary roller element. [Figure 12B] FIG. 13 is a conceptual diagram of another exemplary ultrasonic transducer including another exemplary roller element. [Figure 12C] FIG. 1 is a conceptual diagram of an exemplary environment for producing composite wood products using ultrasonic energy. [Figure 13A] FIG. 2 is a side view of an exemplary roller element. [Figure 13B] FIG. 13 is a side view of another exemplary roller element. [Figure 13C] FIG. 13 is a side view of yet another exemplary roller element. [Figure 14A] FIG. 2 is a front view of an exemplary portion of an exemplary roller element including a plurality of exemplary protrusions. [Figure 14B] FIG. 2 is a top view of an exemplary portion of an exemplary roller element including a plurality of exemplary protrusions. [Figure 14C] FIG. 2 is a front view illustrating an exemplary portion of an exemplary roller element including a plurality of exemplary recesses. [Figure 14D] FIG. 2 is a top view illustrating an exemplary portion of an exemplary roller element including a plurality of exemplary recesses. [Figure 14E] FIG. 2 is a front view of an exemplary portion of an exemplary roller element including one or more exemplary protrusions and one or more exemplary recesses. [Figure 15A] FIG. 2 is a conceptual diagram of an example control module and an example ultrasonic transducer supplying ultrasonic energy to a plurality of example wood elements to produce a composite wood product using ultrasonic energy. [Figure 15B] FIG. 15B is a block diagram of the example control module of FIG. 15A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Like reference symbols in different drawings represent like elements. Described herein are devices, systems, and methods that can be used to bond wood or other plant products using ultrasonic energy. In some implementations of the devices, systems, and methods described herein, a composite wood product can be produced by applying a filler to multiple wood elements and joining the multiple wood elements into a composite wood product. The joining is accomplished by applying low frequency ultrasonic energy to the multiple wood elements. For example, the low frequency ultrasonic energy can have a frequency in the range of 10 kHz to 20 MHz. In some embodiments, the low frequency ultrasonic energy can have a frequency in the range of 15 kHz to 1 MHz. In some embodiments, the low frequency ultrasonic energy can have a frequency in the range of 20 kHz to 100 kHz.

[0011] The ultrasonic transducer can be used to provide ultrasonic energy in joining the wood elements into a composite wood product. In various embodiments, the ultrasonic transducer can generate ultrasonic waves and transmit ultrasonic energy to the wood elements and the filler. In some examples, the ultrasonic waves can be provided as a continuous wave, and in some examples, the ultrasonic waves can be provided as a pulsed wave. In some examples, the transducer can provide periodic ultrasonic waves, and the ultrasonic waves can include one or more of a variety of waveforms. For example, in various embodiments, the waveforms can include one or more of a sinusoidal waveform, a rectangular waveform, a square waveform, a trapezoidal waveform, a triangular waveform, a sawtooth waveform, or other suitable waveforms. The transducer can generate ultrasonic waves, including one or more of an ultrasonic longitudinal wave, an ultrasonic radial wave, and an ultrasonic transverse wave, and for example, the ultrasonic waves can provide ultrasonic energy to the wood elements, the filler, or both the wood elements and the filler.

[0012] The ultrasonic energy can provide mechanical stimulation to the wood elements. For example, when ultrasonic waves pass through or are absorbed by the wood elements, the ultrasonic waves can vibrate molecules within the wood elements. Molecular level vibrations within the wood elements can create friction between the vibrating molecules and generate heat within the wood elements. Furthermore, in some examples, when ultrasonic waves pass through or are absorbed by the wood elements, the ultrasonic waves will create small or microscopic pressure differences within the wood elements. Such pressure differences can create cavitation within the wood elements, where gas or steam within high pressure areas within the wood elements can be forced toward low pressure areas within the wood elements and, when forced, microscopic gas or steam bubbles can be generated within the wood elements. In one or more of these embodiments, the ultrasonic energy will provide mechanical stimulation, for example, in the bonding of wood or other plant products. This mechanical stimulation can be provided, for example, without the ultrasonic transducer being in physical contact with the wood elements or filler. In some examples, the ultrasonic transducer or a portion of the transducer may be in physical contact with one or more wood elements, the filler, or both the filler and one or more wood elements, and the aforementioned mechanical stimulus will be provided.

[0013] The ultrasonic energy can further provide mechanical stimulation to multiple wood elements, which can be located close to each other at a macro level. The mechanical stimulation provided by the ultrasonic waves can, for example, move or vibrate one or more wood elements, and cause friction between the wood elements due to such movement or vibration. For example, the mechanical stimulation provided by the ultrasonic waves can cause one or more wood elements to move or vibrate, and one or more surfaces of a first wood element can contact one or more surfaces of one or more other wood elements (e.g., a second wood element, a second wood element and a third wood element, or one or more other wood elements) and face resistance when moving, rubbing or vibrating. In one or more of these embodiments, the ultrasonic energy can provide mechanical stimulation, for example, in the joining of wood or other plant products. This mechanical stimulation can be provided even if, for example, the ultrasonic transducer is not in physical contact with the wood elements or the filler. In some examples, the ultrasonic transducer or a part of the transducer can be in physical contact with one or more wood elements, the filler, or both the filler and one or more wood elements, and can provide the aforementioned mechanical stimulation.

[0014] Similarly, in various embodiments, ultrasonic waves can provide mechanical stimulation to the filler. For example, when ultrasonic waves pass through or are absorbed by the filler, they can vibrate molecules within the filler. Molecular level vibrations within the filler can create friction between the vibrating molecules and generate heat within the filler. Furthermore, in some instances, when ultrasonic waves pass through or are absorbed by the filler, they will create small or microscopic pressure differences within the filler. Such pressure differences can create cavitation within the filler, which will create microscopic gas or steam bubbles within the filler as the pressure difference pushes or forces gas or steam from areas of high pressure within the filler to areas of low pressure within the filler. In one or more of these forms, ultrasonic energy can provide mechanical stimulation, for example, in the bonding of wood or other plant products. This mechanical stimulation will be provided, for example, even if the ultrasonic transducer is not in physical contact with the wood elements or the filler. In some examples, the ultrasonic transducer, or a portion of the transducer, may be in physical contact with one or more wood elements, the filler, or both the filler and one or more wood elements, and the aforementioned mechanical stimulus will be provided.

[0015] Ultrasonic energy can also provide mechanical stimulation to the filler at a macro level. For example, in just a few examples, the mechanical stimulation provided by ultrasound will agitate the filler, causing it to move, vibrate, spread, spread, flow, or penetrate. In one or more of these embodiments, ultrasonic energy can provide mechanical stimulation, for example, in the bonding of wood or other plant products. This mechanical stimulation will be provided even if, for example, the ultrasonic transducer is not in physical contact with the wood elements or the filler. In some examples, the ultrasonic transducer or a part of the transducer may be in physical contact with one or more wood elements, the filler, or both the filler and one or more wood elements, and the aforementioned mechanical stimulation will be provided.

[0016] In some embodiments, the ultrasonic energy can stimulate the diffusion of the filler, for example, to penetrate into and penetrate deeper into the wood elements. In some embodiments, the ultrasonic energy can stimulate the diffusion of the filler, for example, to spread the filler over a larger area of ​​the wood elements, to cover the wood elements, or to contact the wood elements. In one or more of these forms, the ultrasonic energy can provide a diffusion stimulus in the joint of wood or other plant products. This diffusion stimulus may be provided, for example, even if the ultrasonic transducer is not in physical contact with the wood elements or the filler. In some examples, the ultrasonic transducer or a part of the transducer may be in physical contact with one or more wood elements, the filler, or both the filler and one or more wood elements, and the aforementioned diffusion stimulus may be provided.

[0017] According to some embodiments, the ultrasonic energy can also provide a thermal stimulus to the wood elements, the filler, or the wood elements and the filler. This thermal stimulus may be, for example, in addition to the heat generated by the mechanical stimulus or the above-mentioned stimuli. In some embodiments, the temperature of the wood elements will increase as the wood elements absorb the ultrasonic energy or a portion of the ultrasonic energy that the transducer supplies to the wood elements. Similarly, the temperature of the filler will increase as the filler absorbs the ultrasonic energy or a portion of the ultrasonic energy that the transducer supplies to the filler. In some examples, the increase in temperature of the filler, the wood elements, or both the filler and the wood elements can stimulate better diffusion of the filler and deeper penetration of the filler into the wood elements by stimulating the flow of the filler (e.g., in implementations where the filler is liquid or flowable). In one or more of these forms, the ultrasonic energy can provide a thermal stimulus to the joint of wood or other plant products. This thermal stimulus can be provided, for example, even without the ultrasonic transducer being in physical contact with the wood elements or the filler. In some examples, an ultrasonic transducer, or a portion of the transducer, may be in physical contact with one or more wood elements, the filler, or both the filler and one or more wood elements and can provide the thermal stimulus described above.

[0018] In some examples, friction generated between wood elements or between the filler and wood elements by application of ultrasonic energy will force or advance the filler into cracks, pores, gaps, spaces, voids, or interstices in one or more wood elements. In some embodiments, friction may stimulate atomization of the filler (e.g., the filler is separated into smaller or finer particles), and in some examples will stimulate the filler to be forced or advanced into cracks, pores, gaps, spaces, voids, or interstices in one or more wood elements. In some examples, friction can generate additional heat, which can also stimulate deeper penetration of the filler into the wood elements, for example, by heating the filler (e.g., in implementations where the filler is liquid or capable of flowing) and promoting better flow of the filler. In one or more of these forms, ultrasonic energy can generate friction between wood elements or between the filler and wood elements to stimulate the joining of wood or other plant products. This stimulus may be provided, for example, even if the ultrasonic transducer is not in physical contact with the wood elements or the infill material, in some examples, the ultrasonic transducer or a portion of the transducer may be in physical contact with one or more wood elements, the infill material, or both the infill material and one or more wood elements, and the aforementioned stimulus may be provided.

[0019] In various embodiments, the filler can take many different forms. In some embodiments, the filler can include an adhesive, and in other embodiments, the filler may not include an adhesive. In some embodiments, the filler can include a plastic, and in other embodiments, the filler may not include a plastic. In some embodiments, the filler can include a metal, and in other embodiments, the filler may not include a metal. Combinations of the foregoing forms are also possible (e.g., the filler includes an adhesive and a plastic, the filler material includes an adhesive and a metal, or the filler material includes an adhesive, a plastic, and a metal).

[0020] In some embodiments, the filler is a liquid. In some embodiments, the filler is a solid. For example, in some embodiments, the filler may include a powder. In some embodiments, the filler is a gas. According to some embodiments, a combination of the above examples of one or more filler states may also be used. For example, in some embodiments, the filler may be a combination or mixture of liquid and solid. In some embodiments, the filler may be a combination or mixture of liquid and gas. In some embodiments, the filler may be a combination or mixture of solid and gas. In some embodiments, the filler may be a combination or mixture of liquid, solid, and gas. In some embodiments, the filler may be a combination or mixture of liquid, solid, and gas.

[0021] In some embodiments, the filler material can be applied to the plurality of wood elements before ultrasonic energy is applied to the plurality of wood elements. In some embodiments, the filler material can be applied to the plurality of wood elements simultaneously with ultrasonic energy being applied to the plurality of wood elements. In some embodiments, the filler material can be applied to the plurality of wood elements after ultrasonic energy is applied to the plurality of wood elements.

[0022] In some embodiments, ultrasonic energy can be applied to the plurality of wood elements both before and simultaneously with the application of the filler to the plurality of wood elements. In some embodiments, ultrasonic energy can be applied to the plurality of wood elements both simultaneously with and after the application of the filler to the plurality of wood elements. In some embodiments, ultrasonic energy can be applied to the plurality of wood elements both before and after the application of the filler to the plurality of wood elements. In some embodiments, ultrasonic energy can be applied to the plurality of wood elements both before, simultaneously with and after the application of the filler to the plurality of wood elements.

[0023] In some embodiments, in addition to supplying ultrasonic energy to the plurality of wood elements, a compressive force may be applied to the plurality of wood elements. There are many possible options regarding the compressive force and also regarding when the compressive force is applied relative to the supply of ultrasonic energy. In some examples, a press can be used to apply a physical compressive force to the plurality of wood elements. In some embodiments, the compressive force can be applied to the plurality of wood elements simultaneously with the supply of ultrasonic energy to the plurality of wood elements. In some embodiments, the compressive force can be applied to the plurality of wood elements before supplying ultrasonic energy to the plurality of wood elements. In some embodiments, the compressive force can be applied to the plurality of wood elements after supplying ultrasonic energy to the plurality of wood elements. In some embodiments, the compressive force can be a beneficial aid, for example, to develop stronger bonds between the wood elements.

[0024] According to some embodiments, a combination of the above examples of supplying ultrasonic energy in connection with applying a compressive force to a plurality of wood products can also be used. For example, in some embodiments, ultrasonic energy can be supplied to the plurality of wood elements both before applying a compressive force to the plurality of wood elements and simultaneously with applying a compressive force to the plurality of wood elements. In some embodiments, ultrasonic energy can be supplied to the plurality of wood elements both simultaneously with applying a compressive force to the plurality of wood elements and after applying a compressive force to the plurality of wood elements. In some embodiments, ultrasonic energy can be supplied to the plurality of wood elements both before applying a compressive force to the plurality of wood elements and after applying a compressive force to the plurality of wood elements. In some embodiments, ultrasonic energy can be supplied to the plurality of wood elements each before applying a compressive force to the plurality of wood elements, simultaneously with applying a compressive force to the plurality of wood elements, and after applying a compressive force to the plurality of wood elements.

[0025] Some embodiments of the apparatus, systems, and methods described herein can be used to produce composite wood products that are stronger (e.g., have one or more of higher tensile strength, higher compressive strength, and higher shear strength) than composite wood products produced using conventional techniques that do not use ultrasonic energy. Some implementations of the apparatus, systems, and methods described herein can be used to produce composite wood products with improved durability compared to composite wood products produced using conventional techniques that do not use ultrasonic energy. Some implementations of the apparatus, systems, and methods described herein can be used to produce composite wood products with improved moisture resistance compared to composite wood products produced using conventional techniques that do not use ultrasonic energy. The improved moisture resistance can help, for example, reduce or minimize deterioration or decay of the composite wood product. Some implementations of the apparatus, systems, and methods described herein can be used to produce composite wood products with improved heat resistance compared to composite wood products produced using conventional techniques that do not use ultrasonic energy. Some implementations of the apparatus, systems, and methods described herein can be used to produce composite wood products with increased hardness compared to composite wood products produced using conventional techniques that do not use ultrasonic energy. Some implementations of the devices, systems, and methods described herein can be used to improve (e.g., accelerate or speed up) the cure rate in the production of composite wood products or reduce the cure time of composite wood products compared to the cure rate and cure time of composite wood products produced using conventional techniques that do not use ultrasonic energy. Some implementations of the devices, systems, and methods described herein can be used to produce composite wood products that have improved resistance to insects or pests compared to composite wood products produced using conventional techniques that do not use ultrasonic energy.Because wood-based products can be produced using renewable energy sources, such as fast-growing trees, including, but not limited to, hybrid poplar, yellow poplar, aspen, Douglas fir, western hemlock, southern pine, or other suitable hardwood or softwood species, wood-based products can be environmentally friendly and a desirable alternative to steel.

[0026] 1 is a block diagram illustrating an environment 100 for manufacturing composite wood products using ultrasonic energy. In various embodiments, examples of composite wood products can include, but are not limited to, girders, beams, joists, L-joists, rafters, headers, studs, trusses, columns, rim boards, plywood, particle boards, fiber boards, oriented strand boards, flake boards, wafer boards, chip boards, laminates, laminated veneers, cross laminates, parallel strands, laminated strands, and finger joints.

[0027] The environment 100 includes a wood element preparation area 102, a filler application area 104, and an ultrasonic energy delivery area 106. The wood element preparation area 102 can be used to prepare a plurality of wood elements for applying a filler thereto and delivering ultrasonic energy thereto to join the plurality of wood elements to form a composite wood product. In some examples, the wood element preparation area 102 can be used to manufacture wood elements, for example, cutting and processing wood or other wood or plant-based components to manufacture desired wood elements. In some examples, the wood elements can include primary products of such processing, and in some examples, the wood elements can include secondary products or waste products of such processing. Such primary or secondary wood elements can include, for example, but are not limited to, wood sheets, wood veneers, wood strips, wood strands, wood chips, wood flakes, wood scraps, sawdust, other suitable wood or wood particles, elements, components, or products, or other suitable plant-based particles, elements, components, or products.

[0028] In some embodiments, each of the wood element preparation area 102, the filler application area 104, and the ultrasonic energy delivery area 106 can be located in one facility. In some embodiments, one or more of the wood element preparation area 102, the filler application area 104, and the ultrasonic energy delivery area 106 may be located in a different facility than one or more of the other areas 102, 104, 106. By way of example only, in some implementations, the wood element preparation area 102 can be located in a first facility, and the filler application area 104 and the ultrasonic energy delivery area 106 can be located in a second facility.

[0029] In the wood element preparation area 102, various processes can be carried out, in some cases depending on the type of wood element desired. In some examples, the wood can be debarked in the wood element preparation area 102. For example, a debarking machine can strip the bark from the wood at this stage. In some examples, the wood can be cut to length in the wood preparation area 102 before debarking. In some examples, after debarking, the debarked wood can be cut to length in the wood preparation area 102. In some examples, the debarked wood can be immersed in a liquid bath (e.g., a water bath) or steamed with steam (e.g., water vapor) to soften the wood fibers in the wood element preparation area 102. In some examples, the debarked wood is not immersed in a liquid bath or subjected to a steam treatment.

[0030] In some examples, the debarked wood can be cut into sheets, veneers, strips, strands, chips, flakes, or other types of wood elements using one or more cutting devices, such as, for example, a wood lathe, or in some examples, various types of saws. In some examples, the one or more cutting devices can cut to a specific length, cut to a specific desired angle, cut one or more grooves, or perform other specialized cuts, depending on the particular embodiment. In some examples, such cutting can produce wood shavings or sawdust that can be used in some embodiments. In some examples, one or more dryers can be used for one or more drying steps to reduce the moisture content of the wood sheets, veneers, strips, strands, chips, flakes, wood shavings, sawdust, or other types of wood elements, and in various embodiments, one or more drying steps can be performed before or after the cutting step in the wood element preparation area 102.

[0031] 1 , in some examples, the wood elements may be placed adjacent to one another in the wood element preparation area 102 prior to providing the wood elements to the filler application area 104. There are many different ways this can be done, some of which include placing the wood elements adjacent to one another using one or more automated processes (e.g., using one or more placement devices), using one or more manual processes (e.g., by the manual effort of one or more workers), or using a combination of one or more automated processes and one or more manual processes.

[0032] 2 is a conceptual diagram 120 of example wood elements 122 on or within an example funnel 124 being loaded onto an example conveyor 126 as part of an example manufacturing process for producing composite wood products using ultrasonic energy. The funnel 124 and conveyor 126 (or a portion of the conveyor 126) may be included in some implementations of the wood element preparation area 102, for example. In this example embodiment, the example wood elements 122 include wood sheets 128, wood veneers 130, wood strips 132, wood strands 134, wood chips 136, wood flakes 138, wood scraps 140, and sawdust 142. In some examples, other suitable plant-based particles or plant-based elements, components, or products may be included as well, but are not shown in FIG. 2 for simplicity. For illustrative purposes, multiple types of wood elements 128, 130, 132, 134, 136, 138, 140, 142 are shown together on the funnel 124 in FIG. 2, however, in some instances, only a single type of wood element (e.g., only wood sheets 128, or only wood strips 132, or only any of the other illustrated wood elements 130, 134, 136, 138, 140, 142) may be processed at a given time, in which case the funnel 124 may generally include only the particular kind of wood element being processed at the time. In some instances, a subset of the illustrated wood element types, such as any two wood element types, or any three (or more) wood element types, may be processed at a given time, in which case the funnel 124 may generally include wood elements of those particular types.

[0033] The conveyor 126 can take a variety of forms. In some examples, the conveyor 126 can include one or more belts. In some examples, the conveyor 126 can include one or more rollers (e.g., a series of rollers). In some examples, the conveyor 126 can include one or more chains. Combinations of these conveyor examples are also possible. According to some embodiments, the conveyor 126 can generally transport wood elements loaded onto the conveyor 126 from the funnel 124 in a direction 144 toward the filler application area 104. Although FIG. 2 shows the funnel 124 loading the wood elements onto the conveyor 126, in other examples, the funnel 124 is not used and the wood elements may be loaded onto the conveyor 126 by one or more machines. In still other examples, the wood elements may be loaded onto the conveyor manually, for example, by a worker.

[0034] In some examples, the conveyor 126 may include a positioning or stacking mechanism for positioning and / or stacking the wood elements in a particular configuration. In some examples, one or more machines or devices (not shown in FIG. 2 for simplicity) separate from the conveyor 126 may position and / or stack the wood elements in a particular configuration. In some examples, one or more workers may manually position and / or stack the wood elements in a particular configuration. In some examples, a conveyor may not be used to transport the wood elements to the filler application area 104 or the ultrasonic energy delivery area 106, for example, may not be used to transport the wood elements within the area 104 or area 106.

[0035] In the following examples, for simplicity, it is assumed that a single type of wood element is used in the filler application area 104 and the ultrasonic energy delivery area 106. In other examples, more than one type (e.g., 2, 3, 4, 5 or more types) of wood elements can be used in the filler application area 104 and the ultrasonic energy delivery area 106 to produce a composite wood product.

[0036] 3A is a diagram 150 illustrating an example of the application of a filler to a plurality of wood elements. A plurality of wood elements 152 are disposed on a conveyor 154 and move in a direction 156 based on the movement of the conveyor 154. In this example, the illustrated wood elements 152 are wood chips, but in other examples, the wood elements may instead be wood sheets, wood veneers, wood strips, wood strands, wood flakes, wood scraps, sawdust, other suitable wood or wood particles, elements, components or products, or other suitable plant-based particles, elements, components, products, or combinations thereof. In some examples, the conveyor 154 may correspond to the conveyor 126 of FIG. 2, and in other examples, the conveyor 154 may be a different conveyor than the conveyor 126 of FIG. 2.

[0037] In this example, an exemplary applicator 158 is positioned above the conveyor 154 and can apply the filler material 160 onto the wood elements 152 as they pass under the applicator 158. As shown in FIG. 3A, the applicator 158 is a spray nozzle and can spray the filler material 160 onto the wood elements 152. In this example, the applicator 158 may not be in physical contact with the wood elements 152. In some examples, the filler material 160 includes an adhesive. In some embodiments, the filler material 160 does not include an adhesive. In some embodiments, the filler material 160 includes a plastic, and in some embodiments, the filler material 160 does not include a plastic. In some embodiments, the filler material 160 includes a metal, and in other embodiments, the filler material 160 does not include a metal. As discussed above herein, a combination of such materials is also possible for the filler material 160.

[0038] As shown in FIG. 3A, the wood elements 162 that have not passed under the applicator 158 do not generally have the filler material 160 applied thereto, whereas the wood elements 164 that have passed under the applicator 158 generally have the filler material 160 applied thereto. Referring again to FIG. 1, the application of the filler material shown in FIG. 3 may be performed, for example, in the filler material application area 104. In FIG. 150, four spray nozzle applicators are shown, but in other examples, one, two, three, or more than four applicators 158 may instead be used to apply the filler material 160 to the multiple wood elements 152. The applicators 158 may be supplied with the filler material 160, for example, by a filler material supply line 166. In examples in which the filler material 160 includes an adhesive, the applicators 158 may be considered, for example, individually or collectively, as adhesive applicators.

[0039] 3B is a diagram 180 illustrating another example of the application of a filler material to a plurality of wood elements. A plurality of wood elements 182 are disposed on a conveyor 184 and move in a direction 186 based on the movement of the conveyor 184. In this example, the illustrated wood elements 182 are wood strips, but in other examples, the wood elements may instead be wood sheets, wood veneers, wood chips, wood strands, wood flakes, wood scraps, sawdust, other suitable wood or wood particles, elements, components, products, or other suitable plant-based particles, elements, components, products, or combinations thereof. In some examples, the conveyor 184 corresponds to the conveyor 126 of FIG. 2, and in other examples, the conveyor 184 may be a different conveyor than the conveyor 126 of FIG. 2.

[0040] In this example, an exemplary applicator 188 is positioned above the conveyor 184, and the filler material 190 can be applied from the applicator 188 onto the wood elements 182 as the wood elements 182 pass under the applicator 188. In the example of FIG. 3B, the applicator 188 is a roller element that rotates about an axis and can apply the filler material onto the wood elements 182. In this example, the applicator 188 can be in physical contact with the wood elements 182. In some examples, the filler material 190 includes an adhesive. In some embodiments, the filler material 190 does not include an adhesive. In some embodiments, the filler material 190 includes a plastic, and in some embodiments, the filler material 190 does not include a plastic. In some embodiments, the filler material 190 includes a metal, and in other embodiments, the filler material 190 does not include a metal. As discussed above herein, a combination of such materials is also possible for the filler material 190. As shown in Fig. 3B, the wood elements 192 that have not passed under the applicator 188 generally do not have the filler material 190 applied thereto, whereas the wood elements 194 that have passed under the applicator 188 generally have the filler material 190 applied thereto. Referring again to Fig. 1, the application of the filler material shown in Fig. 3B may be performed, for example, in the filler material application area 104. Although a single applicator 188 is illustrated in Fig. 180, in other examples, alternatively, two or more applicators (e.g., two or more smaller rollers) may be used to apply the filler material 190 to the multiple wood elements 182. For example, the filler material 190 may be supplied to the applicator 188 by a filler material supply line 196. In examples in which the filler material 190 includes an adhesive, the applicator 188 may be considered, for example, as an adhesive applicator.

[0041] 3C is a diagram 200 illustrating yet another example of the application of filler to a plurality of wood elements. A plurality of wood elements 202 are disposed on a conveyor 204 and move in a direction 206 based on the movement of the conveyor 204. In this example, the illustrated wood elements 202 are wood veneers, but in other examples, the wood elements may instead be wood sheets, wood strips, wood strands, wood chips, wood flakes, wood scraps, sawdust, other suitable wood or wood particles, elements, components, products, or other suitable plant-based particles, elements, components, products, or combinations thereof. In some examples, the conveyor 204 corresponds to the conveyor 126 of FIG. 2, and in other examples, the conveyor 204 may be a different conveyor than the conveyor 126 of FIG. 2.

[0042] In this example, an exemplary applicator 208 is positioned above the conveyor 204 and can apply the filler material 210 from the applicator 208 onto the wood elements 202 as the wood elements 202 pass under the applicator 208. In the example of FIG. 3C, the applicator 208 is one or more brush elements that can apply the filler material 210 onto the wood elements 202. In this example, the applicator 208 can be in physical contact with the wood elements 202. In some examples, the filler material 210 includes an adhesive. In some embodiments, the filler material 210 does not include an adhesive. In some embodiments, the filler material 210 includes a plastic, and in some embodiments, the filler material 210 does not include a plastic. In some embodiments, the filler material 210 includes a metal, and in other embodiments, the filler material 210 does not include a metal. As discussed herein above, combinations of such materials are also possible for the filler material 210. As shown in Fig. 3C, the wood elements 212 that have not passed under the applicator 208 generally do not yet have the filler material 210 applied to them, whereas the wood elements 214 that have passed under the applicator 208 have the filler material 210 applied to them. Referring again to Fig. 1, the application of the filler material shown in Fig. 3C can be performed, for example, in the filler material application area 104. Although Fig. 200 shows a single applicator 208, in other examples, two or more applicators (e.g., two or more small brushes) may instead be used to apply the filler material 210 to multiple wood elements 202. The applicator 208 may be supplied with the filler material 210, for example, by a filler material supply line 216. In examples where the filler material 210 comprises an adhesive, the applicator 208 may be considered, for example, as an adhesive applicator.

[0043] According to various embodiments, various examples of adhesives can be used as the filler 160, 190, 210. Examples of adhesives that can be used as the filler include, but are not limited to, urea formaldehyde resins, phenol formaldehyde resins, melamine formaldehyde resins, polyurethane resins, and polymeric methylene diphenyl diisocyanate resins. In some examples, urethane adhesives or acrylic urethane adhesives can be used. In some examples, water-based adhesives can be used.

[0044] Following application of the filler 160, 190, 210 in the examples of Figures 3A, 3B and 3C, in some examples, multiple wood elements 164, 194, 214 can be placed adjacent to one another. In some examples, the wood elements can be vertically placed or stacked adjacent to one another. For example, two or more wood strips 194 can be stacked vertically. As another example, two or more wood veneers 214 can be stacked vertically. In some examples, the wood elements can be placed or stacked adjacent to one another horizontally or laterally. Additional arrangements are possible, such as some wood elements being placed or stacked vertically adjacent to one another and some wood elements being placed or stacked horizontally or laterally adjacent to one another.

[0045] In some examples, the arrangement of wood elements adjacent to one another may be generally structured or organized (e.g., vertically oriented or vertically stacked of two, three, four, five or more wood elements). In some examples, the arrangement of wood elements adjacent to one another may be generally less structured, such as randomly or variably arranged multiple wood elements (e.g., wood chips, wood flakes, wood scraps, sawdust, etc.). For example, wood chips 164 may be generally randomly or variably arranged adjacent to one another.

[0046] The placing of the wood elements adjacent to one another may be performed by one or more automated processes (e.g., one or more machines programmed to place the wood elements), by one or more manual processes (e.g., one or more workers manually performing the placing of the wood elements), or by a combination of one or more automated processes and one or more manual processes. In some examples, the wood elements may be placed adjacent to one another by lining up or lying down in a "mat".

[0047] FIG. 4 is a conceptual diagram 230 of an exemplary ultrasonic transducer 232 that delivers ultrasonic energy to a plurality of exemplary wood elements 234 to produce a composite wood product using ultrasonic energy. The delivery of ultrasonic energy to the plurality of exemplary wood elements 234 shown in FIG. 4 can be implemented, for example, in the ultrasonic energy delivery area 106 of FIG. 1. Referring again to FIG. 4, the exemplary ultrasonic transducer 232 has a generic shape and can represent any of the ultrasonic transducer shapes or topologies discussed herein. In general, the ultrasonic transducer 232 can generate ultrasonic energy that can be used to join the plurality of wood elements 234 into a composite wood product. For example, the ultrasonic transducer 232 can generate ultrasonic waves 236 that can deliver ultrasonic energy to the plurality of wood elements 234. As used herein, the term "ultrasonic transducer" is understood to refer to a device that can generate ultrasonic energy, and can radiate ultrasonic energy from the ultrasonic transducer in the form of ultrasonic waves or ultrasonic waves. As used herein, the term "ultrasonic transducer" does not necessarily imply that the device includes a receiver capable of receiving ultrasonic waves (e.g., ultrasonic waves reflected back to the device) and does not necessarily imply that the device is capable of measuring ultrasonic waves. In some implementations of the devices, systems, and methods discussed herein, an ultrasonic transducer may include a receiver capable of receiving ultrasonic waves and, in some implementations, measuring ultrasonic waves, although in the specific examples discussed herein, such receivers or receiving capabilities are generally not included in the ultrasonic transducers described with respect to the examples shown herein.

[0048] 4, the plurality of wood elements 234 includes four wood elements 238a, 238b, 238c, and 238d arranged adjacent to one another. In this example, the wood elements are generally stacked on top of one another, with the first wood element 238a generally positioned on the surface 240, the second wood element 238b generally positioned on top of the first wood element 238a, the third wood element 238c generally positioned on top of the second wood element 238b, and the fourth wood element 238d generally positioned on top of the third wood element 238c.

[0049] In some examples, one or more of the wood elements 238a, 238b, 238c, 238d may correspond to one or more of the wood elements 194 or 192 of FIG. 3B. For example, one or more of the elements may include a filler applied on a surface or a portion of a surface, or on multiple surfaces. For example, the filler may be disposed on the top surface 242 of the first wood element 238a. The filler may be disposed on the top surface 244 of the second wood element 238b. The filler may also be disposed on the top surface 246 of the third wood element 238c. The filler may also be disposed on the bottom surface of the wood elements 238b, 238c, 238d, for example. In some examples, one or more of the wood elements 238a, 238b, 238c, 238d may correspond to the wood element 194 of FIG. 3B (e.g., the elements 238a, 238b, 238c may have infill disposed on the top surfaces 242, 244, 246, respectively), and one or more of the wood elements 238a, 238b, 238c, 238d may not correspond to the wood element 194 shown in FIG. 3B (e.g., the element 238d may not have infill disposed on its surface prior to placing the elements 238a, 238b, 238c, 238d adjacent to one another). In some examples, infill may not be disposed on any of the surfaces of the wood elements 238a, 238b, 238c, 238d. In this example, infill 248 is to be disposed on the surfaces 242, 244, and 246.

[0050] The plurality of wood elements 238a, 238b, 238c, 238d in this example can correspond to a plurality of wood strands, while in other examples the plurality of wood elements 238a, 238b, 238c, 238d may correspond to a plurality of wood sheets, a plurality of wood veneers, a plurality of wood strips, a plurality of wood chips, a plurality of wood flakes, a plurality of wood scraps, sawdust, any combination of the foregoing, or other suitable wood or wood particles, elements, components, or products, or other suitable plant-derived particles, elements, components, or products.

[0051] In some examples, the ultrasonic energy transmitted by the ultrasonic transducer 236 has a frequency within a frequency range of 10 kHz to 20 MHz. In some examples, the ultrasonic energy transmitted by the ultrasonic transducer 236 has a frequency within a frequency range of 15 kHz to 1 MHz. In some examples, the ultrasonic energy transmitted by the ultrasonic transducer 236 has a frequency within a frequency range of 20 kHz to 100 kHz. Generally, the ultrasonic transducer 232 can deliver low frequency ultrasonic energy to the plurality of wood elements 234.

[0052] In some examples, the ultrasonic waves 236 may be provided as a continuous wave, and in some examples, the ultrasonic waves 236 may be provided as a pulsed wave. In some examples, the transducer 232 may provide periodic ultrasonic waves, and the ultrasonic waves may include one or more of a variety of waveforms. For example, in various embodiments, the waveforms may include one or more of a sinusoidal waveform, a rectangular waveform, a square waveform, a trapezoidal waveform, a triangular waveform, a sawtooth waveform, or other suitable waveform shapes, or suitable combinations thereof. The transducer 232 may generate ultrasonic waves 236, which may include one or more of an ultrasonic longitudinal wave, an ultrasonic radial wave, and an ultrasonic transverse wave, and the ultrasonic waves 236 may provide ultrasonic energy to the plurality of wood elements 238a, 238b, 238c, 238d, the filler material 248, or both the plurality of wood elements 238a, 238b, 238c, 238d and the filler material 248. For clarity, the ultrasonic waves 236 shown in FIG. 4 are shown as being emitted from the ultrasonic transducer 232 onto multiple wood elements 234, however, the ultrasonic waves 236 may be irradiated by, absorbed by, or passed through one or more (e.g., two, three, or all) of the wood elements 238d, 238c, 238b, and 238a.

[0053] In some examples, the transmitted ultrasonic energy can provide mechanical stimulation to one or more of the plurality of wood elements 238a, 238b, 238c, 238d. For example, when the ultrasonic waves 236 are transmitted through or absorbed by the wood elements, the ultrasonic waves 236 can vibrate molecules within the wood elements. The vibrations at the molecular level within the wood elements (e.g., elements 238a, 238b, 238c, 238d) will create friction between the vibrating molecules and generate heat within the wood elements. Furthermore, in some examples, when the ultrasonic waves 236 are transmitted through or absorbed by the wood elements, the ultrasonic waves 236 can create small or microscopic pressure differences within the wood elements. Such pressure differences can create cavitation within the wood elements, and microscopic gas or steam bubbles will be generated within the wood elements as gas or steam is forced or pushed from high pressure areas within the wood elements toward low pressure areas within the wood elements due to the pressure difference. In one or more of these forms, the ultrasonic energy can provide a mechanical stimulus to, for example, bond wood or other plant products. This mechanical stimulus may be provided even if, for example, the ultrasonic transducer 232 is not in physical contact with the wood elements 238a, 238b, 238c, 238d or the filler material 248. In some examples, the ultrasonic transducer 232, or a portion thereof, may be in physical contact with one or more of the wood elements 238a, 238b, 238c, 238d, the filler material 248, or both the filler material 248 and one or more of the wood elements 238a, 238b, 238c, 238d to provide the aforementioned mechanical stimulus.

[0054] The ultrasonic energy can further provide a mechanical stimulus at a macro level to one or more of the plurality of wood elements 238a, 238b, 238c, 238d. For example, the mechanical stimulus provided by the ultrasonic waves 236 may, for example, move or vibrate one or more of the wood elements, and such movement or vibration may create friction between the wood elements. For example, a surface of one of the wood elements may be resisted as it moves, rubs, or vibrates in contact with one or more surfaces of another wood element. In one or more of these ways, the ultrasonic energy may provide a mechanical stimulus, for example, in the joining of wood or other plant products. This mechanical stimulus may be provided, for example, even if the ultrasonic transducer 232 is not in physical contact with the wood elements 238a, 238b, 238c, 238d or the filler material 248. In some examples, the ultrasonic transducer 232, or a portion thereof, may be in physical contact with one or more of the wood elements 238a, 238b, 238c, 238d, the infill material 248, or both the infill material 248 and one or more of the wood elements 238a, 238b, 238c, 238d, and the aforementioned mechanical stimulus will be provided.

[0055] In some examples, the ultrasonic waves 236 can provide mechanical stimulation to the filler material 248. For example, as the ultrasonic waves 236 pass through or are absorbed by the filler material 248, the ultrasonic waves 236 will vibrate molecules within the filler material 248. The vibrations at the molecular level within the filler material 248 can create friction between the vibrating molecules and generate heat within the filler material 248. Additionally, in some examples, as the ultrasonic waves 236 pass through or are absorbed by the filler material 248, the ultrasonic waves will create small or microscopic pressure differences within the filler material 248. Such pressure differences can create cavitation within the filler material 248, which can force gas or vapor from areas of high pressure within the filler material 248 to areas of low pressure within the filler material 248, or create microscopic gas or vapor bubbles within the filler material 248 as they are forced. In one or more of these ways, ultrasonic energy can provide mechanical stimulation, for example, in the bonding of wood or other plant products. This mechanical stimulus can be provided, for example, even if the ultrasonic transducer 232 is not in physical contact with the wood elements 238a, 238b, 238c, 238d or the infill material 248. In some examples, the ultrasonic transducer 232, or a portion thereof, may be in physical contact with one or more of the wood elements 238a, 238b, 238c, 238d, the infill material 248, or both the infill material 248 and one or more of the wood elements 238a, 238b, 238c, 238d, and the aforementioned mechanical stimulus will be provided.

[0056] In some examples, the ultrasonic energy can also provide mechanical stimulation to the filler material 248 at a macro level. For example, the mechanical stimulation provided by the ultrasonic waves 236 can agitate, move, vibrate, diffuse, expand, flow, or permeate the filler material 248, just to name a few. In one or more of these ways, the ultrasonic energy can provide mechanical stimulation, for example, in the bonding of wood or other plant products. This mechanical stimulation would be provided even if, for example, the ultrasonic transducer 232 is not in physical contact with the wood elements 238a, 238b, 238c, 238d or the filler material 248. In some examples, the ultrasonic transducer 232, or a portion thereof, may be in physical contact with one or more of the wood elements 238a, 238b, 238c, 238d, the filler material 238, or both the filler material 238 and one or more of the wood elements 238a, 238b, 238c, 238d, and the aforementioned mechanical stimulation would be provided.

[0057] In some examples, the ultrasonic energy can stimulate diffusion of the filler material 248, causing the filler material 248 to penetrate one or more of the wood elements 238a, 238b, 238c, 238d, or to penetrate deeper into one or more of the wood elements. In some embodiments, the ultrasonic energy can stimulate diffusion of the filler material 248, for example, causing the filler material to spread more widely across, cover, or contact one or more of the wood elements. In one or more of these methods, the ultrasonic energy can provide a diffusion stimulus in the joining of wood or other plant products. This diffusion stimulus can be provided, for example, even if the ultrasonic transducer 232 is not in physical contact with the wood elements 238a, 238b, 238c, 238d or the filler material 248. In some examples, the ultrasonic transducer 232, or a portion thereof, may be in physical contact with one or more of the wood elements 238a, 238b, 238c, 238d, the infill material 248, or both the infill material 248 and one or more of the wood elements 238a, 238b, 238c, 238d, and the aforementioned diffuse stimulation will be provided.

[0058] According to some embodiments, in some instances, the ultrasonic energy may also provide a thermal stimulus to one or more of the wood elements 238a, 238b, 238c, 238d, the infill material 248, or the wood elements and the infill material. This thermal stimulus may be in addition to any heat generated by, for example, the mechanical or other stimuli. In some embodiments, the temperature of one or more of the wood elements 238a, 238b, 238c, 238d will increase as the wood elements absorb the ultrasonic energy or a portion of the ultrasonic energy. Similarly, the temperature of the infill material 248 will increase as the infill material 248 absorbs the ultrasonic energy or a portion of the ultrasonic energy. In some examples, increasing the temperature of the filler, the wood elements, or both the filler and one or more wood elements will stimulate better diffusion of the filler 248, stimulating deeper penetration of the filler, or (e.g., in embodiments where the filler is liquid or capable of flowing) stimulating better flow of the filler 248 can stimulate deeper infusion of the filler 248 into one or more of the wood elements 238a, 238b, 238c, 238d. In one or more of these methods, the ultrasonic energy will provide a thermal stimulation in the bonding of the wood or other plant product. This thermal stimulation can be provided, for example, even if the ultrasonic transducer 232 is not in physical contact with the wood elements 238a, 238b, 238c, 238d or the filler material 248. In some examples, the ultrasonic transducer 232, or a portion thereof, may be in physical contact with one or more of the wood elements 238a, 238b, 238c, 238d, the infill material 248, or both the infill material 248 and one or more of the wood elements 238a, 238b, 238c, 238d, and the aforementioned thermal stimulus will be provided.

[0059] In some examples, friction created by application of ultrasonic energy between wood elements (e.g., between any of wood elements 238a, 238b, 238c, 238d) or between the infill 248 and one or more wood elements can force or advance the infill 248 into gaps, pores, interstices, spaces, voids, or cavities of one or more of the wood elements 238a, 238b, 238c, 238d. In some embodiments, the friction can stimulate atomization of the infill 248 (e.g., breaking down the infill 248 into smaller or finer particles), and in some examples can stimulate the infill 248 to be forced or advanced into gaps, pores, interstices, spaces, voids, or cavities of one or more wood elements. In some instances, the friction may generate additional heat, for example, by heating the filler material 248 and stimulating better flow of the filler material 248 (e.g., in implementations where the filler material is liquid or flowable), which may also stimulate deeper penetration of the filler material 248 into one or more wood elements. In one or more of these methods, ultrasonic energy may generate friction between one or more of the wood elements 238a, 238b, 238c, 238d, or between the filler material 248 and the wood elements, providing stimulation in the bonding of wood or other plant products. This stimulation may be provided, for example, even when the ultrasonic transducer 232 is not in physical contact with the wood elements 238a, 238b, 238c, 238d or the filler material 248. In some examples, the ultrasonic transducer 232, or a portion thereof, may be in physical contact with one or more of the wood elements 238a, 238b, 238c, 238d, the infill material 248, or both the infill material 248 and one or more of the wood elements 238a, 238b, 238c, 238d, and the aforementioned stimuli will be provided.

[0060] 4 shows the ultrasonic transducer 232 providing ultrasonic waves 236 from a position approximately above the wood elements 238a, 238b, 238c, 238d, but in other examples, the ultrasonic transducer 232 can provide ultrasonic waves 236 from a position approximately to the side (e.g., approximately to the left or right), in front (e.g., in front as the wood elements approach), or behind the wood elements, or from a position approximately below the wood elements 238a, 238b, 238c, 238d. In some examples, there may be two or more (e.g., 2, 3, 4, 5, 6, or more) ultrasonic transducers 232 that can provide ultrasonic waves to the wood elements simultaneously or at different times. For example, some implementations may include two or more ultrasonic transducers 232 that can provide ultrasonic waves to the wood elements simultaneously from a position approximately above the wood elements. As another example, some implementations may include two or more ultrasonic transducers 232 that can simultaneously deliver ultrasonic waves to multiple wood elements from approximately lateral, front, rear, or below the multiple wood elements. As yet another example, some implementations may include one or more (e.g., 1, 2, 3, or more) ultrasonic transducers 232 that can simultaneously deliver ultrasonic waves to multiple wood elements from approximately one or more positions above the multiple wood elements, and may include one or more (e.g., 1, 2, 3, or more) ultrasonic transducers 232 that can simultaneously deliver ultrasonic waves to multiple wood elements from approximately one or more positions below the multiple wood elements. As will be apparent to those skilled in the art, other combinations are possible.

[0061] FIG. 5 is a conceptual diagram 260 of the exemplary ultrasonic transducer 232 of FIG. 4. The exemplary ultrasonic transducer 232 includes an exemplary housing 262. One or more exemplary ultrasonic energy generating elements 264 are disposed within the housing 262, and may be disposed, for example, between an exemplary ground electrode 266 and an exemplary positive electrode 268. In some examples, the one or more ultrasonic energy generating elements 264 are one or more piezoelectric transducers. For example, a piezoelectric transducer, such as one or more piezoelectric crystals or piezoelectric elements, can utilize the piezoelectric properties of a material to convert electrical energy into mechanical energy. In some examples, the piezoelectric crystals or piezoelectric elements can include a piezoelectric ceramic material. In some examples, the one or more ultrasonic energy generating elements 264 are one or more magnetostrictive transducers. For example, a magnetostrictive transducer, such as one or more wire coils disposed around one or more magnetostrictive materials, can generate mechanical energy based on the magnetostrictive properties of the magnetostrictive material and a magnetic field that can be provided by the wire and the magnetostrictive material. Examples of magnetostrictive materials include nickel, iron, cobalt, and the like.

[0062] The positive electrode 268 may be energized by an electrical conductor 270 capable of conducting a live electrical signal to an electrical ground 272, and the ground electrode 266 may be electrically coupled to the electrical ground 272. In some examples, the housing 262 may also be electrically coupled to the electrical ground 272. In some examples, each of the electrical conductor 270 and the electrical ground 272 may be provided to the transducer 232 by a power cable 274.

[0063] A raw electrical signal supplied to the positive electrode 268 will cause an electrical current to flow between the positive electrode 268 and the ground electrode 266. When an electrical current flows between the positive electrode 268 and the ground electrode 266, the electrical current can excite one or more ultrasonic energy generating elements 264 to generate ultrasonic waves, as described above.

[0064] The transducer 232 includes an exemplary horn 276, also referred to as a sonotrode, that can direct ultrasonic waves to an ultrasonic target, such as a number of wood elements. In some examples, one or more exemplary matching layers 278 can be included between the ground electrode 266 and an opening 280 defined in the housing 262. The one or more matching layers 278 can include a material that is electrically conductive to provide better energy transfer of ultrasonic energy to the horn 276 and the target. For embodiments that include one or more matching layers 278, exemplary materials that can be used for the one or more matching layers 278 include epoxy, polyurethane, polystyrene, and the like. One or more exemplary backing layers 282, located on the opposite side of the positive electrode 268 from the one or more ultrasonic energy generating elements 264, can prevent ultrasonic waves from propagating away from the opening 280 in the housing 262. Additionally, an exemplary acoustic insulation layer 284 is generally disposed between the inner surface of the housing 262 and the one or more backing layers 282 and can provide acoustic insulation to prevent or limit leakage of ultrasonic waves from the transducer 232 other than at the opening 280 through the horn 276.

[0065] In general, the ultrasonic transducer 232 and horn 276 can have many different shapes and topologies, depending on the embodiment. For example, some ultrasonic transducers can include two or more (e.g., two, three, or four or more) openings 280 in the transducer housing so that ultrasonic waves generated by the transducer can impact one or more targets from one or more locations or directions. Some ultrasonic transducers can have, for example, two or more sets of ultrasonic energy generating elements (e.g., piezoelectric elements, magnetostrictive elements, or a combination thereof) and two or more sets of positive and ground electrodes.

[0066] 6A-6H are diagrams of various implementations of ultrasonic transducers, including various horn configurations. FIG. 6A is a conceptual diagram 300 of an exemplary ultrasonic transducer 302, including an exemplary cymbal-shaped horn 304 that can be used to manufacture composite wood products using ultrasonic energy. Similar to the transducers described above, the ultrasonic transducer 302 can generate ultrasonic waves 306 that are directed through the horn 304 to a target 308 (e.g., multiple wood elements). In some examples, the cymbal-shaped horn 304 can be shaped like a typical percussion instrument. In some examples, it can be shaped like a short cylinder, as shown in FIG. 6A. The horn 304 defines an aperture 310 approximately near the center of the horn 304, and the ultrasonic waves 306 will radiate from the aperture 310. The cymbal-shaped horn 304 can function, for example, as an acoustic waveguide.

[0067] 6B is a conceptual diagram 320 of an example ultrasonic transducer 322 including an example Langevin horn 324 that can be used to manufacture composite wood products using ultrasonic energy. The ultrasonic transducer 322 can generate ultrasonic waves 326 that are directed to a target 328 (e.g., multiple wood elements) via the horn 324. The Langevin horn 324 can define an opening 330 through which the ultrasonic waves 326 are emitted. The Langevin horn 324 can function, for example, as an acoustic waveguide.

[0068] 6C is a conceptual diagram 340 of an example ultrasonic transducer 342 including an example ring-shaped horn 344 that can be used to manufacture composite wood products using ultrasonic energy. The ring-shaped horn 344 has a number of openings 346 defined therein. The ultrasonic transducer 342 can generate ultrasonic waves 348 that emanate from the number of openings 346 defined in the ring-shaped horn 344 and are directed through the horn 344 to a target 350 (e.g., a number of wood elements). The ring-shaped horn 344 can function, for example, as an acoustic waveguide. In some examples, the number of openings 346 can be defined, for example, on an underside of the ring-shaped horn 344 in an implementation in which the ring-shaped horn 344 is located approximately above the target. In some examples, the number of openings 346 can be defined, for example, on an upper surface of the ring-shaped horn 344 in an implementation in which the ring-shaped horn 344 is located approximately below the target. In some examples, multiple openings 346 may be defined, for example, on an inwardly facing surface of ring-shaped horn 344 in implementations where a target or portion of a target is located within a space defined by ring-shaped horn 344. In some examples, openings 346 may be defined by a combination of the possible ring positions discussed above.

[0069] FIG. 6D is a conceptual diagram 360 of an example ultrasonic transducer 362 including an example pyramidal horn 364 that can be used to manufacture composite wood products using ultrasonic energy. The ultrasonic transducer 362 can generate ultrasonic waves 366 that are directed to a target 368 (e.g., a plurality of wood elements) through the horn 364. In the example shown in FIG. 6D, the pyramidal horn 364 has four sides, and the base of the pyramidal shape has a square or rectangular shape. In various examples, the pyramidal horn can have any suitable number of sides (e.g., 3, 4, 5, or 6 or more). The horn 364 defines an aperture 370 approximately near the center of the horn 364 from which the ultrasonic waves 366 can be emitted. The pyramidal horn 364 can function, for example, as an acoustic waveguide.

[0070] 6E is a conceptual diagram 380 of an example ultrasonic transducer 382 including an example spherical horn 384 that can be used to manufacture composite wood products using ultrasonic energy. The ultrasonic transducer 382 can generate ultrasonic waves 386 that emanate from the spherical horn 384 and are directed through the horn 384 to a target 388 (e.g., a plurality of wood elements). The spherical horn 384 may have any suitable diameter. The spherical horn 384 can function, for example, as an acoustic waveguide.

[0071] FIG. 6F is a conceptual diagram 400 of an example ultrasonic transducer 402 including an example dome-shaped horn 404 that can be used to manufacture composite wood products using ultrasonic energy. The ultrasonic transducer 402 can generate ultrasonic waves 406 that are directed to a target 408 (e.g., a plurality of wood elements) through the horn 404. The horn 404 defines an opening 410 approximately near the center of the horn 404, and the ultrasonic waves 406 may radiate from the opening 410. The dome-shaped horn 404 can function as an acoustic waveguide, for example. Although not shown in FIG. 6 for simplicity, in some examples, the dome-shaped horn 404 may be inverted relative to the orientation described for the ultrasonic transducer 402 of FIG. 6F. For example, in some embodiments, the horn may be shaped like a saucer or cup.

[0072] FIG. 6G is a conceptual diagram 420 of an example ultrasonic transducer 422 including an example wedge-shaped horn 424 that can be used to manufacture composite wood products using ultrasonic energy. The ultrasonic transducer 422 can generate ultrasonic waves 426 that are directed through the horn 424 to a target 428 (e.g., a plurality of wood elements). As shown in FIG. 6G, the wedge-shaped horn 424 includes four sides, and the base of the wedge has a rectangular shape. In various examples, the wedge-shaped horn may have any suitable number of sides (e.g., 3, 4, 5, or 6 or more). The horn 424 has a slot-shaped opening 430 defined therein, and the ultrasonic waves 426 may radiate from the opening 430. For example, the wedge-shaped horn 424 can function as an acoustic waveguide.

[0073] FIG. 6H is a conceptual diagram 440 of an exemplary ultrasonic transducer 442 that can be used to manufacture composite wood products using ultrasonic energy, including an exemplary horn 444 having a generally tubular or cylindrical shape of FIG. 6H, the horn 444 including an exemplary chamber 446. In various examples, the chamber 446 can define a space within the horn 444 where, for example, various elements or materials can be introduced into the chamber 446 and then ultrasonically processed within the horn 444. The chamber 446 can have any suitable number of input channels that can be used to feed elements or materials into the chamber 446, for example. The chamber 446 includes two input channels, an exemplary first input channel 448 (designated as "Input A" in FIG. 6H) and an exemplary second input channel 450 (designated as "Input B" in FIG. 6H). In other examples, the chamber 446 can include one, three, four, or more input channels. Examples of elements or materials that can be introduced into chamber 446 via the input channel can include one or more types of wood elements, one or more types of filler (e.g., any type of filler discussed herein), or combinations thereof, just to name a few.

[0074] In some examples, a plurality of wood elements 452 (e.g., sawdust, wood flakes, wood chips, wood scraps, etc.) can be fed into the chamber 446, for example, via a first input channel 448, and a filler material 454 can be fed into the chamber 446 via a second input channel 450. The plurality of wood elements 452 and the filler material 454 can be exposed to ultrasonic waves 456 in the chamber 446, the ultrasonic waves 456 being generated by the ultrasonic transducer 442. In some examples, the plurality of wood elements 452 in the chamber 446 can be attached or coated with the filler material 454, and the ultrasonic waves 456 in the chamber 446 can provide one or more of a mechanical and thermal stimulus to the plurality of wood elements 452 and the filler material 454 in the chamber 446, and can also stimulate the diffusion of the filler material 454 onto and into the wood elements 452, for example, as described above with respect to the beneficial effects that ultrasonic waves have.

[0075] The wood elements 452 and filler material 454 will be extruded from the horn 444 and directed toward a target 458 (e.g., a plurality of wood elements). Ultrasonic waves 460 generated by the ultrasonic transducer 442 are directed toward the target 458 through the horn 444. The horn 444 can function, for example, as an acoustic waveguide.

[0076] 6H illustrates horn 444 as having a tubular or cylindrical shape, any of the horn shapes discussed herein may include chambers through which various elements or materials may pass, similar to chamber 446, which will be sonicated as they pass through the chamber. In some examples, the horn and chamber may be sized to accommodate larger wood elements, such as, for example, one or more of wood strips, wood strands, wood veneers, and wood sheets.

[0077] In some examples, a chamber may be included to sonicate an element or material through, similar to any of the ultrasonic transducers discussed herein, and in some examples, a horn may not be used. In some examples, a horn may also be used with a transducer that includes a chamber for sonicating an element or material within the transducer chamber.

[0078] FIG. 7 is a flow chart 500 of an exemplary method that can be used to manufacture a composite wood product. In a first step 502, a filler material is applied to a plurality of wood elements. The filler material can be applied by one or more applicators, such as, for example, any of the applicators 158, 188, 208 shown in FIGS. 3A, 3B, and 3C, or any of the other example applicators described herein. In some embodiments, the filler material may include an adhesive. In some embodiments, the filler material may not include an adhesive. In some embodiments, the filler material may include a plastic, while in other embodiments, the filler material may not include a plastic. In some embodiments, the filler material may include a metal, while in other embodiments, the filler material may not include a metal. Combinations of the foregoing (e.g., the filler material includes an adhesive and a plastic, the filler material includes an adhesive and a metal, or the filler material includes an adhesive, a plastic, and a metal) are also possible. In some embodiments, the filler material may be a liquid. In some embodiments, the filler material may be a solid. In some embodiments, the filler material may be a gas. According to some embodiments, combinations of the above examples of one or more filler states may also be used. For example, in some embodiments, the filler may be a combination or mixture of liquid and solid. In some embodiments, the filler material may be a combination or mixture of liquid and gas. In some embodiments, the filler may be a combination or mixture of solid and gas. In some embodiments, the filler may be a combination or mixture of liquid, solid and gas.

[0079] In step 504, the wood elements are joined into a composite wood product, including providing ultrasonic energy having a frequency in the range of 10 kHz to 20 MHz to the wood elements. The ultrasonic energy can be provided to the wood elements by one or more ultrasonic transducers, such as, for example, ultrasonic transducer 232 shown in FIG. 4 or any of the other examples of ultrasonic transducers described herein. In some examples, the ultrasonic energy provided to the wood elements may have a frequency in the range of 15 kHz to 1 MHz. In some examples, the ultrasonic energy provided to the wood elements may have a frequency in the range of 20 kHz to 100 kHz. In some examples, the wood elements can be positioned in close proximity to one another prior to joining the wood elements.

[0080] In some examples, a filler material is applied to the plurality of wood elements prior to applying ultrasonic energy to the plurality of wood elements. In some examples, a filler material is applied to the plurality of wood elements simultaneously with applying ultrasonic energy to the plurality of wood elements. In some examples, ultrasonic energy is applied to the plurality of wood elements prior to applying the filler material to the plurality of wood elements.

[0081] 8 is a block diagram of an exemplary environment 550 for manufacturing composite wood products using ultrasonic energy. In various embodiments, examples of composite wood products can include, but are not limited to, girders, beams, joists, L-joists, rafters, headers, studs, trusses, columns, rim boards, plywood, particle boards, fiberboards, oriented strand boards, flake boards, wafer boards, chipboards, laminated lumber, laminated veneers, cross-laminated lumber, parallel strand lumber, strand laminated lumber, and finger joints. The environment 550 includes the filler application area 104 and the ultrasonic energy supply area 106, each of which are described above with reference to FIG. 1 and other figures, and includes a compressive force application area 552. Although not shown in FIG. 8 for simplicity, it will be understood that in some implementations, the wood element preparation area 102 of FIG. 1 may also be included in the environment 550.

[0082] The compressive force application area 552 can be used to apply a compressive force to the plurality of wood elements. In some examples, a press can be used to apply a physical compressive force to the plurality of wood elements. FIG. 9 is a conceptual diagram of an example environment 580 for manufacturing a composite wood product using ultrasonic energy. The environment 580 includes an example filler applicator 582, example ultrasonic transducers 584a, 584b, 586a, 586b, and an example press 588. The filler applicator 582 can apply filler to the plurality of wood elements 590 in a manner similar to that described above with reference to the applicator 188 of FIG. 3B. In the example shown in FIG. 9, the applicator 582 is a roller element, although any of the other types of applicators described herein (e.g., one or more spray nozzles, brushes, rollers, or other types of applicators) can alternatively be used.

[0083] The plurality of wood elements 594 may be arranged adjacent to one another. For example, the plurality of wood elements 594 may be stacked vertically as described herein above, or may be arranged in any suitable manner. In some examples, the plurality of wood elements 594 includes one or more elements 592 to which a filler material is applied by the applicator 582. In some examples, the plurality of wood elements 594 includes one or more wood elements 592 to which a filler material is applied and one or more wood elements to which no filler material is applied. Also, in some examples, the plurality of wood elements 594 does not include a filler material.

[0084] One or more ultrasonic transducers can provide ultrasonic energy to the plurality of wood elements 594. In the example of Fig. 9, ultrasonic transducers 584a and 584b are arranged on the sides of a conveyor 595 capable of transporting the plurality of wood elements 594, and are arranged on the sides of the plurality of wood elements when the plurality of wood elements are located at a target position 596 to receive ultrasonic energy. The first ultrasonic transducer 584a is arranged on the left side of the conveyor 595, and the second ultrasonic transducer 584b is arranged on the right side of the conveyor 595. Furthermore, in this example, ultrasonic transducers 586a and 586b are arranged on the conveyor 595, and are arranged on the plurality of wood elements 594 when the plurality of wood elements are located at a target position 596 to receive ultrasonic energy. In this example, a conveyor 595 can move a plurality of wood elements 594 to a target position 596 relative to the ultrasonic transducers, and ultrasonic transducers 584a and 584b can supply ultrasonic energy to the plurality of wood elements 594 in right and left directions from left and right lateral positions of the wood elements, respectively. Similarly, ultrasonic transducers 586a and 586b can supply ultrasonic energy to the plurality of wood elements 594 in a top to bottom direction.

[0085] In other examples, additional ultrasonic transducers (e.g., 5, 6, 7, or 8 or more) or fewer ultrasonic transducers (e.g., 1, 2, or 3) may be used. In some examples, ultrasonic energy may be provided from only one direction (e.g., only downward from one or more ultrasonic transducers on the wood elements, or only in any other direction), and in these examples, more or fewer ultrasonic transducers may be used than those shown in FIG. 9 (e.g., transducers 584a and 584b may not be used). In some examples, ultrasonic energy may be provided from two directions (e.g., downward and a first lateral direction, or up and down, or left and right, or any other combination), and in these examples, more or fewer ultrasonic transducers may be used than those shown in FIG. 9. In the example of FIG. 9, ultrasonic energy is generally provided in three directions, namely, from top to bottom (e.g., from ultrasonic transducers 586a and 586b), from a first lateral direction (e.g., from ultrasonic transducer 584a), and from a second lateral direction (e.g., from ultrasonic transducer 584b). In some examples, ultrasonic energy may be provided to multiple wood elements from more than two directions (e.g., four, five, or more than six directions). For example, ultrasonic energy may be provided to the wood elements rearward (e.g., from a front or forward position of the wood element), forward (e.g., from the rear or rear side of the wood element), or upward (e.g., from below or underside of the wood element) by providing additional ultrasonic transducers (not shown in FIG. 9 for simplicity). Of course, any of these alternative ultrasonic transducer positions or configurations may also be utilized in a system that provides ultrasonic energy to multiple wood elements from a single direction, two directions, three directions, or more than three directions.

[0086] According to some implementations, in some examples, one or more of the illustrated ultrasonic transducers 584a, 584b, 586a, 586b can be moved or repositioned to deliver ultrasonic energy to the wood elements from one or more of these other directions or positions. While the ultrasonic transducers described above with reference to Figure 9 are shown in an environment 580 that includes a press 588, it will be understood that any of the ultrasonic transducers or configurations described with reference to Figure 9 or anywhere herein can be used in embodiments that do not include a press or that do not include a compressive force application area.

[0087] In some examples, the conveyor 595 may be stopped for a period of time while the ultrasonic transducer supplies ultrasonic energy to the plurality of wood elements 594. In some examples, the conveyor 595 may continue to move while the ultrasonic transducer supplies ultrasonic energy to the plurality of wood elements 594. In some examples, the speed of the conveyor 595 may be adjusted (e.g., slowed down) for a period of time while the ultrasonic transducer supplies ultrasonic energy to the plurality of wood elements 594. In some examples, the one or more ultrasonic transducers may be generally stationary relative to the movement of the conveyor 595. In some examples, the one or more ultrasonic transducers may be configured to move, for example, move relative to the conveyor 595, move relative to the target position 596, or move relative to the plurality of wood elements 594.

[0088] The press 588 can transmit one or more compression forces to the wood elements 594. In some examples, the press 588 can transmit a downward compression force to the wood elements 594. In some examples, the press 588 can transmit one or more lateral compression forces (e.g., a compression force from the left side, a compression force from the right side, or both the left side and the right side). In some examples, the press 588 can transmit a compression force in front of the wood elements 594, behind the wood elements 594, or from both the front and the back of the wood elements 594. Combinations of compression forces applied in this way are also possible. For example, according to some embodiments, the press 588 can transmit a downward compression force and one or more additional compression forces (e.g., compression forces from the left, from the right, from both the left and the left, from the front, from the back, from both the front and the back, from each of the left and the right, the front and the back, or other) to the wood elements 588. In some examples, the press 588 can be substantially stationary with respect to the movement of the conveyor 595. In some examples, the press 588 may be configured to move relative to a conveyor 595, to move relative to a target position 597 to receive a compressive force against the wood elements 594, or to move relative to multiple wood elements 594.

[0089] In some examples, ultrasonic energy can be applied to the wood elements, and then compressive forces can be applied to the wood elements. For example, according to some embodiments, the conveyor 595 can move generally in a first direction 598, and one or more ultrasonic transducers (transducers 584a, 584b, 586a, 586b in the example of FIG. 9) can apply ultrasonic energy to the wood elements before one or more presses (e.g., press 588 in the example of FIG. 9) apply one or more compressive forces to the wood elements. In some examples, one or more compressive forces can be applied to the wood elements, and then ultrasonic energy can be applied to the wood elements. For example, according to some embodiments, the conveyor 595 can move generally in a second direction 599, and one or more presses (e.g., press 588 in the example of FIG. 9) can apply one or more compressive forces to the wood elements before one or more ultrasonic transducers (e.g., transducers 584a, 584b, 586a, 586b in the example of FIG. 9) apply ultrasonic energy to the wood elements. According to some embodiments, in each of the two previous examples, a filler may be applied to the plurality of wood elements prior to applying the compressive force and supplying the ultrasonic energy.

[0090] In some examples, one or more ultrasonic transducers can be integrated with the press and can provide ultrasonic energy to the multiple wood elements simultaneously (or before, after, or in a combination of the above, depending on the embodiment) with the press transmitting one or more compressive forces to the multiple wood elements. FIG. 10A is a conceptual diagram 600 of an example press 602 and an example ultrasonic transducer 604 integrated with the press 602 and that can be used to manufacture a composite wood product using ultrasonic energy. In some embodiments, the ultrasonic transducer 604 and the press 602 can provide ultrasonic energy and compressive forces, respectively, to the multiple wood elements 606 simultaneously. The example of FIG. 10A shows the wood elements 606 (in this example, two wood veneers stacked vertically, although any wood element discussed herein can alternatively be used) on a conveyor 608 that can move the multiple wood elements 606 to a target position 609 below the press 602 and ultrasonic transducer 604.

[0091] The press 602 can apply a downward compressive force 610 to the plurality of wood elements 606 when the wood elements 606 are at the target position 609, and at the same time, the ultrasonic transducer 604 can provide ultrasonic energy to the plurality of wood elements. The press 602 includes a surface 612 that can apply the compression 610 to the plurality of wood elements 606. In some examples, the ultrasonic transducer 604 can be positioned flush with the surface 612 of the press 602 that can apply the compressive force 610 to the plurality of wood elements 606. In some examples, the ultrasonic transducer 604 can be positioned recessed relative to the surface 612 of the press 602 that can apply the compressive force 610 to the plurality of wood elements 606. In this example, the press 602 and the ultrasonic transducer 604 can each provide a compressive force and ultrasonic energy in a first direction (e.g., downward relative to the target position 609 in this example). In some examples, the press 602 and the ultrasonic transducer 604 can each provide a compressive force and ultrasonic energy at different times. For example, the ultrasonic transducer 604 can first apply ultrasonic energy to the wood elements, and then the press 602 can apply a compressive force to the wood elements. Alternatively, the press 602 can first apply a compressive force to the wood elements, and then the ultrasonic transducer 604 can apply ultrasonic energy to the wood elements. In some examples, the press 602 and the ultrasonic transducer 604 can apply a compressive force and ultrasonic energy, respectively, simultaneously and at different times.

[0092] 10B is a conceptual diagram 620 illustrating an example press 622 and one or more example ultrasonic transducers 624a, 624b integrated with the press 622 that can be used to manufacture a composite wood product using ultrasonic energy. In some embodiments, the ultrasonic transducers 624a, 624b and the press 622 can each simultaneously deliver ultrasonic energy and one or more compressive forces to the plurality of wood elements 626. The example of FIG. 10B illustrates four ultrasonic transducers 624a integrated with the press 622 and positioned to deliver ultrasonic energy in a first direction (e.g., in this example, from a position above the plurality of wood elements downward) toward the plurality of wood elements 626 when the plurality of wood elements 626 are at a target position 627. The example of Fig. 10B shows one ultrasonic transducer 624b integrated with the press 622 and arranged to supply ultrasonic energy towards the wood elements 626 from a second direction (e.g., lateral, i.e., from the right to the left of the wood elements in this example) when the wood elements 626 are at the target position 627. The example of Fig. 10B shows the wood elements 626 (four wood sheets arranged in a 2x2 (2 height x 2 width) arrangement, although any wood element discussed herein could be used instead) on a conveyor 628 that can move the wood elements 626 to the target position 627.

[0093] In this example, the press 622 can apply a downward compressive force 630 to the wood elements 626, for example, when the wood elements 626 are at the target position 627. The press 622 includes a first surface 631 that can apply the downward compressive force 630 to the wood elements 626. In this example, the press 622 can also apply a lateral compressive force 632 to the wood elements 626, for example, when the wood elements 626 move to the target position 6. In this example, the lateral compressive force 632 can be a leftward compressive force applied by the press 622 from the right of the wood elements 626 when the wood elements are at the target position 627. The press 602 includes a second surface 633 that can apply the lateral force 632 to the wood elements 626. In some examples, the lateral compressive force may be a rightward compressive force applied by the press 622 (e.g., using a surface of the press opposite the second surface 633 in FIG. 10B ) from the left of the plurality of wood elements 626 when the plurality of wood elements is located at the target position 627. In some examples, two lateral compressive forces may be applied by the press 622. For example, according to some embodiments, both a leftward lateral compressive force and a rightward lateral force may be applied by the press 622.

[0094] In some examples, press 622 can apply one or more downward forces (e.g., force 630) and one or more lateral forces (e.g., force 632, or other lateral forces described above) simultaneously. In some examples, press 622 can apply one or more downward forces and one or more lateral forces at different times. For example, press 622 may apply downward force 630 first and then lateral force 632 (or other lateral force). As another example, press 622 may apply lateral force 632 (or other lateral force) first and then apply downward force 630.

[0095] In some examples, the ultrasonic transducer 624a can be positioned flush with a first surface 631 of the press 622 that can apply a downward compressive force 630 to the plurality of wood elements 626. In some examples, the ultrasonic transducer 624a can be positioned recessed relative to the first surface 631 of the press 622. Similarly, in some examples, the ultrasonic transducer 624b can be positioned flush with a second surface 633 of the press 622 that can apply a lateral compressive force 632 to the plurality of wood elements 626, and in some examples, the ultrasonic transducer 624b can be positioned recessed relative to the second surface 633. In this example, the press 622 and the ultrasonic transducers 624a, 624b may provide one or more compressive forces 630, 632 and ultrasonic energy, respectively, in a first direction (e.g., downward relative to the target location 627 in this example) and in a second direction (e.g., lateral relative to the target location 627 in this example). In some examples, the press 622 and ultrasonic transducers 624a, 624b can provide one or more compressive forces and ultrasonic energy, respectively, at different times, for example in a similar manner as described above with reference to FIG. 10A.

[0096] 10C is a conceptual diagram 640 of an example press 642 and one or more example ultrasonic transducers 644a, 644b integrated with the press 642 that can be used to manufacture a composite wood product using ultrasonic energy. In some implementations, the ultrasonic transducers 644a, 644b and the press 642 can simultaneously deliver ultrasonic energy and one or more compressive forces to the wood elements 646, respectively. The example of FIG. 10C shows three ultrasonic transducers 644a integrated with the press 642 and positioned to deliver ultrasonic energy in a first direction (e.g., downward from a position on the wood elements in this example) toward the wood elements 646 when the wood elements 646 are at a target position 647. The example of Fig. 10C shows three ultrasonic transducers 644b integrated with the press 642 and arranged to supply ultrasonic energy towards the plurality of wood elements 646 from a second direction (e.g., from a position in front of the plurality of wood elements 646 to a rearward direction when the wood elements are at the target position 647). The example of Fig. 10C shows the wood elements 646 (four wood strips arranged in a 2x2 (2 heights x 2 widths) although any of the wood elements discussed herein can be used instead) on a conveyor 648 that can move the plurality of wood elements 646 to the target position 647.

[0097] In this example, the press 642 can apply a downward compression force 650 to the wood elements 646, for example, when the wood elements 646 are at the target position 647. The press 642 includes a first surface 651 that can apply the downward compression force 650. In this example, the press 642 can also apply a rearward compression force 652 to the wood elements 646, for example, when the wood elements 646 are at the target position 647. In this example, the rearward compression force 652 can be applied by the press 622 from a position in front of the wood elements 646, when the wood elements are at the target position 647. The press 642 includes a second surface 653 that can apply the rearward compression force 652 to the wood elements 646. In some examples, the press can apply a forward compression force from a position behind the wood elements 646 (for example, using a surface of the press opposite to the second surface 653 in FIG. 10C ) when the wood elements are at the target position 647. In some examples, the press 622 can apply both a rearward force and a forward force to the multiple wood elements.

[0098] In some examples, press 642 can apply one or more downward forces (e.g., force 650) and one or more other forces (e.g., force 652, or other forces described above) simultaneously. In some examples, press 642 can apply one or more downward forces and one or more other forces at different times. For example, press 642 may apply downward force 650 first and then apply rearward force 652 (or forward force, or other force). As another example, press 642 may apply rearward force 652 (or forward force, or other force) first and then apply downward force 650.

[0099] In some examples, the ultrasonic transducer 644a can be positioned flush with a first surface 651 of the press 642 that can apply a downward compressive force 650 to the plurality of wood elements 646. In some examples, the ultrasonic transducer 644a can be positioned recessed relative to the first surface 651 of the press 642. Similarly, in some examples, the ultrasonic transducer 644b can be positioned flush with a second surface 653 of the press 642 that can apply a backward compressive force 652 to the plurality of wood elements 646. In some examples, the ultrasonic transducer 644b can be positioned recessed relative to the second surface 653. In this example, the press 642 and the ultrasonic transducers 644a, 644b can provide one or more compressive forces 650, 652 and ultrasonic energy in a first direction (e.g., downward relative to the target position 647 in this example) and a second direction (e.g., backward relative to the target position 647 in this example), respectively. In some examples, the press 642 and ultrasonic transducers 644a, 644b can each provide one or more compressive forces and ultrasonic energy at different times, for example in a manner similar to that described above with reference to FIG. 10A.

[0100] 10B and 10C show that ultrasonic energy can be supplied to the wood elements from more than one direction according to some implementations. For example, the examples of Fig. 10B and 10C show that ultrasonic energy can be supplied to the wood elements from a downward direction (e.g., from a position approximately above the wood elements) and from another direction different from the downward direction (e.g., from a position to the left or right of the wood elements, laterally, e.g., from a position in front of the wood elements to a rearward direction, and, e.g., from a position in the rear of the wood elements to a forward direction).

[0101] FIG. 11A is a block diagram illustrating an environment 670 for manufacturing a composite wood product using ultrasonic energy. The environment 670 includes the filler application area 104 and ultrasonic energy application area 106, as described above with reference to FIG. 1 and other figures, including the components included in the areas 104 and 106, and also includes a defect inspection area 672. In some examples, after joining the multiple wood elements into a composite wood product, defect inspection of the composite wood product can be performed in the defect inspection area 672. In various embodiments, the defect inspection can include supplying ultrasonic energy to the composite wood product. In some examples, this additional ultrasonic energy can be supplied by the same ultrasonic transducer or transducers that supply ultrasonic energy to the multiple wood elements in joining the wood elements. In some examples, this additional ultrasonic energy can be supplied by one or more ultrasonic transducers that are different from the ones that supply ultrasonic energy to the multiple wood elements in joining the wood elements.

[0102] The defect inspection area 672 can include a defect inspection component that supplies ultrasonic energy (e.g., via one or more ultrasonic transducers) to the composite wood product to inspect the product for defects. In some examples, the defect inspection component can include one or more cameras. In some examples, the ultrasonic energy may be supplied by one or more ultrasonic transducers that are separate from the defect inspection component. Although not shown in FIG. 11A for simplicity, in some implementations, one or more of the compressive force application areas 552 shown in FIG. 8 and the wood element preparation area 102 of FIG. 1 can be included in the environment 670.

[0103] 11B is a block diagram illustrating an environment 680 for manufacturing a composite wood product using ultrasonic energy. The environment 680 includes the filler application area 104 and the ultrasonic energy delivery area 106, respectively, as described above with reference to FIG. 1 and other figures, including components that may be included in areas 104 and 106, and also includes a composite wood product treatment area 682. In some examples, after multiple wood elements are joined into a composite wood product, the composite wood product may be subjected to a treatment performed in the composite wood product treatment area 682.

[0104] In various embodiments, applying a treatment to the composite wood product can include supplying ultrasonic energy to the composite wood product. This additional ultrasonic energy can be supplied, in some examples, by the same ultrasonic transducer or transducers that supply ultrasonic energy to the wood elements in the joining of the wood elements. In some examples, this additional ultrasonic energy can be supplied by a different ultrasonic transducer or transducers than those that supply ultrasonic energy to the wood elements in the joining of the wood elements.

[0105] Examples of treatments that can be applied to the composite wood product can include one or more sealants, fire retardant treatments, insect or pest repellent treatments, stains, paints, or other post-treatments, and as described, such treatments may include providing ultrasonic energy to the composite wood product. In some examples, edge treatments may be applied to the composite wood product, and as described, such treatments may also include providing ultrasonic energy to the composite wood product. In some examples, ultrasonic energy can provide one or more advantages over treatments similar to those described above with respect to fillers. For example, ultrasonic energy can stimulate spreading or penetration or deeper penetration of the treatment into the composite wood product, or can stimulate better flow of the treatment for liquid or flowable treatments.

[0106] The composite wood product treatment area 682 can include a treatment application component capable of applying a treatment to the composite wood product. In some examples, the treatment application component can include one or more of a roller, a brush, a spray applicator, and the like. In some examples, the treatment application component can provide ultrasonic energy (e.g., via one or more ultrasonic transducers) to the composite wood product. In some examples, the ultrasonic energy can be provided by one or more ultrasonic transducers separate from the treatment application component. Although not shown in FIG. 11B for simplicity, it will be understood that in some implementations, one or more of the compressive force application areas 552 of FIG. 8, the wood element preparation area 102 of FIG. 1, and the defect inspection area 672 of FIG. 11A can also be included in the environment 680.

[0107] FIG. 11C is a block diagram illustrating an environment 690 for manufacturing a composite wood product using ultrasonic energy. The environment 690 includes the filler application area 104 and the ultrasonic energy supply area 106, which include components that can be included in the areas 104 and 106, respectively, as described above with reference to FIG. 1 and other figures, and also includes a pretreatment area 692. In some examples, a pretreatment can be applied to the plurality of wood elements prior to applying the filler to the plurality of wood elements, which can be performed in the pretreatment area 692 and includes supplying ultrasonic energy to the plurality of wood elements. In some examples, such pretreatment with ultrasonic energy can clean the wood elements. For example, the cleaning helps to remove dirt and other impurities from the wood elements. The pretreatment area 692 can include a pretreatment supply component. According to some embodiments, the pretreatment of the wood elements can include supplying ultrasonic energy at an ultrasonic energy level that is lower than the ultrasonic energy level used in joining the plurality of wood elements. For example, one or more ultrasonic transducers can supply ultrasonic energy to the plurality of wood elements as a pretreatment of the plurality of wood elements. This pre-treatment supply of ultrasonic energy, in some examples, can be provided by the same ultrasonic transducer or transducers that provide ultrasonic energy to the wood elements in joining the wood elements. In some examples, this pre-treatment supply of ultrasonic energy can be provided by one or more ultrasonic transducers that are different from the ones that provide ultrasonic energy to the wood elements in joining the wood elements. Although not shown in FIG. 11C for simplicity, in some implementations, it is understood that one or more of the compressive force application regions 552 of FIG. 8, the wood element preparation region 102 of FIG. 1, the defect inspection region 672 of FIG. 11A, and the composite wood product treatment region 682 of FIG. 11B may also be included in the environment 690.

[0108] In some examples, an ultrasonic transducer including a roller element can be used to deliver ultrasonic energy to a plurality of wood elements. The roller element can have a variety of shapes and sizes depending on the embodiment. For example, in some embodiments, the roller element can include a cylindrical body. In some embodiments, the roller element can include a spherical body. In some examples, the roller element body can include an outer surface configured to physically contact the plurality of wood elements while delivering ultrasonic energy. In some examples, the roller element body can include an outer surface configured to physically contact and roll against the plurality of wood elements while delivering ultrasonic energy. In some examples, the roller element body outer surface can be substantially smooth. In some examples, the roller element body outer surface can include a plurality of protrusions. In some examples, the roller element body outer surface can include a plurality of recessed features. In some examples, the roller element body outer surface can include one or more protrusions and one or more recessed features.

[0109] 12A is a conceptual diagram of an example environment 700 for producing a composite wood product using ultrasonic energy, including an example ultrasonic transducer 704 including an example roller element 706. The environment 700 includes an example filler applicator 702, an example ultrasonic transducer 704, and an example roller element 706. The filler applicator 702 can apply filler to a plurality of wood elements 708 in a manner similar to that described above with reference to the applicator 158 of FIG. 3A. In the example shown in FIG. 12A, the applicator 702 is a spray nozzle, although any other type of applicator described herein (e.g., one or more brushes, rollers, or other types of applicators) could be used instead.

[0110] The wood elements 710 may be arranged adjacent to each other. For example, the wood elements 710 may be stacked vertically, arranged horizontally, or arranged in any suitable manner. In the example shown in FIG. 12A, the wood elements, which in this example are wood veneers, may be arranged in a 2×2. In some examples, the wood elements 710 include one or more elements 712 to which a filler material has been applied by the applicator 702. In some examples, the wood elements 710 include one or more elements 712 to which a filler material has been applied and one or more wood elements to which no filler material has been applied. Also, in some examples, the wood elements 710 do not include a filler material. The wood elements 710 may be placed on a conveyor 714 and may move on the conveyor 714 in a direction 716. The conveyor 714 may move the wood elements 710 to a target position 717 relative to the ultrasonic transducer 704, the roller element 706, or both the ultrasonic transducer 704 and the roller element 706.

[0111] According to some examples, ultrasonic energy may be generated by an ultrasonic transducer 704 and may be provided to the plurality of wood elements 710 via a roller element 706. The ultrasonic energy may be directed from the ultrasonic transducer 704 to the roller element 706 by an exemplary ultrasonic horn 718 that may be coupled to the ultrasonic transducer 704 and configured to direct the ultrasonic energy from the ultrasonic transducer 704 to the roller element 706. The roller element 706 may rotate about an axis, such as an axle 720, that may couple the roller element 706 to the horn 718. In some examples, the roller element 706 may rotate in a first direction 722 about the axle 720. For example, the first direction 722 may be a clockwise direction. In some examples, the first direction 722 may be a clockwise direction relative to the axle 720. In some examples, the roller element 706 may rotate in a second direction 724 about the axle 720. For example, the second direction 724 may be a counterclockwise direction. In some examples, the second direction 724 may be a counterclockwise direction relative to the axle 720. In some examples, the roller element 706 may rotate in both the first direction 722 and the second direction 724 about the axle 720. In some examples, the second direction 724 may be opposite the first direction 722.

[0112] In some examples, the roller element 706 may include a cylindrical body 726, and an outer surface 728 of the cylindrical body 726 may be configured to physically contact one or more wood elements of the plurality of wood elements 710 while ultrasonic energy is supplied to the plurality of wood elements 710. For example, the roller element 706 may rotate about its axis in a first direction 722 or a second direction 724, and as the cylindrical body 726 of the roller element 706 rotates, the outer surface 728 of the cylindrical body 726 of the roller element 706 may physically contact one or more wood elements of the plurality of wood elements 710. In the example shown in FIG. 12A, it can be seen that as the roller element 706 rolls across the top surface of the plurality of wood elements 710, the outer surface 728 will contact two wood elements of the plurality of wood elements 710 (e.g., the top two elements of a 2×2 stack).

[0113] FIG. 12B is a conceptual diagram of another exemplary ultrasonic transducer 730 including another exemplary roller element 732. The ultrasonic transducer 730 may be the same as the ultrasonic transducer 704 described above with reference to FIG. 12A. The ultrasonic transducer 730 may generate ultrasonic energy that may be directed from the ultrasonic transducer 730 to the roller element 732 by an exemplary ultrasonic horn 734 that may be coupled to the ultrasonic transducer 730 and configured to direct the ultrasonic energy from the transducer 730 to the roller element 732. In this example, the roller element 732 includes a spherical body 736. That is, the roller element 732 may have a generally spherical shape. An outer surface 738 of the spherical body 736 may be in physical contact with one or more of the plurality of wood elements 737 of the plurality of wood elements. Similar to the roller element 706 of FIG. 12A, the roller element 732 can roll on the wood element, but in some embodiments, the spherical body 736 of the roller element 732 can roll in any number of directions 739a, 739b, 739c, 739d, 739e, 739f, 739g, 739h, 7391, 739j, etc., similar to the way a ball used in early computer mice rolls on a mouse pad. For example, according to some implementations, the roller element 732 can rotate in any direction in a two-dimensional plane. According to some embodiments, one or more exemplary support members 740 can mechanically support the spherical body 736 of the roller element 732. In some examples, the support member 740 can be a roller. In some examples, the support member 740 can be a pad, cushion, stop, or other suitable component for at least partially holding the roller element 732 against the horn 734. In some examples, there may be more or fewer support members 740 than shown in Figure 12B. In some examples, the ultrasonic transducer 730, horn 734 and roller element 732 can be replaced with the ultrasonic transducer 704, horn 718 and roller element 706 of Figure 12A.

[0114] In some examples, ultrasonic energy can be provided to the plurality of wood elements via roller element 706 or 732. In various embodiments, ultrasonic energy can have a frequency in the range of 10 kHz to 20 MHz. In some examples, ultrasonic energy can have a frequency in the range of 15 kHz to 1 MHz, or in the range of 20 kHz to 100 kHz. In some examples, ultrasonic energy can be radiated from exterior surface 728 or 738 to the plurality of wood elements 710. According to various implementations, ultrasonic energy can be transferred from roller element 706 or 732 to the plurality of wood elements 710 by one or more of ultrasonic longitudinal waves, ultrasonic radial waves, or ultrasonic transverse waves. In some examples, at least a portion of exterior surface 728 or 738 can remain in physical contact with at least one of the plurality of wood elements 710 while ultrasonic energy is provided. In some examples, ultrasonic energy will continue to be supplied even when outer surface 728 or 738 is not in physical contact with any of the plurality of wood elements 710, e.g., before, after, or both before and after outer surface 728 or 738 contacts the wood element.

[0115] In some examples, the system including the ultrasonic transducer 704 or 730 and the roller element 706 or 732, respectively, can stimulate the bonding of the wood elements by providing ultrasonic energy to the plurality of wood elements 710. As described above herein with reference to other systems for manufacturing composite wood products using ultrasonic energy, the ultrasonic energy provided can provide various mechanical stimuli (e.g., vibration stimuli at molecular and macro levels) to the plurality of wood elements 710 and the filler material, thermal stimuli to the plurality of wood elements 710, diffusion stimuli to the filler material, and further, friction generated between the wood elements due to the provision of ultrasonic energy can further stimulate bonding. The sonication pressure (e.g., pressure from ultrasonic waves) due to the provision of ultrasonic energy will also stimulate the bonding of the plurality of wood elements. Advantageously, the ultrasonic transducer 704 or 730 and the roller element 706 or 732, respectively, can continuously stimulate the plurality of wood elements 710 and the filler material, which will beneficially assist in bonding.

[0116] The roller elements 706 or 732 can include any suitable material. In some examples, the roller elements 706 or 732 include titanium. In some examples, the roller elements 706 or 732 include aluminum. In some examples, the roller elements 706 or 732 can provide a compressive force to the plurality of wood elements 710 when the outer surface 728 or 738 rolls over the wood elements. In some examples, the roller elements 706 or 732 may not provide a compressive force to the plurality of wood elements when the outer surface 728 or 738 rolls over the wood elements.

[0117] In some embodiments, the ultrasonic transducer 704 or 730 may move simultaneously with the roller element 706 or 732 as it rolls over the multiple wood elements 710. FIG. 12C is a conceptual diagram illustrating an environment 742 for manufacturing a composite wood product using ultrasonic energy. According to some implementations, an exemplary ultrasonic transducer 743 includes an exemplary horn 744 and an exemplary roller element 745, which may represent the transducer 704 or 730, the horn 718 or 734, and the roller element 706 or 732 of FIGS. 12A and 12B, respectively. In some implementations, an exemplary motion controller 746 may control the motion of the transducer 743. In some examples, the motion controller 746 may control the motion of the transducer 743, which in turn may control the motion of the horn 744 and the roller element 745. The motion controller 746 may include one or more motors (e.g., a servo motor, a stepper motor, a linear motor, a direct drive motor, an AC motor, or a DC motor, just to name a few) and may include a motion control module that provides one or more signals to the one or more motors to control the movement of the ultrasonic transducer 743. In the example of FIG. 12C, the motion controller 746 is shown separate from the ultrasonic transducer 743, but in some implementations the motion controller 746 may be integral with the ultrasonic transducer 743.

[0118] The motion controller 746 can control the ultrasonic transducer 743 to move in various directions or patterns depending on the application. In some examples, the motion controller 746 can command the ultrasonic transducer 743 (and in some examples, the horn 744 and the roller element 745) to move linearly 748 (e.g., forward, backward, or back and forth, respectively). In some examples, the ultrasonic transducer 743 can be configured to move in a single axis motion system. In some examples, the motion controller 746 can command the ultrasonic transducer 743 (and in some examples, the horn 744 and the roller element 745) to move in a two-dimensional pattern (e.g., move in a two-dimensional plane), such as a pattern covering the surface of one or more wood elements of a plurality of wood elements. In some examples, the motion controller 746 can command the ultrasonic transducer 743 to move in a three-dimensional pattern (e.g., move in three-dimensional space). 12C shows a pattern 749 that is intended to show that the ultrasonic transducer in some examples (and, by extension, the horn 744 and roller element 745 in some examples) can move in any direction in three-dimensional space; for simplicity, arrows pointing out of and into the page are not shown in the pattern 749. In some examples, the ultrasonic transducer 743 (and, in some examples, the horn 744 and roller element 745) can be configured to move in a multi-axis motion system, such as a two-axis motion system or a three-axis motion system.

[0119] In some examples, the operation controller 746 can include one or more of a processing component, a communication module, a memory, a power module, and one or more sensors. Although not shown in Figure 12C for simplicity, in some examples, the operation controller 746 can include one or more of the processing component 872, the communication module 874, the memory 876, the power module 878, and one or more sensors 880 of Figure 15B, which can be used to provide the operation control functions described above, as described in more detail below with reference to Figure 15B.

[0120] In some implementations, the ultrasonic transducer 743 can be configured to move along one or more tracks. In some embodiments, the ultrasonic transducer 743 can be configured to move along one or more rails or sliders. In some examples, the ultrasonic transducer 743 can be configured to move across a two-dimensional grid. In some examples, the ultrasonic transducer 743 can be configured to move across a two-dimensional grid set at a given height (or width or depth) or can be configured to move across a two-dimensional grid set at various heights (or widths or depths) (e.g., to move in three-dimensional space). Referring again to FIG. 12C, the ultrasonic transducer 743 can be configured to move along or across a motion guide 747. In some examples, the motion guide 747 can be one or more rails, sliders, or tracks. In some examples, the motion guide 747 can be a two-dimensional grid. In some examples, the motion guide 747 may be a movable two-dimensional grid that is movable in a third dimension different from the two dimensions of the grid.

[0121] In some examples, the ultrasonic transducer may remain substantially stationary as the roller element rolls over the plurality of wood elements. According to some implementations, in some examples, the horn can be configured to expand or contract as the roller element rolls over the plurality of wood elements.

[0122] In some examples, both the horn and the roller element may be considered to be part of the ultrasonic transducer, and according to some examples, such part of the ultrasonic transducer may be in physical contact with the wood elements or the infill material while ultrasonic energy is being delivered to the plurality of wood elements. In some examples, the horn or the roller element may not be considered to be part of the ultrasonic transducer.

[0123] According to some examples, whether the roller elements include a cylindrical body or a spherical body, the exterior surface of each body can include various features. In some examples, the exterior surface of the cylindrical body 728 or the spherical body 738 can be substantially smooth, can include a number of protrusions, can include a number of recessed features, or can include one or more protrusions and one or more recessed features.

[0124] Figure 13A is a side view 750 of an example roller element 752, ultrasonic transducer 754, and horn 756, which may respectively represent the example roller element 706, ultrasonic transducer 704, and horn 718 of Figure 12A, and the example roller element 732, ultrasonic transducer 730, and horn 734 of Figure 12B. As shown in Figure 13A, an outer surface 758 of the body of roller element 752 is substantially smooth.

[0125] In some examples, the outer surface of the body of the roller element may include a plurality of protrusions. Figure 13B is a side view 760 of another example roller element 762, ultrasonic transducer 754, and horn 756, which may represent the roller element 706, ultrasonic transducer 704, and horn 718 of the example of Figure 12A, or the roller element 732, ultrasonic transducer 730, and horn 734 of the example of Figure 12B. As can be seen in Figure 13B, the outer surface 764 of the body of the roller element 762 includes a plurality of protrusions 766, which protrude from the outer surface 764.

[0126] In some examples, the outer surface of the body of the roller element may include a plurality of recessed features or features recessed relative to the surface of the roller element. Figure 13C is a side view 780 of another example roller element 782, ultrasonic transducer 754, and horn 756, which may represent roller element 706, ultrasonic transducer 704, and horn 718 of the example of Figure 12A, or roller element 732, ultrasonic transducer 730, and horn 734 of the example of Figure 12A, or the example of Figure 12B. As can be seen in Figure 13C, the outer surface 784 of the body of the roller element 782 includes a plurality of recessed features 786, which are recessed from the outer surface 784.

[0127] In various embodiments, the protrusions 766 or recesses 786 may have various shapes. FIG. 14A is a front view 800 and FIG. 14B is a top view 802 of an exemplary roller element 804 including a plurality of exemplary protrusions 806, 808, 810, 812, 814. The body of the roller element 804 has or includes an outer surface 805 from which the protrusions 806, 808, 810, 812, 814 extend or on which the protrusions 806, 808, 810, 812, 814 are located. The first protrusion 806 includes a rounded outer surface 807. In some examples, the first protrusion 806 may have an approximately "dome" shape. As can be seen from the top view 802 of FIG. 14B, the base of the first protrusion 806 is circular, although any other suitable shape (e.g., oval, square, rectangle, triangle, rhombus, diamond, or other suitable shape) can alternatively be used for the base of the protrusion 806 having a rounded outer surface 807.

[0128] The second protrusion 808 includes a substantially flat outer surface 809. As can be seen from the top view 802 in FIG. 14B, the base of the second protrusion 808 has a square shape, as does the outer surface 809 of the second protrusion 808, although any other suitable shape (e.g., oval, circular, rectangular, triangular, rhombus, diamond, or other suitable shape) may alternatively be used for the base or outer surface 809 of the protrusion 808 having the substantially flat outer surface 809. In some examples, the base and outer surface 809 of the second protrusion 808 may have different shapes, including combinations of any of the aforementioned shapes.

[0129] The third protrusion 810 has an outer surface that includes a point 811. In some examples, the point 811 may be the apex of the protrusion 810. In some examples, the third protrusion 810 may have an approximately "pyramid" shape. As can be seen from the top view 802 of FIG. 14B, the base of the third protrusion 810 has a square shape, although any other suitable shape (e.g., oval, circle, rectangle, triangle, rhombus, diamond, or other suitable shape) may alternatively be used for the base of the protrusion 810 having an outer surface that includes a point.

[0130] The fourth protrusion 812 has an outer surface that includes ridges 813. As can be seen from the top surface 802 in FIG. 14B, the base of the fourth protrusion 812 has a rectangular shape, although any other suitable shape (e.g., oval, circle, square, triangle, rhombus, diamond, or other suitable shape) can alternatively be used for the base of the protrusion 812 having an outer surface that includes ridges.

[0131] The fifth projection 814 includes an outer surface having the shape of a cylinder with a rounded top. The outer surface of the fifth projection 814 includes cylindrical sides 816 and a rounded top surface 815. As shown in the front view 800 of FIG. 14A, the rounded surface 815 is raised and offset from the surface 805 of the roller element 804 by the cylindrical sides 816. In some examples, the fifth projection 814 may have the shape of a raised dome or cylindrical silo. As can be seen from the top view 802 of FIG. 14B, the base of the fifth projection 814 is circular, although any other suitable shape (e.g., oval, square, rectangle, triangle, rhombus, diamond, or other suitable shape) may alternatively be used for the base of the fifth projection 814.

[0132] FIG. 14C is a front view 820, and FIG. 14D is a side view 820, showing an exemplary portion of an exemplary roller element 824 including an exemplary plurality of recesses 826, 828, 830, 832, 834. The body of the roller element 824 includes an outer surface 825 into which the recesses 826, 828, 830, 832, 834 are recessed or disposed. The first recess 826 includes a rounded surface 827. The first recess 826 may be concave. The first recess 826 may have a dimple shape. As can be seen from the top view 822 of FIG. 14D, the base of the first recess 826 is circular, although other suitable shapes (e.g., oval, square, rectangular, triangular, rhombus, diamond, or other suitable shapes) may alternatively be used for the base of the recess 826.

[0133] The second recess 828 includes a substantially flat outer surface 809. As can be seen from the top view 822 of FIG. 14D , the base of the second recess 828 has a square shape, as does the outer surface 829 of the second recess 828, although other suitable shapes (e.g., oval, circular, rectangular, triangular, rhombus, diamond, or other suitable shapes) may alternatively be used for the base or outer surface 829 of the recess 828. In some examples, the base and outer surface 829 of the second recess 828 may have different shapes, including a combination of any of the aforementioned shapes.

[0134] The third recess 830 has an outer surface that includes a point 831. In some examples, the point 831 may be the bottom of the recess 830. In some examples, the point 831 may be the inverted apex of the recess 830. As can be seen from the top view 822 of FIG. 14d, the base of the third recess 830 has a square shape, although any other suitable shape (e.g., oval, circle, rectangle, triangle, rhombus, diamond, or other suitable shape) may alternatively be used for the base of the recess 830 having an outer surface that includes a point.

[0135] The fourth recess 832 has an outer surface that includes a ridge 833, or a concave or inverted ridge. As can be seen from the top view 822 in Figure 14D, the base of the fourth recess 832 has a rectangular shape, although any other suitable shape (e.g., oval, circle, square, triangle, rhombus, diamond, or other suitable shape) could alternatively be used for the base of the recess 832 having an outer surface that includes a ridge.

[0136] The fifth recess 834 includes an outer surface 835 having the shape of a cylinder with a rounded bottom. The outer surface of the fifth recess 834 includes cylindrical sides 836 and a rounded bottom surface 835. As can be seen from the front view 820 of FIG. 14C, the rounded surface 835 is recessed and offset from the surface 825 of the roller element 824 by the cylindrical sides 836. In some examples, the fifth recess 834 may have a recessed dome or inverted cylindrical silo shape. As can be seen from the top view 822 of FIG. 14D, the base of the fifth recess 834 is circular, although other suitable shapes (e.g., oval, square, rectangular, triangular, rhombus, diamond, or other suitable shapes) can alternatively be used for the base of the recess 834.

[0137] In some examples, the exterior surface of the cylindrical body may include one or more protrusions and one or more recesses. Figure 14E is a front view 840 of an exemplary portion of an exemplary roller element 842 including one or more exemplary protrusions 806 and one or more exemplary recesses 826. The body of the roller element 842 includes an exterior surface 844 from which the protrusions 806 protrude and the recesses 826 are recessed or located.

[0138] In some examples, the devices, systems, and methods described herein may be used to provide varying or different amounts of ultrasonic energy to the wood elements, or to deliver ultrasonic energy to one or more target areas or locations within the wood elements, or to provide a combination thereof. In some examples, a first amount of ultrasonic energy may be provided to the wood elements, and then a second amount of ultrasonic energy may be requested from the wood elements. In some embodiments, the first amount of ultrasonic energy may have an intensity higher than an intensity of the second amount of ultrasonic energy. In some embodiments, the first amount of ultrasonic energy may have an intensity lower than an intensity of the second amount of ultrasonic energy. In some examples, the first amount of ultrasonic energy may be provided to the wood elements for a first period of time, and then the second amount of ultrasonic energy may be provided to the wood elements for a second period of time that is different from the first period of time (e.g., longer or shorter than the first duration).

[0139] In some examples, a first amount of ultrasonic energy can be delivered to a first target location on or within the wood elements, and then a second amount of ultrasonic energy can be delivered to a second target location on or within the wood elements. In some examples, the ultrasonic transducer may remain stationary through both the delivery of the first amount of ultrasonic energy to the first target location and the delivery of the second amount of ultrasonic energy to the second target location. In some examples, the ultrasonic transducer, or one or more portions of the ultrasonic transducer, may move or be moved while delivering the first amount of ultrasonic energy to the first target location, while delivering the second amount of ultrasonic energy to the second target location, or between the time of delivering the first amount and the second amount. As described above, various combinations of different amounts of ultrasonic energy may be included for different periods of time to target different locations on or within the wood elements.

[0140] FIG. 15A is a conceptual diagram 850 illustrating an example control module 852 and an ultrasonic transducer 854 providing ultrasonic energy to a plurality of example wood elements 856 to manufacture a composite wood product using ultrasonic energy. According to some examples, the example control module 852 can provide one or more control signals 857 to the example ultrasonic transducer 854 to control one or more of the amount of ultrasonic energy, the intensity of the ultrasonic energy, the duration of the ultrasonic energy, the depth of transmission of the ultrasonic energy, and the target location for the transmission of the ultrasonic energy. In general, the control module 852 can be used with any of the example ultrasonic systems described herein and can be used to provide one or more of the aforementioned control signals 857 to one or more ultrasonic transducers in any of the example systems described herein. In some examples, the control module 852 can provide one or more control signals to multiple ultrasonic transducers, but for simplicity, only one transducer 854 is shown in FIG. 15A.

[0141] The exemplary ultrasonic transducer 854 has a general shape and can represent any of the ultrasonic transducer shapes or topologies described herein. For example, the transducer 854 can represent any of the transducer and horn combinations discussed herein, and can also represent any of the transducer, horn, and roller element combinations discussed herein.

[0142] 15B is a block diagram 870 of the example control module 852 of FIG. 15A. The control module 852 includes a processing component 872, a communication module 874, a memory 876 (e.g., including retained data in some examples), and a power module 878. The processing component 872 may include one or more microcontrollers, microprocessors, or digital signal processors in some examples and may execute instructions stored in the memory 876 to perform tasks for the control module 852. The communication module 874 may include a transmitter to transmit information in some examples directly, via a wired connection, and in some examples, via wired or wireless communication across one or more networks (e.g., a local area network (LAN), a wide area network (WAN), the Internet, a Wi-Fi network, a cellular network, a virtual private network (VPN), a mobile data network (e.g., a 3G / 4G / 5G network, a combination of the foregoing, etc.)).

[0143] In some examples, the communications module 874 includes a receiver that can be used to receive messages from other devices or systems. The memory 876 may include one or more types of volatile or non-volatile memory, including random access memory (RAM), read only memory (ROM), flash memory, storage devices (e.g., solid state hard drives, hard disk drives), and / or other forms of volatile or non-volatile memory, in various examples.

[0144] The power supply module 878 can provide one or more power supply voltages to power components of the control module 852 or other devices or components (e.g., in some examples, the transducer 854). In some examples, the power supply module 878 can receive alternating current (AC) power, such as from a wall outlet, and convert the AC power to a supply voltage usable by the control module 852 or other devices or components. In some examples, the power supply module 878 includes a battery, which in some examples is rechargeable.

[0145] In some examples, the control module 852 includes one or more sensors 880, such as one or more sensors capable of detecting when one or more wood elements are in a target position for delivery of ultrasonic energy. In some examples, the one or more sensors 880 can sense an ambient environmental parameter, such as one or more of temperature, humidity, air pressure, air quality, or other environmental parameters. In some examples, the control module 852 can receive input from one or more external sensors or one or more external devices in contact with the one or more external sensors, and such input can provide the control module 852 with information regarding any of the aforementioned sensor parameters. For example, the control module 852 can receive input from an external sensor indicating that one or more wood elements are in a target position for delivery of ultrasonic energy.

[0146] The ultrasonic delivery control module 882 can be used to manage or control aspects of the ultrasonic energy delivery to the plurality of wood elements 856. For example, the ultrasonic delivery control module 882 can generate one or more control signals 857 shown in FIG. 15A. In various examples, the ultrasonic delivery control module 882 can use inputs from one or more sensors 880, from the communication module 874, and from the memory 876, and can use the processing component 872 to manage or control aspects of the ultrasonic energy delivery. Although FIG. 15B illustrates the ultrasonic delivery control module 882 as a stand-alone module for simplicity, in some implementations, the module 882 can be included within the processing component 872. Although FIG. 15A illustrates the control module 852 in a separate housing from the transducer 854, in some examples, the control module 852, or one or more portions of the control module 852, can be located within the transducer 854.

[0147] 15A, the control module 852 can instruct the ultrasonic transducer 854, for example, via one or more control signals 857, to deliver varying amounts of ultrasonic energy to a plurality of wood elements 856, which in this example includes wood elements 858a, 858b, 858c arranged vertically in the same manner as the wood elements of FIG 4. In some examples, the control module 852 can instruct the ultrasonic transducer 854, for example, via one or more control signals 857, to deliver ultrasonic energy to various positions or portions of the plurality of wood elements 856.

[0148] The control module can direct the supply of a first amount of ultrasonic energy 860 to a first location or portion of the plurality of wood elements, such as, for example, wood elements 858a, 858b, and 858c. This can stimulate, for example, bonding of wood elements 858a, 858b, and 858c. The control module can then direct the supply of a second amount of ultrasonic energy 862, such as a lesser amount of ultrasonic energy, to a second location or portion of the plurality of wood elements, such as, for example, wood element 858d, which can stimulate bonding of element 858d to element 858c. Each of elements 858a, 858b, and 858c can be one type of wood element, such as, for example, a wood strand, and element 858d can be another type of wood element, such as, for example, a wood veneer. Wood veneer 858d, for example, may be more delicate than wood strands 858a, 858b, 858c and may advantageously benefit from a lesser amount of ultrasonic energy 860 delivered in stimulating bonding to element 858c, for example. In some examples, control module 852 may include motion controller 746, shown in FIG. 12C, which may provide motion control functionality to ultrasonic transducer 854.

[0149] In a general aspect, a system for producing a composite wood product includes an applicator configured to apply a filler material to a plurality of wood elements and an ultrasonic transducer configured to deliver ultrasonic energy to the plurality of wood elements, the ultrasonic energy having a frequency within a frequency range of 10 kHz to 20 MHz.

[0150] Embodiments may include one or more of the following: A plurality of wood elements may be joined into a composite wood product. The applicator may include an adhesive applicator and the filler may include an adhesive. The filler may be free of an adhesive. The filler may include a plastic. The filler may include a metal. The plurality of wood elements may be positioned proximate to one another before the ultrasonic transducer supplies ultrasonic energy to the plurality of wood elements. The applicator may apply the filler to the plurality of wood elements at the same time that the ultrasonic transducer supplies ultrasonic energy to the plurality of wood elements. The ultrasonic transducer may supply ultrasonic energy to the plurality of wood elements before the applicator applies the filler to the plurality of wood elements. The ultrasonic transducer may supply ultrasonic energy to the plurality of wood elements after the applicator applies the filler to the plurality of wood elements. The system may include a press configured to apply a compressive force to the plurality of wood elements. The press may apply a compressive force to the plurality of wood elements before the ultrasonic transducer supplies ultrasonic energy to the plurality of wood elements. The press can apply a compressive force to the plurality of wood elements simultaneously as the ultrasonic transducer delivers ultrasonic energy to the plurality of wood elements. The press can apply a compressive force to the plurality of wood elements after the ultrasonic transducer delivers ultrasonic energy to the plurality of wood elements. The ultrasonic energy can have a frequency within a frequency range of 15 kHz to 1 MHz. The ultrasonic energy can have a frequency within a frequency range of 20 kHz to 100 kHz. The system can further include a defect inspection component, and the ultrasonic transducer can be further configured to deliver an additional amount of ultrasonic energy to the composite wood product, and the defect inspection component can be configured to inspect the composite wood product for defects. The defect inspection component can include a camera. The system can further include the defect inspection component and a second ultrasonic transducer, and the second ultrasonic transducer can be configured to deliver ultrasonic energy to the composite wood product, and the defect inspection component can be configured to inspect the composite wood product for defects.The defect inspection component may include a camera. The ultrasonic transducer may be further configured to provide ultrasonic energy to the plurality of wood elements before the applicator applies the filler to the plurality of wood elements. The plurality of wood elements may be cleaned by providing ultrasonic energy to the plurality of wood elements before the applicator applies the filler to the plurality of wood elements. The system may further include a treatment applicator configured to apply a treatment to the composite wood product, and the ultrasonic transducer may further be configured to provide an additional amount of ultrasonic energy to the composite wood product. The system may further include a treatment applicator and a second ultrasonic transducer, and the treatment applicator may be configured to apply a treatment to the composite wood product, and the second ultrasonic transducer may be configured to provide ultrasonic energy to the composite wood product. The ultrasonic transducer may be selected from the group of a Langevin transducer, a ring transducer, a cymbal transducer, a dome transducer, a horn transducer, a pyramid transducer, a wedge transducer, and a spherical transducer. The ultrasonic transducer may generate the ultrasonic energy as a square wave. The ultrasonic transducer may generate the ultrasonic energy as a sine wave. The ultrasonic transducer may generate the ultrasonic energy as a wave selected from the group consisting of a trapezoidal wave and a triangular wave. The ultrasonic transducer may generate the ultrasonic energy as a continuous waveform. The ultrasonic transducer may generate the ultrasonic energy as a pulsed waveform. The system may further include a conveyor configured to transport the plurality of wood elements. The system may further include a funnel configured to direct the plurality of wood elements onto the conveyor. The system may further include a chamber configured to accommodate the plurality of wood elements.

[0151] In a general aspect, a system for manufacturing a composite wood product includes an applicator configured to apply a filler material to a plurality of wood elements and an ultrasonic transducer configured to generate ultrasonic energy, the ultrasonic energy having a frequency within a frequency range of 10 kHz to 20 MHz. The system also includes a roller element including a cylindrical body configured to rotate about an axis, the cylindrical body including an outer surface. The system further includes an ultrasonic horn configured to direct the ultrasonic energy to the roller element, the roller element configured to deliver the ultrasonic energy to the plurality of wood elements, the roller element configured such that the outer surface of the cylindrical body remains in physical contact with at least one wood element of the plurality of wood elements when the ultrasonic energy is delivered.

[0152] Embodiments may include one or more of the following: The outer surface of the cylindrical body may be substantially smooth. The outer surface of the cylindrical body may include a plurality of recesses. The outer surface of the cylindrical body may include a plurality of indentations. The outer surface of the cylindrical body may include a plurality of protrusions. At least one protrusion of the plurality of protrusions may include a rounded outer surface. At least one protrusion of the plurality of protrusions may include a substantially flat outer surface. At least one protrusion of the plurality of protrusions may include an outer surface including a point. At least one protrusion of the plurality of protrusions may have an outer surface including a ridge. The plurality of wood elements may be joined into a composite wood product. The applicator may include an adhesive applicator and the filler material may include an adhesive. The filler material may be free of an adhesive. The filler material may include a plastic. The filler material may include a metal. The plurality of wood elements may be positioned adjacent to one another before the roller element delivers ultrasonic energy to the plurality of wood elements. The applicator may apply the filler material to the plurality of wood elements simultaneously as the roller element delivers ultrasonic energy to the plurality of wood elements. The roller element may supply ultrasonic energy to the plurality of wood elements before the applicator applies the filler material to the plurality of wood elements. The roller element may supply ultrasonic energy to the plurality of wood elements after the applicator applies the filler material to the plurality of wood elements. The system may further include a press configured to apply a compressive force to the plurality of wood elements. The press may apply a compressive force to the plurality of wood elements before the roller element supplies ultrasonic energy to the plurality of wood elements. The press may apply a compressive force to the plurality of wood elements at the same time that the roller element supplies ultrasonic energy to the plurality of wood elements. The press may apply a compressive force to the plurality of wood elements after the roller element supplies ultrasonic energy to the plurality of wood elements. The ultrasonic energy may have a frequency in a frequency range of 15 kHz to 1 MHz. The ultrasonic energy may have a frequency in a frequency range of 20 kHz to 100 kHz.The system may further include a defect inspection component, and the roller element may be further configured to supply ultrasonic energy to the composite wood product, and the defect inspection component may be configured to inspect the composite wood product for defects. The defect inspection component may include a camera. The roller element may be configured to supply ultrasonic energy to the plurality of wood elements before the applicator applies the filler to the plurality of wood elements. Supplying ultrasonic energy to the plurality of wood elements may clean the plurality of wood elements before the applicator applies the filler to the plurality of wood elements. The system may further include a treatment applicator configured to apply a treatment to the composite wood product, and the roller element may be further configured to supply ultrasonic energy to the composite wood product. The ultrasonic transducer may generate the ultrasonic energy as a square wave. The ultrasonic transducer may generate the ultrasonic energy as a sine wave. The ultrasonic transducer may generate the ultrasonic energy as a wave selected from the group consisting of a trapezoidal wave and a triangular wave. The ultrasonic transducer may generate the ultrasonic energy as a continuous waveform. The ultrasonic transducer may generate the ultrasonic energy as a pulsed waveform. The system may further include a conveyor configured to transport the plurality of wood elements. The system may further include a funnel configured to direct the plurality of wood elements onto the conveyor. The system may further include a chamber configured to accommodate the plurality of wood elements.

[0153] In a general aspect, a system for manufacturing a composite wood product includes an applicator configured to apply a filler material to a plurality of wood elements and an ultrasonic transducer configured to generate ultrasonic energy, the ultrasonic energy having a frequency within a frequency range of 10 kHz to 20 MHz. The system includes a roller element having a spherical body, the spherical body including an outer surface. The system further includes an ultrasonic horn configured to direct the ultrasonic energy to the roller element, the roller element configured to deliver the ultrasonic energy to the plurality of wood elements, the roller element configured such that a portion of the outer surface of the spherical body remains in physical contact with at least one wood element of the plurality of wood elements when the ultrasonic energy is delivered.

[0154] Embodiments may include one or more of the following: The outer surface of the spherical body may be substantially smooth. The outer surface of the spherical body may include a plurality of recesses. The outer surface of the spherical body may include a plurality of indentations. The outer surface of the spherical body may include a plurality of protrusions. At least one of the plurality of protrusions may include a rounded outer surface. At least one of the plurality of protrusions may include a substantially flat outer surface. At least one of the plurality of protrusions may include an outer surface including a point. At least one of the plurality of protrusions may have an outer surface including a ridge. The plurality of wood elements may be joined into a composite wood product. The applicator may include an adhesive applicator and the filler material may include an adhesive. The filler material may be free of an adhesive. The filler material may include a plastic. The filler material may include a metal. The plurality of wood elements may be positioned adjacent to one another before the roller element delivers ultrasonic energy to the plurality of wood elements. The applicator may apply the filler material to the plurality of wood elements simultaneously as the roller element delivers ultrasonic energy to the plurality of wood elements. The roller element can deliver ultrasonic energy to the plurality of wood elements before the applicator applies the filler to the plurality of wood elements. The roller element can deliver ultrasonic energy to the plurality of wood elements after the applicator applies the filler to the plurality of wood elements. The system can further include a press configured to apply a compressive force to the plurality of wood elements. The press can deliver the compressive force to the plurality of wood elements before the roller element delivers ultrasonic energy to the plurality of wood elements. The press can deliver the compressive force to the plurality of wood elements simultaneously as the roller element delivers ultrasonic energy to the plurality of wood elements. The press can deliver the compressive force to the plurality of wood elements after the roller element delivers ultrasonic energy to the plurality of wood elements. The ultrasonic energy can have a frequency in a frequency range of 15 kHz to 1 MHz. The ultrasonic energy can have a frequency in a frequency range of 20 kHz to 100 kHz.The system may further include a defect inspection component, and the roller element may be further configured to supply ultrasonic energy to the composite wood product, and the defect inspection component may be configured to inspect the composite wood product for defects. The defect inspection component may include a camera. The roller element may be configured to supply ultrasonic energy to the plurality of wood elements before the applicator applies the filler to the plurality of wood elements. Supplying ultrasonic energy to the plurality of wood elements may clean the plurality of wood elements before the applicator applies the filler to the plurality of wood elements. The system may further include a treatment applicator configured to apply a treatment to the composite wood product, and the roller element may be further configured to supply ultrasonic energy to the composite wood product. The ultrasonic transducer may generate the ultrasonic energy as a square wave. The ultrasonic transducer may generate the ultrasonic energy as a sine wave. The ultrasonic transducer may generate the ultrasonic energy as a wave selected from the group consisting of a trapezoidal wave and a triangular wave. The ultrasonic transducer may generate the ultrasonic energy as a continuous waveform. The ultrasonic transducer may generate the ultrasonic energy as a pulsed waveform. The system may further include a conveyor configured to transport the plurality of wood elements. The system may further include a funnel configured to direct the plurality of wood elements onto the conveyor. The system may further include a chamber configured to accommodate the plurality of wood elements.

[0155] The above description provides examples of some embodiments. Other embodiments not explicitly described above are possible, such as embodiments based on modifications and / or variations of the features described above. For example, the techniques described above can be performed in a different order, including one or more additional steps and / or excluding one or more specified steps. Similarly, the devices, systems, and methods may include one or more additional features, may exclude one or more specified features, and / or may include specified features or steps that are combined in a different manner than presented above. Features or steps described as singular may be implemented as multiple such features or steps. Similarly, features or steps described as multiple may be implemented as a single example of such features or steps. Furthermore, steps and techniques described above as being performed by some devices and / or systems may alternatively or additionally be performed by other devices and / or systems described above or other devices and / or systems not explicitly described. The drawings are for illustrative purposes and may not show some embodiments in detail. Changes in size, arrangement, shape, angle, curvature, and / or mutual positional features are possible. Accordingly, other embodiments are within the scope of the following claims.

Claims

1. 1. A method for making a composite wood product, comprising: Applying filler to multiple wood elements; applying a compressive force to the plurality of wood elements with a press having a first surface for applying a compressive force to the plurality of wood elements; joining the plurality of wood elements into a composite wood product, the joining comprising applying ultrasonic energy to the plurality of wood elements; the ultrasonic energy has a frequency within a frequency range of 10 kHz to 20 MHz; The method wherein the ultrasonic energy is supplied by an ultrasonic transducer integrated with the press, the ultrasonic transducer being positioned flush with the first surface of the press.

2. 1. A method for making a composite wood product, comprising: Applying filler to multiple wood elements; applying a compressive force to the plurality of wood elements with a press having a first surface for applying a compressive force to the plurality of wood elements; joining the plurality of wood elements into a composite wood product, the joining comprising applying ultrasonic energy to the plurality of wood elements; the ultrasonic energy has a frequency within a frequency range of 10 kHz to 20 MHz; The method wherein the ultrasonic energy is supplied by an ultrasonic transducer integral with the press, the ultrasonic transducer being recessed relative to the first surface of the press.

3. 1. A method for making a composite wood product, comprising: Applying filler to multiple wood elements; applying a compressive force to the plurality of wood elements using a press having a first surface for applying a first compressive force to the plurality of wood elements and a second surface for applying a second compressive force to the plurality of wood elements; joining the plurality of wood elements into a composite wood product, the joining comprising applying ultrasonic energy to the plurality of wood elements; the ultrasonic energy has a frequency within a frequency range of 10 kHz to 20 MHz; The method wherein the ultrasonic energy is supplied by a first ultrasonic transducer integral with the press, the first ultrasonic transducer being positioned flush with the first surface of the press.

4. 1. A method for making a composite wood product, comprising: Applying filler to multiple wood elements; applying a compressive force to the plurality of wood elements using a press having a first surface for applying a first compressive force to the plurality of wood elements and a second surface for applying a second compressive force to the plurality of wood elements; joining the plurality of wood elements into a composite wood product, the joining comprising applying ultrasonic energy to the plurality of wood elements; the ultrasonic energy has a frequency within a frequency range of 10 kHz to 20 MHz; The method wherein the ultrasonic energy is supplied by a first ultrasonic transducer integral with the press, the first ultrasonic transducer being recessed relative to the first surface of the press.

5. 1. A method for making a composite wood product, comprising: Applying filler to multiple wood elements; applying a compressive force to the plurality of wooden elements by a roller element having a spherical body with a surface for applying a compressive force to the plurality of wooden elements; joining the plurality of wood elements into a composite wood product, the joining comprising applying ultrasonic energy to the plurality of wood elements; the ultrasonic energy has a frequency within a frequency range of 10 kHz to 20 MHz; The method wherein the ultrasonic energy is delivered through the roller element by an ultrasonic transducer.

6. 1. A method for making a composite wood product, comprising: Applying filler to multiple wood elements; applying a compressive force to the plurality of wood elements by a roller element having a surface for applying a compressive force to the plurality of wood elements; joining the plurality of wood elements into a composite wood product, the joining comprising applying ultrasonic energy to the plurality of wood elements; the ultrasonic energy has a frequency within a frequency range of 10 kHz to 20 MHz; the ultrasonic energy is delivered through the roller element by an ultrasonic transducer; A motion controller controls one or more of the motion of the ultrasonic transducer and the roller.

7. 1. A method for making a composite wood product, comprising: Applying filler to multiple wood elements; applying a compressive force to the plurality of wood elements by a roller element having a surface for applying a compressive force to the plurality of wood elements; joining the plurality of wood elements into a composite wood product, the joining comprising applying ultrasonic energy to the plurality of wood elements; the ultrasonic energy has a frequency within a frequency range of 10 kHz to 20 MHz; the ultrasonic energy is delivered through the roller element by an ultrasonic transducer; the ultrasonic energy comprises a first amount of ultrasonic energy and a second amount of ultrasonic energy; the first amount of ultrasonic energy is delivered to a first depth of the plurality of wood elements; the second amount of ultrasonic energy is delivered to a second depth within the plurality of wood elements; the second depth is different from the first depth; The method, wherein the second amount of ultrasonic energy is different from the first amount of ultrasonic energy.

8. 1. A method for making a composite wood product, comprising: applying a metal-containing filler to the plurality of wood elements; applying a compressive force to the plurality of wood elements by a roller element having a surface for applying a compressive force to the plurality of wood elements; joining the plurality of wood elements into a composite wood product, the joining comprising applying ultrasonic energy to the plurality of wood elements; the ultrasonic energy has a frequency within a frequency range of 10 kHz to 20 MHz; The method wherein the ultrasonic energy is delivered through the roller element by an ultrasonic transducer.

9. 1. A method for making a composite wood product, comprising: Applying filler to multiple wood elements; applying a compressive force to the plurality of wood elements by a roller element having a surface for applying a compressive force to the plurality of wood elements; joining the plurality of wood elements into a composite wood product; the joining includes applying ultrasonic energy to the plurality of wood elements; the ultrasonic energy has a frequency within a frequency range of 10 kHz to 20 MHz; the ultrasonic energy is delivered through the roller elements by an ultrasonic transducer; The method inspects the composite wood product for defects, the inspection comprising applying ultrasonic energy to the composite wood product.

10. 1. A method for making a composite wood product, comprising: Applying filler to multiple wood elements; applying a compressive force to the plurality of wood elements by a roller element having a surface for applying a compressive force to the plurality of wood elements; joining the plurality of wood elements into a composite wood product; the joining includes applying ultrasonic energy to the plurality of wood elements; the ultrasonic energy has a frequency within a frequency range of 10 kHz to 20 MHz; the ultrasonic energy is delivered through the roller elements by an ultrasonic transducer; pretreating the plurality of wood elements before applying the filler to the plurality of wood elements, the pretreatment comprising applying ultrasonic energy to the plurality of wood elements and cleaning the plurality of wood elements; method.

11. The method of any one of claims 1 to 10, wherein the filler material comprises an adhesive.

12. The method of any one of claims 1 to 10, wherein the filler material does not include an adhesive.

13. The method of any one of claims 1 to 10, wherein the filler material comprises a plastic.

14. The method of any one of claims 1 to 7, wherein the filler material comprises a metal.

15. The method according to any one of claims 1 to 10, wherein the plurality of wooden elements are placed adjacent to each other before joining the plurality of wooden elements.

16. The method according to any one of the preceding claims, wherein the ultrasonic energy is supplied to the plurality of wooden elements after applying the filler material to the plurality of wooden elements.

17. The method according to any one of claims 1, 2, 5 to 10, wherein the compressive force is applied to the plurality of wooden elements before the ultrasonic energy is applied to the plurality of wooden elements.

18. The method according to any one of claims 1, 2, 5 to 10, wherein the compressive force is applied to the plurality of wooden elements simultaneously with the supply of ultrasonic energy to the plurality of wooden elements.

19. The method according to any one of claims 1, 2, 5 to 10, wherein the compressive force is applied to the plurality of wooden elements after the supply of ultrasonic energy to the plurality of wooden elements.

20. The method of any one of claims 1 to 10, wherein the ultrasonic energy has a frequency in the frequency range of 15 kHz to 1 MHz.

21. 21. The method of claim 20, wherein the ultrasonic energy has a frequency within a frequency range of 20 kHz to 100 kHz.

22. inspecting the composite wood product for defects; The method of any one of claims 1 to 8, wherein the inspecting comprises applying ultrasonic energy to the composite wood product.

23. further comprising pre-treating the plurality of wood elements before applying the filler material; The method of any one of claims 1 to 9, wherein the pre-treatment comprises applying ultrasonic energy to the plurality of wood elements.

24. 24. The method of claim 23, wherein the pre-treating comprises applying ultrasonic energy to the plurality of wood elements and cleaning the plurality of wood elements.

25. The method of any one of claims 1 to 10, further comprising applying a treatment to the composite wood product after joining the composite wood product and supplying ultrasonic energy to the composite wood product.

26. 3. The method of claim 1, wherein both the compressive force and the ultrasonic energy are applied to the plurality of wood elements in the same direction.

27. 27. The method of claim 26, wherein the same direction is a downward direction.

28. 27. The method of claim 26, wherein the same direction is a lateral direction.

29. The method of any one of claims 5 to 10, wherein the surface is substantially smooth.

30. The method of any one of claims 5 to 10, wherein the surface comprises a plurality of protrusions.

31. 31. The method of claim 30, wherein a first protrusion of the plurality of protrusions is at least one of a protrusion having a rounded outer surface, a protrusion having a substantially flat outer surface, a protrusion having an outer surface including points, a protrusion having an outer surface including ridges, and a protrusion having an outer surface in the shape of a cylinder with a rounded top.

32. The method according to any one of claims 5 to 10, wherein the surface has a plurality of recesses.

33. 33. The method of claim 32, wherein a first recess of the plurality of recesses is at least one of a recess having a rounded surface, a recess having a substantially flat surface, a recess having a surface with points, a recess having a surface with ridges, and a recess having a surface in the shape of a cylinder with a rounded bottom.

34. The method according to any one of claims 5 to 10, wherein the surface has at least one protrusion and at least one recess.

35. The method according to any one of claims 5 to 10, wherein the roller element applies the compressive force to the plurality of wooden elements as the roller element rolls over the plurality of wooden elements.

36. the ultrasonic energy is delivered through the roller element by the ultrasonic transducer and a guiding element; The method of any one of claims 5 to 10, wherein the guiding element couples the roller element to the ultrasonic transducer and guides the ultrasonic energy from the ultrasonic transducer to the roller element.

37. 37. The method of claim 36, wherein the guiding element comprises an ultrasonic horn.

38. The method of any one of claims 6 to 10, wherein the roller element comprises a cylindrical body.

39. A method according to any one of claims 6 to 10, wherein the roller elements rotate about an axis in at least a first direction.

40. The method of any one of claims 6 to 10, wherein the roller element rotates about an axis in a first direction and in a second direction opposite to the first direction.

41. 1. A system for manufacturing a composite wood product, comprising: a filler applicator for applying filler to the plurality of wood elements; a roller element for applying a compressive force to the plurality of wooden elements, the roller element having a spherical body and a surface for applying the compressive force to the plurality of wooden elements; an ultrasonic transducer for supplying ultrasonic energy to the plurality of wood elements via the roller element to join the plurality of wood elements into a composite wood product, the ultrasonic energy having a frequency within a frequency range of 10 kHz to 20 MHz; a motion controller for controlling one or more of the motions of the ultrasonic transducer and the roller element; A system with.

42. 1. A system for manufacturing a composite wood product, comprising: a filler applicator for applying filler to the plurality of wood elements; a roller element for applying a compressive force to the plurality of wooden elements, the roller element having a surface for applying the compressive force to the plurality of wooden elements, the surface having a plurality of protrusions; an ultrasonic transducer for supplying ultrasonic energy to the plurality of wood elements via the roller element to join the plurality of wood elements into a composite wood product, the ultrasonic energy having a frequency within a frequency range of 10 kHz to 20 MHz; a motion controller for controlling one or more of the motions of the ultrasonic transducer and the roller element; A system with.

43. 1. A system for manufacturing a composite wood product, comprising: a filler applicator for applying filler to the plurality of wood elements; a roller element for applying a compressive force to the plurality of wooden elements, the roller element having a surface for applying the compressive force to the plurality of wooden elements, the surface having a plurality of recesses; an ultrasonic transducer for supplying ultrasonic energy to the plurality of wood elements via the roller element to join the plurality of wood elements into a composite wood product, the ultrasonic energy having a frequency within a frequency range of 10 kHz to 20 MHz; a motion controller for controlling one or more of the motions of the ultrasonic transducer and the roller element; A system with.

44. 1. A system for manufacturing a composite wood product, comprising: a filler applicator for applying filler to the plurality of wood elements; a roller element for applying a compressive force to the plurality of wooden elements, the roller element having a surface for applying the compressive force to the plurality of wooden elements, the surface having at least one protrusion and at least one recess; an ultrasonic transducer for supplying ultrasonic energy to the plurality of wood elements via the roller element to join the plurality of wood elements into a composite wood product, the ultrasonic energy having a frequency within a frequency range of 10 kHz to 20 MHz; a motion controller for controlling one or more of the motions of the ultrasonic transducer and the roller element; A system with.

45. 1. A system for manufacturing a composite wood product, comprising: a filler applicator for applying filler to the plurality of wood elements; a roller element for applying a compressive force to the plurality of wooden elements, the roller element having a surface for applying the compressive force to the plurality of wooden elements; an ultrasonic transducer for supplying ultrasonic energy to the plurality of wood elements via the roller element to join the plurality of wood elements into a composite wood product, the ultrasonic energy having a frequency within a frequency range of 10 kHz to 20 MHz; a pre-treatment supply component for pre-treating the plurality of wood elements before applying the filler material; a motion controller for controlling one or more of the motions of the ultrasonic transducer and the roller element; A system with.

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