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 an apparatus, system, and method for joining wood or other plant products using ultrasonic energy.

Background Art

[0002] Wood-based products are manufactured by using wood, veneer, wood chips, or other small wood elements, and joining them with resin to form structural products. This allows smaller or lower-quality wood or wood elements to be used in the production of substitutes for large-sized wood. Wood-based products are used for structural purposes such as beams, girders, joists, headers, studs, and columns, either in place of or together with wood products.

[0003] Ultrasonic energy has been used in diagnostic imaging in medical applications. In ultrasonic imaging, high-frequency sound wave pulses are transmitted from a probe into the body. The sound wave pulses propagate through the body as waves, passing through some body fluids and tissues and being partially absorbed by other body tissues. This absorption causes a partial reflection or echo of the sound waves to be sent back towards the probe. Sensors within the probe measure the echoes of the sound waves, and this information can be used to create diagnostic images of the examined area of the body.

[0004] Ultrasonic energy is also used in diagnostic imaging and non-destructive testing in industrial applications, such as the inspection of metal welds, the detection of defects in concrete and the evaluation of concrete consistency, and the detection of defects in wood. In one application, the probe transmits high-frequency sound wave pulses into the substance being imaged or inspected, and sensors within the probe measure the echoes of the sound waves returning to the probe. In another application, after high-frequency sound wave pulses are transmitted from the probe into the material, another receiving unit on the side of the material opposite the probe receives the sound waves that have passed through the material being imaged or inspected.

Summary of the Invention

[0005] In a general embodiment, a method for manufacturing a composite wood product includes applying a filler to multiple wood elements and joining the multiple wood elements to form a composite wood product, the joining of which includes supplying ultrasonic energy to the multiple wood elements. The ultrasonic energy has a frequency in the frequency range of 10 kHz to 20 MHz.

[0006] The embodiment may include one or more of the following: The ultrasonic transducer can supply ultrasonic energy. The filler may or may not contain adhesive. The filler may contain plastic. The filler may contain metal. The multiple wood elements may be placed close to each other before joining them. Applying the filler to the multiple wood elements and supplying ultrasonic energy to the multiple wood elements may be done simultaneously. The ultrasonic energy may be supplied to the multiple wood elements before applying the filler to the multiple wood elements. Alternatively, the ultrasonic energy may be supplied to the multiple wood elements after applying the filler to the multiple wood elements. This method may further include applying a compressive force to the multiple wood elements. The compressive force may be applied to the multiple wood elements before supplying ultrasonic energy to the multiple wood elements. Alternatively, the compressive force may be applied to the multiple wood elements simultaneously with supplying ultrasonic energy to the multiple wood elements. Furthermore, the compressive force may be applied to the multiple wood elements after supplying ultrasonic energy to the multiple wood elements. The ultrasonic energy may have a frequency in the frequency range of 15 kHz to 1 MHz. Furthermore, the ultrasonic energy may have a frequency within the frequency range of 20 kHz to 100 kHz. This method may further include inspecting for defects in the composite wood product, which includes supplying ultrasonic energy to the composite wood product. This method may further include pre-treating a plurality of wood elements before applying a filler, which includes supplying ultrasonic energy to the plurality of wood elements. The pre-treatment may also include supplying ultrasonic energy to the plurality of wood elements and cleaning the plurality of wood elements. Furthermore, this method may include treating the composite wood product after joining the composite wood product and supplying ultrasonic energy to the composite wood product.

[0007] Details of one or more embodiments are shown in the relevant drawings and their descriptions below. In a particular embodiment, one or more advantages can be obtained. For example, in an embodiment of the disclosed method, the apparatus and system can be used to manufacture composite wood products that are stronger (e.g., one or more of higher tensile strength, higher compressive strength, and higher shear strength) than composite wood products manufactured using the prior art. In another example, embodiments of the disclosed method, apparatus and system can be used to manufacture composite wood products with improved durability compared to composite wood products manufactured using the prior art. In yet another example, embodiments of the disclosed method, apparatus and system can be used to manufacture composite wood products with improved moisture resistance compared to composite wood products manufactured using the prior art. In yet another example, embodiments of the disclosed method, apparatus and system can be used to manufacture composite wood products with improved heat resistance compared to composite wood products manufactured using the prior art. In yet another example, embodiments of the disclosed method, apparatus and system can be used to manufacture composite wood products with increased hardness compared to composite wood products manufactured using the prior art. In yet another example, embodiments of the disclosed methods, apparatus and systems can be used to improve the curing rate or shorten the curing time (e.g., accelerate or speed up) in the manufacture of composite wood products compared to the curing rate or curing time of composite wood products manufactured using the prior art. In yet another example, embodiments of the disclosed methods, apparatus and systems can be used to manufacture composite wood products with improved resistance to insects or pests compared to composite wood products manufactured using the prior art.

[0008] Other features, purposes, and advantages of the technology described herein will be apparent from the text, drawings, and claims. Similar reference numerals in various drawings indicate similar elements. [Brief explanation of the drawing]

[0009] [Figure 1] This is a block diagram illustrating an environment for manufacturing composite wood products using ultrasonic energy. [Figure 2] This 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] This figure shows an example of applying a filler material to multiple wood elements. [Figure 3B] This figure shows another example of the application of filler material to multiple wood elements. [Figure 3C] This figure shows yet another application example of the filler material to multiple wood elements. [Figure 4] This is a conceptual diagram showing an exemplary ultrasonic transducer that supplies ultrasonic energy to multiple exemplary wood elements for manufacturing composite wood products using ultrasonic energy. [Figure 5] Figure 4 is a conceptual diagram of an exemplary ultrasonic transducer. [Figure 6A] This is a conceptual diagram of an exemplary ultrasonic transducer, including an exemplary cymbal-shaped horn, which can be used to manufacture composite wood products using ultrasonic energy. [Figure 6B] This is a conceptual diagram of an exemplary ultrasonic transducer, including an exemplary Langevin horn, which can be used to manufacture composite wood products using ultrasonic energy. [Figure 6C] This is a conceptual diagram of an exemplary ultrasonic transducer, including an exemplary ring-shaped horn, which can be used to manufacture composite wood products using ultrasonic energy. [Figure 6D] This is a conceptual diagram of an exemplary ultrasonic transducer, including an exemplary pyramidal horn, which can be used to manufacture composite wood products using ultrasonic energy. [Figure 6E] This is a conceptual diagram of an exemplary ultrasonic transducer, including an exemplary spherical horn, which can be used to manufacture composite wood products using ultrasonic energy. [Figure 6F] This is a conceptual diagram of an exemplary ultrasonic transducer, including an exemplary dome-shaped horn, which can be used to manufacture composite wood products using ultrasonic energy. [Figure 6G] This is a conceptual diagram of an exemplary ultrasonic transducer, including an exemplary wedge-shaped horn, which can be used to manufacture composite wood products using ultrasonic energy. [Figure 6H] This is a conceptual diagram of an exemplary ultrasonic transducer having an exemplary horn, including an exemplary chamber, and having a general shape such as a tube or cylinder, which can be used to manufacture composite wood products using ultrasonic energy. [Figure 7] This is a flowchart illustrating an exemplary method that can be used to manufacture composite wood products. [Figure 8] This is a block diagram of an exemplary environment for manufacturing composite wood products using ultrasonic energy. [Figure 9] This is a conceptual diagram of an exemplary environment for manufacturing composite wood products using ultrasonic energy. [Figure 10A] This 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] This is a conceptual diagram of another exemplary press that can be used to manufacture composite wood products using ultrasonic energy, and an exemplary ultrasonic transducer integrated with that press. [Figure 10C] This is a conceptual diagram of yet another exemplary press that can be used to manufacture composite wood products using ultrasonic energy, and an exemplary ultrasonic transducer integrated with that press. [Figure 11A] This is a block diagram of an exemplary environment for manufacturing composite wood products using ultrasonic energy. [Figure 11B] This is a block diagram of an exemplary environment for manufacturing composite wood products using ultrasonic energy. [Figure 11C]A block diagram of an exemplary environment for manufacturing composite wood products using ultrasonic energy. [Figure 12A] A conceptual diagram of an exemplary environment for manufacturing composite wood products using ultrasonic energy, the environment including an exemplary ultrasonic transducer including an exemplary roller element. [Figure 12B] A conceptual diagram of another exemplary ultrasonic transducer including another exemplary roller element. [Figure 12C] A conceptual diagram of an exemplary environment for manufacturing composite wood products using ultrasonic energy. [Figure 13A] A side view of an exemplary roller element. [Figure 13B] A side view of another exemplary roller element. [Figure 13C] A side view of yet another exemplary roller element. [Figure 14A] A front view of an exemplary portion of an exemplary roller element including a plurality of exemplary protrusions. [Figure 14B] A top view of an exemplary portion of an exemplary roller element including a plurality of exemplary protrusions. [Figure 14C] A front view showing an exemplary portion of an exemplary roller element including a plurality of exemplary recesses. [Figure 14D] A top view showing an exemplary portion of an exemplary roller element including a plurality of exemplary recesses. [Figure 14E] 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] A conceptual diagram of an exemplary control module and an exemplary ultrasonic transducer for supplying ultrasonic energy to a plurality of exemplary wood elements to manufacture composite wood products using ultrasonic energy. [Figure 15B] A block diagram of the exemplary control module of FIG. 15A.

Best Mode for Carrying Out the Invention

[0010] In each drawing, the same reference symbol represents the same element. This section describes apparatuses, systems, and methods that can be used to bond wood or other plant products using ultrasonic energy. In some implementations of the apparatuses, systems, and methods described herein, composite wood products can be manufactured by applying a filler to multiple wood elements and joining the multiple wood elements to form a composite wood product. This joining is performed by supplying low-frequency ultrasonic energy to the multiple wood elements. For example, the low-frequency ultrasonic energy may have a frequency in the range of 10 kHz to 20 MHz. In some embodiments, the low-frequency ultrasonic energy may have a frequency in the range of 15 kHz to 1 MHz. In some embodiments, the low-frequency ultrasonic energy may have a frequency in the range of 20 kHz to 100 kHz.

[0011] Ultrasonic transducers can be used to provide ultrasonic energy when joining multiple wood elements to form composite wood products. In various embodiments, ultrasonic transducers can generate ultrasound and transmit ultrasonic energy to multiple wood elements and fillers. In some examples, the ultrasound can be supplied as a continuous wave, and in some examples, the ultrasound may be supplied as a pulsed wave. In some examples, the transducer can supply periodic ultrasound, and the ultrasound may include one or more of a variety of waveforms. For example, in various embodiments, the waveform may include one or more of a sine wave, rectangular wave, square wave, trapezoidal wave, triangular wave, sawtooth wave, or other suitable waveforms. The transducer can generate ultrasound including one or more of longitudinal waves, radiant waves, and transverse waves, and for example, the ultrasound can supply ultrasonic energy to multiple wood elements, fillers, or both multiple wood elements and fillers.

[0012] Ultrasonic energy can provide mechanical stimulation to multiple wood elements. For example, when ultrasound passes through or is absorbed by wood elements, it can cause molecules within the wood elements to vibrate. Molecular-level vibrations within wood elements can create friction between the vibrating molecules, potentially generating heat within the wood elements. Furthermore, in some examples, when ultrasound passes through or is absorbed by wood elements, it will create small or minute pressure differences within the wood elements. Such pressure differences can cause cavitation within the wood elements, and due to these pressure differences, gas or vapor in high-pressure areas within the wood elements is pushed toward low-pressure areas, and when pushed, microscopic gas or vapor bubbles may be generated within the wood elements. In one or more of these embodiments, ultrasonic energy will 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 filler. In some examples, the ultrasonic transducer or a portion of the transducer may be in physical contact with one or more wood elements, filler, or both the filler and one or more wood elements, and the aforementioned mechanical stimulation will be provided.

[0013] Ultrasonic energy can further provide mechanical stimulation to multiple wood elements that can be positioned close to each other at a macroscopic level. The mechanical stimulation provided by ultrasound may, for example, move or vibrate one or more wood elements, and such movement or vibration may cause friction between the wood elements. For example, the mechanical stimulation provided by ultrasound may cause one or more wood elements to move or vibrate, and one or more surfaces of a first wood element may come into contact with 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 may face resistance when moving, rubbing or vibrating. In one or more of these embodiments, ultrasonic energy can provide mechanical stimulation in, for example, 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 filler. In some examples, the ultrasonic transducer or a part of the transducer may be in physical contact with one or more wood elements, filler, or both filler and one or more wood elements, and the aforementioned mechanical stimulation can be provided.

[0014] Similarly, in various embodiments, ultrasound can provide mechanical stimulation to fillers. For example, when ultrasound passes through or is absorbed by a filler, it can cause molecules within the filler to vibrate. This molecular-level vibration within the filler can create friction between the vibrating molecules, generating heat within the filler. Furthermore, in some examples, when ultrasound passes through or is absorbed by a filler, it will create small or minute pressure differences within the filler. Such pressure differences can cause cavitation within the filler, and microscopic gas or vapor bubbles will be generated within the filler as the pressure difference pushes or pushes gas or vapor from high-pressure areas to low-pressure areas within the filler. In one or more of these embodiments, ultrasonic energy can provide mechanical stimulation, for example, in the joining of wood or other plant products. This mechanical stimulation may be provided even if, for example, the ultrasonic transducer is not in physical contact with the wood element 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, filler, or both the filler and one or more wood elements, and the aforementioned mechanical stimulation will be provided.

[0015] Ultrasonic energy can also provide mechanical stimulation to fillers at a macroscopic level. For example, in just a few cases, the mechanical stimulation provided by ultrasound will agitate the filler, causing it to move, vibrate, diffuse, spread, flow, or penetrate. In one or more of these embodiments, ultrasonic energy can provide mechanical stimulation in, for example, the joining of wood or other plant products. This mechanical stimulation may be provided even if, for example, the ultrasonic transducer is not in physical contact with the wood element 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 stimulation will be provided.

[0016] In some embodiments, ultrasonic energy can stimulate the diffusion of a filler, causing it to penetrate, for example, into a wood element and even deeper into the wood element. In some embodiments, ultrasonic energy stimulates the diffusion of a filler, causing it to spread, for example, over a wider area of ​​the wood element, covering the wood element or bringing it into contact with the wood element. In one or more of these embodiments, ultrasonic energy can provide a diffusion stimulus in the joining of wood or other plant products. This diffusion stimulus may be provided even if, for example, the ultrasonic transducer is not in physical contact with the wood element 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 diffusion stimulus will be provided.

[0017] According to some embodiments, ultrasonic energy can also provide thermal stimulation to multiple wood elements, filler, or multiple wood elements and filler. This thermal stimulation would be added to, for example, mechanical stimulation or heat generated by the aforementioned stimulation. In some embodiments, the temperature of the wood elements will rise as the wood elements absorb ultrasonic energy or a portion of ultrasonic energy supplied to them by the transducer. Similarly, the temperature of the filler will rise as the filler absorbs ultrasonic energy or a portion of ultrasonic energy supplied to it by the transducer. In some examples, the rise 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 (for example, if the filler is liquid or in a flowable implementation). In one or more of these embodiments, ultrasonic energy can provide thermal stimulation to the bonding of wood or other plant products. This thermal stimulation can be provided, for example, even without physical contact between the ultrasonic transducer and 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, a filler, or both the filler and one or more wood elements, and the aforementioned thermal stimulation can be provided.

[0018] In some examples, the friction generated by the application of ultrasonic energy between wood elements or between the filler and wood elements will cause the filler to be pushed or advanced into cracks, pores, gaps, spaces, voids, or interstitials in one or more wood elements. In some embodiments, the friction may stimulate the micronization of the filler (e.g., the separation of the filler into smaller or finer particles), and in some examples, it will stimulate the filler to be pushed or advanced into cracks, pores, gaps, spaces, voids, or interstitials within one or more wood elements. In some examples, the friction may generate further heat, which can heat the filler (e.g., in implementations where the filler is liquid or flowable) and promote better flow of the filler, thereby stimulating, for example, deeper penetration of the filler into the wood elements. In one or more of these embodiments, ultrasonic energy can generate friction between wood elements or between the filler and wood elements, stimulating the joining of wood or other plant products. This stimulus will be provided even if, for example, the ultrasonic transducer is not in physical contact with the wood element or filler. In some examples, the ultrasonic transducer or a part of the transducer may be in physical contact with one or more wood elements, filler, or both filler and one or more wood elements, and the aforementioned stimulus will be provided.

[0019] In various embodiments, the filler can take many different forms. In some embodiments, the filler may include an adhesive, while in other embodiments, the filler may not include an adhesive. In some embodiments, the filler may include a plastic, while in other embodiments, the filler may not include a plastic. In some embodiments, the filler may include a metal, while in other embodiments, the filler may not include a metal. Combinations of the aforementioned forms are also possible (for example, the filler includes an adhesive and a plastic, the filler includes an adhesive and a metal, or the filler 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, combinations of the above examples of one or more filler states can 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.

[0021] In some embodiments, the filler can be applied to the wood elements before supplying ultrasonic energy to them. In some embodiments, the filler can be applied to the wood elements simultaneously with supplying ultrasonic energy to them. In some embodiments, the filler can be applied to the wood elements after supplying ultrasonic energy to them.

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

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

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

[0025] Some embodiments of the apparatus, systems, and methods described herein can be used to manufacture composite wood products that are stronger (e.g., one or more of higher tensile strength, higher compressive strength, or higher shear strength) than composite wood products manufactured using conventional techniques that do not use ultrasonic energy. Some implementations of the apparatus, systems, and methods described herein can be used to manufacture composite wood products with improved durability compared to composite wood products manufactured using conventional techniques that do not use ultrasonic energy. Some implementations of the apparatus, systems, and methods described herein can be used to manufacture composite wood products with improved moisture resistance compared to composite wood products manufactured using conventional techniques that do not use ultrasonic energy. Improved moisture resistance helps, for example, reduce or minimize deterioration and decay of composite wood products. Some implementations of the apparatus, systems, and methods described herein can be used to manufacture composite wood products with improved heat resistance compared to composite wood products manufactured using conventional techniques that do not use ultrasonic energy. Some implementations of the apparatus, systems, and methods described herein can be used to manufacture composite wood products with increased hardness compared to composite wood products manufactured using conventional techniques that do not use ultrasonic energy. Some implementations of the apparatus, systems, and methods described herein can be used to improve the curing rate (e.g., accelerate or speed up) or reduce the curing time of composite wood products in the manufacture of composite wood products compared to composite wood products manufactured using conventional techniques that do not use ultrasonic energy. Some implementations of the apparatus, systems, and methods described herein can be used to manufacture composite wood products with improved resistance to insects or pests compared to composite wood products manufactured using conventional techniques that do not use ultrasonic energy.Wood products can be manufactured using renewable energy sources such as fast-growing trees like hybrid poplar, yellow poplar, aspen, Douglas fir, hemlock, southern pine, or other suitable hardwood or conifer species (but not limited to these), making them an environmentally friendly and desirable alternative to iron.

[0026] Figure 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 may include, but are not limited to, girders, beams, joists, L-joists, rafters, headers, studs, trusses, columns, rim boards, plywood, particleboard, fiberboard, oriented strand board, flakeboard, waferboard, chipboard, laminates, plywood veneer, cross-laminated materials, parallel strands, laminated strands, and finger joints.

[0027] Environment 100 includes a wood element preparation area 102, a filler application area 104, and an ultrasonic energy supply area 106. The wood element preparation area 102 can be used to prepare multiple wood elements in order to apply filler to multiple wood elements and to supply ultrasonic energy to multiple wood elements to join the multiple wood elements and form a composite wood product. In some examples, the wood element preparation area 102 can be used to manufacture wood elements, for example, to cut and process wood or other wood or plant-based components to manufacture a desired wood element. In some examples, the wood element may include primary products of such processing, and in some examples, the wood element may include secondary products or waste of such processing. Such primary or secondary wood elements may include, but are not limited to, wood sheets, wood veneers, wood strips, wood strands, wood chips, wood flakes, wood scrap, 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, the wood element preparation area 102, the filler application area 104, and the ultrasonic energy supply area 106 can each be located within a single facility. In some embodiments, one or more of the wood element preparation area 102, the filler application area 104, and the ultrasonic energy supply area 106 may be located within a different facility from one or more of the other areas 102, 104, and 106. For example, in some implementations, the wood element preparation area 102 may be located within a first facility, while the filler application area 104 and the ultrasonic energy supply area 106 may be located within a second facility.

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

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

[0031] Referring again to Figure 1, in some examples, the wood elements may be placed in close proximity to each other within the wood element preparation area 102 before providing the wood elements to the filler application area 104. There are many different ways in which this can be done, some of which involve using one or more automated processes (e.g., using one or more placement devices), one or more manual processes (e.g., by the manual work of one or more workers), or a combination of one or more automated processes and one or more manual processes to place the wood elements in close proximity to each other.

[0032] Figure 2 is a conceptual diagram 120 of exemplary wood elements 122 on or within an exemplary funnel 124, placed on an exemplary conveyor 126, as part of an exemplary manufacturing process for producing composite wood products using ultrasonic energy. The funnel 124 and conveyor 126 (or part of the conveyor 126) may be included, for example, in several implementation forms of a wood element preparation area 102. In this exemplary embodiment, the exemplary 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-derived particles or plant-derived elements, components, or products may also be included, but are not shown in Figure 2 for brevity. For illustrative purposes, multiple types of wood elements 128, 130, 132, 134, 136, 138, 140, and 142 are shown together on the funnel 124 in Figure 2. However, in some examples, only a single type of wood element (e.g., only wood sheet 128, or only wood strip 132, or only any of the other illustrated wood elements 130, 134, 136, 138, 140, and 142) can be processed at a given time, and in such examples, the funnel 124 can generally contain only the specific type of wood element being processed at that time. In some examples, any two wood element types, or any three (or more) wood element types, or a subset of the illustrated wood element types can be processed at a given time, and in such examples, the funnel 124 can generally contain these specific types of wood elements.

[0033] The conveyor 126 can take various forms. In some examples, the conveyor 126 may include one or more belts. In some examples, the conveyor 126 may include one or more rollers (e.g., a series of rollers). In some examples, the conveyor 126 may include one or more chains. It is also possible to combine these examples of conveyors. According to some embodiments, the conveyor 126 can generally transport wood elements, which are placed on the conveyor 126 from the funnel 124, in a direction 144 toward the filler application area 104. Figure 2 shows the funnel 124 that places wood elements onto the conveyor 126, but in other examples, the funnel 124 may not be used, and the wood elements may be placed on the conveyor 126 by one or more machines. In yet another example, the wood elements may be placed on the conveyor manually by an operator, for example.

[0034] In some examples, the conveyor 126 may include a placement or stacking mechanism for arranging or stacking (or both) the wood elements into a specific configuration. In some examples, one or more machines or devices (not shown in Figure 2 for brevity) different from the conveyor 126 may perform the arranging or stacking (or both) of the wood elements into a specific configuration. In some examples, one or more workers may manually perform the arranging or stacking (or both) of the wood elements into a specific configuration. In some examples, the conveyor may not be used to transport the wood elements to the filler application area 104 or the ultrasonic energy supply area 106, or, for example, to transport the wood elements within area 104 or area 106.

[0035] In the following example, for simplicity, a single type of wood element is assumed to be used in the filler application area 104 and the ultrasonic energy supply area 106. In other examples, two or more types (e.g., two, three, four, five or more types) of wood elements can be used in the filler application area 104 and the ultrasonic energy supply area 106 to manufacture a composite wood product.

[0036] Figure 3A is Figure 150, which shows an example of applying a filler to multiple wood elements. Multiple wood elements 152 are arranged on a conveyor 154 and move in 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 or products, or a combination thereof. In some examples, the conveyor 154 may correspond to the conveyor 126 in Figure 2, and in other examples, the conveyor 154 may be a different conveyor from the conveyor 126 in Figure 2.

[0037] In this example, an exemplary applicator 158 is positioned on a conveyor 154, and the filler 160 can be applied to the wood element 152 as the wood element 152 passes under the applicator 158. As shown in Figure 3A, the applicator 158 is a spray nozzle and can spray the filler 160 onto the wood element 152. In this example, the applicator 158 does not need to be in physical contact with the wood element 152. In some examples, the filler 160 includes an adhesive. In some embodiments, the filler 160 does not include an adhesive. In some embodiments, the filler 160 includes plastic, and in some embodiments, the filler 160 does not include plastic. In some embodiments, the filler 160 includes metal, and in other embodiments, the filler 160 does not include metal. As described above, combinations of such materials are also possible as the filler 160.

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

[0039] Figure 3B is Figure 180, which shows another application example of the filler material to multiple wood elements. Multiple wood elements 182 are arranged on a conveyor 184 and move in 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 in Figure 2, and in other examples the conveyor 184 may be a different conveyor from the conveyor 126 in Figure 2.

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

[0041] Figure 3C is Figure 200, which shows yet another application example of filler to multiple wood elements. Multiple wood elements 202 are placed on a conveyor 204 and move in 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 scrap, 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 in Figure 2, and in other examples the conveyor 204 may be a different conveyor from the conveyor 126 in Figure 2.

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

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

[0044] Following the application of fillers 160, 190, and 210 in the examples in Figures 3A, 3B, and 3C, in some examples multiple wood elements 164, 194, and 214 can be placed close to each other. In some examples, wood elements can be placed or stacked vertically close to each other. For example, two or more wood strips 194 can be stacked vertically. In another example, two or more wood veneers 214 can be stacked vertically. In some examples, wood elements may be placed or stacked close to each other horizontally or transversely. Additional arrangements are also possible, such as placing or stacking some wood elements vertically close to each other, and placing or stacking some wood elements horizontally or transversely close to each other.

[0045] In some examples, the arrangement of adjacent wood elements may generally be structural or systematic (e.g., two, three, four, five or more wood elements arranged vertically or stacked vertically). In some examples, the arrangement of adjacent wood elements may generally be less structured, such as randomly or variably arranging multiple wood elements (e.g., wood chips, wood flakes, wood scraps, sawdust, etc.). For example, the wood chips 164 may be arranged randomly or variably in close proximity to each other.

[0046] Placing multiple timber elements in close proximity to each other may be done by one or more automated processes (e.g., one or more machines programmed to place the timber elements), by one or more manual processes (e.g., one or more workers manually placing the timber elements), or by a combination of one or more automated processes and one or more manual processes. In some examples, multiple timber elements may be placed in close proximity to each other by lining up or lying down within a “mat”.

[0047] Figure 4 is a conceptual diagram 230 of an exemplary ultrasonic transducer 232 that supplies ultrasonic energy to multiple exemplary wood elements 234 for manufacturing a composite wood product using ultrasonic energy. The supply of ultrasonic energy to the multiple exemplary wood elements 234 shown in Figure 4 can be carried out, for example, in the ultrasonic energy supply region 106 of Figure 1. Referring again to Figure 4, the exemplary ultrasonic transducer 232 has a general-purpose shape and can represent either the shape or topology of the ultrasonic transducer discussed herein. In general, the ultrasonic transducer 232 can generate ultrasonic energy that can be used to join multiple wood elements 234 to form a composite wood product. For example, the ultrasonic transducer 232 may generate ultrasonic waves 236 that can supply ultrasonic energy to multiple wood elements 234. When used herein, the term “ultrasonic transducer” is understood to refer to a device that can generate ultrasonic energy and can radiate ultrasonic energy in the form of ultrasonic waves or ultrasonic waves from an ultrasonic transducer. As used herein, the term “ultrasonic transducer” does not necessarily mean that the device includes a receiver capable of receiving ultrasound (e.g., ultrasound reflected back to the device) or that it is capable of measuring ultrasound. In some implementations of the devices, systems, and methods discussed herein, an ultrasonic transducer may include a receiver capable of receiving ultrasound and, in some implementations, measuring ultrasound; however, in the specific examples discussed herein, such a receiver or receiving function is generally not included in the ultrasonic transducer as described in relation to the examples presented herein.

[0048] In this example in Figure 4, the multiple wood elements 234 include four wood elements 238a, 238b, 238c, and 238d that are placed in close proximity to each other. In this example, the wood elements are generally stacked on top of each other, with the first wood element 238a generally placed on the surface 240, the second wood element 238b generally placed on top of the first wood element 238a, the third wood element 238c generally placed on top of the second wood element 238b, and the fourth wood element 238d generally placed on top of the third wood element 238c.

[0049] In some examples, one or more of the wood elements 238a, 238b, 238c, and 238d may correspond to one or more of the wood elements 194 or 192 in Figure 3B. For example, one or more of these elements may include filler applied to a surface, part of a surface, or multiple surfaces. For example, the filler may be placed on the top surface 242 of the first wood element 238a. The filler may be placed on the top surface 244 of the second wood element 238b. The filler may also be placed on the top surface 246 of the third wood element 238c. Furthermore, for example, the filler may be placed on the bottom surfaces of the wood elements 238b, 238c, and 238d. In some examples, one or more of the wood elements 238a, 238b, 238c, and 238d may correspond to the wood element 194 in Figure 3B (for example, elements 238a, 238b, and 238c may have filler placed on their upper surfaces 242, 244, and 246, respectively), and one or more of the wood elements 238a, 238b, 238c, and 238d may not correspond to the wood element 194 shown in Figure 3B (for example, element 238d may not have filler placed on its surface before elements 238a, 238b, 238c, and 238d are placed in close proximity to each other). In some examples, the filler may not be placed on any of the surfaces of the wood elements 238a, 238b, 238c, and 238d. In this example, the filler 248 is placed on surfaces 242, 244, and 246.

[0050] In this example, the multiple wood elements 238a, 238b, 238c, and 238d can correspond to multiple wood strands. In other examples, the multiple wood elements 238a, 238b, 238c, and 238d may correspond to multiple wood sheets, multiple wood veneers, multiple wood strips, multiple wood chips, multiple wood flakes, multiple wood scraps, sawdust, any combination of the aforementioned, 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 236 has a frequency in the range of 10 kHz to 20 MHz. In some examples, the ultrasonic energy transmitted by the ultrasonic 236 has a frequency in the range of 15 kHz to 1 MHz. In some examples, the ultrasonic energy transmitted by the ultrasonic 236 has a frequency in the range of 20 kHz to 100 kHz. Generally, the ultrasonic transducer 232 can supply low-frequency ultrasonic energy to multiple wood elements 234.

[0052] In some examples, the ultrasonic wave 236 may be supplied as a continuous wave, and in some examples, the ultrasonic wave 236 may be supplied as a pulsed wave. In some examples, the transducer 232 can supply periodic ultrasonic waves, and the ultrasonic waves may include one or more of a variety of waveforms. For example, in various embodiments, the waveform 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 that include, for example, one or more of a longitudinal ultrasonic wave, a radiant ultrasonic wave, and a transverse ultrasonic wave, and the ultrasonic waves 236 can supply ultrasonic energy to a plurality of wood elements 238a, 238b, 238c, 238d and a filler material 248, or to both a plurality of wood elements 238a, 238b, 238c, 238d and the filler material 248. For clarity, although the ultrasonic waves 236 shown in Figure 4 are shown being emitted from an ultrasonic transducer 232 onto multiple wood elements 234, the ultrasonic waves 236 may be irradiated onto, absorbed by, or pass through one or more (e.g., two, three, or all) wood elements 238d, 238c, 238b, and 238a.

[0053] In some examples, the transmitted ultrasonic energy can mechanically stimulate one or more of the multiple wood elements 238a, 238b, 238c, and 238d. For example, when ultrasonic waves 236 are transmitted through or absorbed by the wood elements, they can cause molecules within the wood elements to vibrate. Molecular-level vibrations within the wood elements (e.g., elements 238a, 238b, 238c, and 238d) will create friction between the vibrating molecules and generate heat within the wood elements. Furthermore, in some examples, when ultrasonic waves 236 are transmitted through or absorbed by the wood elements, they can create small or minute pressure differences within the wood elements. Such pressure differences can cause cavitation within the wood elements, where gas or vapor is pushed or compressed by the pressure difference from high-pressure areas to low-pressure areas within the wood elements, resulting in the formation of microscopic gas or vapor bubbles within the wood elements. In one or more of these configurations, ultrasonic energy can provide mechanical stimulation to, for example, the joining of wood or other plant products. This mechanical stimulation 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, and the aforementioned mechanical stimulation may be provided.

[0054] The ultrasonic energy can further provide macroscopic mechanical stimulation to one or more of the multiple wood elements 238a, 238b, 238c, and 238d. For example, the mechanical stimulation provided by the ultrasonic wave 236 may, for example, move or vibrate one or more wood elements, and such movement or vibration will create friction between the wood elements. For example, one surface of one wood element will experience resistance when it moves, rubs, or vibrates in contact with one or more surfaces of another wood element. In one or more of these methods, the ultrasonic energy can provide mechanical stimulation in, for example, the joining of wood or other plant products. This mechanical stimulation may be provided even if, for example, the ultrasonic transducer 232 is not in physical contact with the wood elements 238a, 238b, 238c, and 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, and 238d, the filler 248, or both the filler 248 and one or more of the wood elements 238a, 238b, 238c, and 238d, thereby providing the aforementioned mechanical stimulation.

[0055] In some examples, the ultrasound 236 can provide mechanical stimulation to the filler 248. For example, when the ultrasound 236 passes through or is absorbed by the filler 248, the ultrasound 236 will vibrate the molecules inside the filler 248. Molecular-level vibrations within the filler 248 can create friction between the vibrating molecules, generating heat within the filler 248. Furthermore, in some examples, when the ultrasound 236 passes through or is absorbed by the filler 248, the ultrasound will create a small or minute pressure difference within the filler 248. Such a pressure difference will cause cavitation within the filler 248, and when gas or vapor is pushed or compressed from a high-pressure area to a low-pressure area within the filler 248, microscopic gas or vapor bubbles will be generated within the filler 248. In one or more of these methods, 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 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, and the aforementioned mechanical stimulation will be provided.

[0056] In some examples, ultrasonic energy can provide mechanical stimulation to the filler 248 at a macroscopic level. For example, in just a few cases, the mechanical stimulation provided by the ultrasonic waves 236 can agitate the filler 248, causing it to move, vibrate, diffuse, expand, flow, or penetrate. In one or more of these methods, ultrasonic energy can provide mechanical stimulation, for example, in the joining of wood or other plant products. This mechanical stimulation 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 248. In some examples, the ultrasonic transducer 232, or a part thereof, may be in physical contact with one or more of the wood elements 238a, 238b, 238c, 238d, the filler 238, or both the filler 238 and one or more of the wood elements 238a, 238b, 238c, 238d, and the aforementioned mechanical stimulation will be provided.

[0057] In some examples, ultrasonic energy can stimulate the diffusion of the filler 248, causing it to penetrate one or more of the wood elements 238a, 238b, 238c, and 238d, or to penetrate even deeper into one or more of the wood elements. In some embodiments, ultrasonic energy can stimulate the diffusion of the filler 248, for example, causing the filler to spread more widely, cover, or come into contact with one or more wood elements. In one or more of these methods, 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, and 238d or the filler 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, and 238d, the filler 248, or both the filler 248 and one or more of the wood elements 238a, 238b, 238c, and 238d, thereby providing the aforementioned diffusive stimulation.

[0058] According to some embodiments, in some examples, ultrasonic energy can also provide thermal stimulation to one or more of the wood elements 238a, 238b, 238c, 238d, the filler 248, or the wood elements and filler. This thermal stimulation would be added to, for example, mechanical stimulation or any heat generated by the aforementioned stimulation. In some embodiments, the temperature of one or more of the wood elements 238a, 238b, 238c, 238d would rise as the wood elements absorb ultrasonic energy or a portion of ultrasonic energy. Similarly, the temperature of the filler 248 would rise as the filler 248 absorbs ultrasonic energy or a portion of ultrasonic energy. In some examples, an increase in 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 and deeper penetration of the filler, and (for example, in embodiments where the filler is liquid or flowable) can stimulate deeper injection of the filler 248 into one or more of the wood elements 238a, 238b, 238c, 238d by stimulating better flow of the filler 248. In one or more of these methods, ultrasonic energy will provide thermal stimulation in the joining of wood or other plant products. 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 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, and 238d, the filler 248, or both the filler 248 and one or more of the wood elements 238a, 238b, 238c, and 238d, thereby providing the aforementioned thermal stimulation.

[0059] In some examples, the friction generated by the application of ultrasonic energy between wood elements (e.g., between any of wood elements 238a, 238b, 238c, and 238d), or between the filler 248 and one or more wood elements, can push or advance the filler 248 into one or more gaps, pores, spaces, voids, or cavities among the wood elements 238a, 238b, 238c, and 238d. In some embodiments, the friction can stimulate the atomization of the filler 248 (e.g., separating the filler 248 into smaller or finer particles), and in some examples, it can stimulate the filler 248 to be pushed or advance into gaps, pores, spaces, voids, or cavities among one or more wood elements. In some cases, the friction may generate further heat, for example, by heating the filler 248 and stimulating its flow, which may also stimulate deeper penetration of the filler 248 into one or more wood elements (for example, when the filler is liquid or in a fluidized form). In one or more of these methods, ultrasonic energy can generate friction between one or more of the wood elements 238a, 238b, 238c, 238d, or between the filler 248 and the wood elements, providing stimulation in the joining of wood or other plant products. This stimulation can 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 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, and 238d, the filler 248, or both the filler 248 and one or more of the wood elements 238a, 238b, 238c, and 238d, and the aforementioned stimulation will be provided.

[0060] Figure 4 shows an ultrasonic transducer 232 supplying ultrasound 236 from a position approximately above multiple wood elements 238a, 238b, 238c, and 238d. In other examples, the ultrasonic transducer 232 can supply ultrasound 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 multiple wood elements, or from a position approximately below the multiple wood elements 238a, 238b, 238c, and 238d. In some examples, there may be two or more (e.g., 2, 3, 4, 5, 6, or more) ultrasonic transducers 232 that can supply ultrasound to multiple wood elements simultaneously or at different times. For example, some implementations may include two or more ultrasonic transducers 232 that can supply ultrasound to multiple wood elements simultaneously from a position approximately above the multiple wood elements. As another example, some implementations may include two or more ultrasonic transducers 232 capable of simultaneously supplying ultrasonic waves to multiple wood elements from positions approximately to the side, in front, behind, 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 capable of simultaneously supplying ultrasonic waves to multiple wood elements from one or more positions approximately above the multiple wood elements, and may also include one or more (e.g., 1, 2, 3 or more) ultrasonic transducers 232 capable of simultaneously supplying ultrasonic waves to multiple wood elements from one or more positions approximately to the side, in front, behind, or below the multiple wood elements. As will be apparent to those skilled in the art, other combinations are also possible.

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

[0062] The positive electrode 268 can be energized by a conductor 270 that can transmit a live electrical signal to the electrical ground 272, and the ground electrode 266 can be electrically coupled to the electrical ground 272. In some examples, the housing 262 can also be electrically coupled to the electrical ground 272. In some examples, the conductor 270 and the electrical ground 272 will each be supplied to the transducer 232 by a power cable 274.

[0063] The raw electrical signal supplied to the positive electrode 268 will generate a current flowing between the positive electrode 268 and the ground electrode 266. When a current flows between the positive electrode 268 and the ground electrode 266, as described above, one or more ultrasonic energy generating elements 264 are excited by the current and can generate ultrasound.

[0064] The transducer 232 includes an exemplary horn 276, also called a sonotrode, which can direct ultrasound towards an ultrasonic target, such as multiple wood elements. In some examples, one or more exemplary matching layers 278 may be included between the ground electrode 266 and the opening 280 defined in the housing 262. The one or more matching layers 278 may include a conductive material to obtain better energy transfer of ultrasonic energy to the horn 276 and the target. For embodiments including one or more matching layers 278, exemplary materials that can be used for the one or more matching layers 278 include epoxy, polyurethane, and polystyrene. One or more exemplary backing layers 282 located on the opposite side of the positive electrode 268 from the perspective of one or more ultrasonic energy generating elements 264 can prevent ultrasound from propagating away from the opening 280 in the housing 262. Furthermore, the exemplary acoustic isolation layer 284 is generally positioned between the inner surface of the housing 262 and one or more backing layers 282, and can provide acoustic isolation to prevent or limit the leakage of ultrasonic waves from the transducer 232, except 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 may include two or more (e.g., two, three, or four or more) openings 280 in the transducer housing so that the ultrasonic waves generated by the transducer can affect one or more targets from one or more positions or directions. Some ultrasonic transducers may 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] Figures 6A–6H illustrate various implementations of ultrasonic transducers, including various horn configurations. Figure 6A is a conceptual diagram 300 of an exemplary ultrasonic transducer 302, which includes an exemplary cymbal-shaped horn 304 that can be used to manufacture composite wood products using ultrasonic energy. Similar to the transducer described above, the ultrasonic transducer 302 can generate ultrasonic waves 306 directed through the horn 304 towards a target 308 (e.g., multiple wood elements). In some examples, the cymbal-shaped horn 304 may have the same shape as a common percussion instrument. In some examples, it may have a shape like a short cylinder, as shown in Figure 6A. In the horn 304, an opening 310 is drawn near the center of the horn 304, and the ultrasonic waves 306 will be radiated from the opening 310. The cymbal-shaped horn 304 can function, for example, as an acoustic waveguide.

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

[0068] Figure 6C is a conceptual diagram 340 of an exemplary ultrasonic transducer 342, which includes an exemplary ring-shaped horn 344 that can be used to manufacture composite wood products using ultrasonic energy. The ring-shaped horn 344 has a plurality of openings 346 drawn within the horn. The ultrasonic transducer 342 can generate ultrasonic waves 348 that are radiated from the plurality of openings 346 drawn in the ring-shaped horn 344 and directed through the horn 344 towards a target 350 (e.g., a plurality of wood elements). The ring-shaped horn 344 can function, for example, as an acoustic waveguide. In some examples, the plurality of openings 346 may be drawn, for example, on the underside of the ring-shaped horn 344 in an implementation where the ring-shaped horn 344 is positioned substantially above the target. In some examples, the plurality of openings 346 may be drawn, for example, on the upper surface of the ring-shaped horn 344 in an implementation where the ring-shaped horn 344 is positioned substantially below the target. In some examples, the multiple openings 346 may be defined, for example, on the inward-facing surface of the ring-shaped horn 344, in an implementation where the target or part of the target is located inside the space defined by the ring-shaped horn 344. In some examples, the openings 346 may be defined by combinations of the possible ring positions described above.

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

[0070] Figure 6E is a conceptual diagram 380 of an exemplary ultrasonic transducer 382, ​​which includes an exemplary 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 are radiated from the spherical horn 384 and directed through the horn 384 towards a target 388 (e.g., multiple wood elements). The spherical horn 384 may have any suitable diameter. The spherical horn 384 may function, for example, as an acoustic waveguide.

[0071] Figure 6F is a conceptual diagram 400 of an exemplary ultrasonic transducer 402, which includes an exemplary 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 directed through the horn 404 towards a target 408 (e.g., multiple wood elements). In the horn 404, an opening 410 is drawn near the center of the horn 404, and the ultrasonic waves 406 will be radiated from the opening 410. The dome-shaped horn 404 can function, for example, as an acoustic waveguide. Although not shown in Figure 6 for brevity, in some examples the dome-shaped horn 404 may be inverted relative to the orientation described for the ultrasonic transducer 402 in Figure 6F. For example, in some embodiments the horn may be shaped like a saucer or cup.

[0072] Figure 6G is a conceptual diagram 420 of an exemplary ultrasonic transducer 422, which includes an exemplary 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 directed through the horn 424 towards a target 428 (e.g., multiple wood elements). As shown in Figure 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 is defined with a slot-shaped opening 430, from which the ultrasonic waves 426 will be radiated. For example, the wedge-shaped horn 424 can function as an acoustic waveguide.

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

[0074] In some examples, multiple wood elements 452 (e.g., sawdust, wood flakes, wood chips, wood scraps, etc.) can be introduced into the chamber 446 via, for example, a first input channel 448, and filler material 454 can be introduced into the chamber 446 via a second input channel 450. The multiple wood elements 452 and filler material 454 may also be exposed to ultrasonic waves 456 within the chamber 446, which are generated by an ultrasonic transducer 442. In some examples, the filler material 454 can be attached to or coated onto the multiple wood elements 452 within the chamber 446, and the ultrasonic waves 456 within the chamber 446 can provide one or more mechanical and thermal stimuli to the multiple wood elements 452 and filler material 454 within the chamber 446, and as described above regarding the beneficial effects of ultrasonic waves, they can also stimulate the diffusion of filler material 454 onto and into the wood elements 452.

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

[0076] Figure 6H shows the horn 444 as having a tubular or cylindrical shape, but any of the horn shapes discussed herein may include a chamber similar to the chamber 446 through which various elements or materials can pass, which will be ultrasonically treated as they pass through the chamber. In some examples, the horn and chamber may be sized to accommodate larger wood elements, such as one or more of wood strips, wood strands, wood veneer, and wood sheets.

[0077] In some examples, a chamber may be included for sonicating elements or materials, 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 elements or materials within the transducer chamber.

[0078] Figure 7 is a flowchart 500 of an exemplary method that can be used to manufacture a composite wood product. In the first step 502, a filler is applied to multiple wood elements. The filler can be applied by one or more applicators, such as, for example, any of the applicators 158, 188, 208 shown in Figures 3A, 3B, and 3C, or any of the applicators of other examples described herein. In some embodiments, the filler may include an adhesive. In some embodiments, the filler may not include an adhesive. In some embodiments, the filler may include a plastic, but in other embodiments, the filler may not include a plastic. In some embodiments, the filler may include a metal, but in other embodiments, the filler may not include a metal. The aforementioned combinations (e.g., the filler includes an adhesive and a plastic, the filler includes an adhesive and a metal, or the filler includes an adhesive, a plastic, and a metal) are also possible. In some embodiments, the filler may be a liquid. In some embodiments, the filler may be a solid. In some embodiments, the filler may be a gas. According to some embodiments, combinations of the above examples in the state of one or more fillers can also be used. For example, in some embodiments, the filler may be a combination or mixture of liquids and solids. In some embodiments, the filler may be a combination or mixture of liquids and gases. In some embodiments, the filler may be a combination or mixture of solids and gases. In some embodiments, the filler may be a combination or mixture of liquids, solids, and gases.

[0079] Step 504 involves joining the wood elements to form a composite wood product and supplying ultrasonic energy having a frequency in the range of 10 kHz to 20 MHz to the wood elements. The ultrasonic energy can be supplied to the wood elements by one or more ultrasonic transducers, such as the ultrasonic transducer 232 shown in Figure 4, or any other example of an ultrasonic transducer described herein. In some examples, the ultrasonic energy supplied to the wood elements may have a frequency in the range of 15 kHz to 1 MHz. In some examples, the ultrasonic energy supplied 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 placed close to each other before joining them.

[0080] In some examples, the filler is applied to multiple wood elements before ultrasonic energy is supplied to them. In some examples, the filler is applied to multiple wood elements at the same time as ultrasonic energy is supplied to them. In some examples, ultrasonic energy is supplied to multiple wood elements before the filler is applied to them.

[0081] Figure 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, though not limited to, may include girders, beams, joists, L-joists, rafters, headers, studs, trusses, columns, rim boards, plywood, particleboard, fiberboard, oriented strand boards, flakeboards, waferboards, chipboards, glued timber, laminated veneer, orthogonal glued timber, parallel strand timber, strand glued timber, and finger joints. Environment 550 includes a filler application area 104 and an ultrasonic energy supply area 106, as described above with reference to Figure 1 and other figures, respectively, and includes a compressive force application area 552. Although not shown in Figure 8 for brevity, it will be understood that in some implementations, the wood element preparation area 102 in Figure 1 may also be included in environment 550.

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

[0083] Multiple wood elements 594 will be arranged in close proximity to one another. For example, multiple wood elements 594 may be stacked vertically as described above, or they may be arranged in any suitable manner. In some examples, multiple wood elements 594 include one or more elements 592 to which filler is applied by the applicator 582. In some examples, multiple wood elements 594 include one or more wood elements 592 to which filler is applied, and one or more wood elements to which filler is not applied. Also, in some examples, multiple wood elements 594 do not include filler.

[0084] One or more ultrasonic transducers can supply ultrasonic energy to multiple wood elements 594. In the example in Figure 9, ultrasonic transducers 584a and 584b are positioned to the side of a conveyor 595 that can transport multiple wood elements 594, and are positioned to the side of the multiple wood elements when the multiple wood elements are at a target position 596 to receive ultrasonic energy. The first ultrasonic transducer 584a is positioned to the left of the conveyor 595, and the second ultrasonic transducer 584b is positioned to the right of the conveyor 595. Furthermore, in this example, ultrasonic transducers 586a and 586b are positioned above the conveyor 595, and are positioned above the multiple wood elements 594 when the multiple wood elements are at a target position 596 to receive ultrasonic energy. In this example, the conveyor 595 can move multiple wood elements 594 to a target position 596 relative to the ultrasonic transducer, and the ultrasonic transducers 584a and 584b can supply ultrasonic energy to the multiple wood elements 594 from their left and right lateral positions to the right and left, respectively. Similarly, the ultrasonic transducers 586a and 586b can supply ultrasonic energy to the multiple wood elements 594 from top to bottom.

[0085] In other examples, additional ultrasonic transducers (e.g., five, six, seven, or eight or more) or fewer ultrasonic transducers (e.g., one, two, or three) may be used. In some examples, ultrasonic energy may be supplied from only one direction (e.g., only downward from one or more ultrasonic transducers on multiple wood elements, or from any other direction), and in these examples, more or fewer ultrasonic transducers than those shown in Figure 9 may be used (e.g., transducers 584a and 584b may not be used). In some examples, ultrasonic energy may be supplied from two directions (e.g., downward and a first transverse direction, or up and down, or left and right, or any other combination), and in these examples, more or fewer ultrasonic transducers than those shown in Figure 9 may be used. In the example in Figure 9, ultrasonic energy is generally supplied from three directions: 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 supplied to multiple wood elements from three or more directions (e.g., four, five, or six or more directions). For example, by providing additional ultrasonic transducers (not shown in Figure 9 for simplicity), ultrasonic energy may be supplied to the wood elements backward (e.g., from the front or front position of the wood element), forward (e.g., from the back or rear side of the wood element), or upward (e.g., from the bottom or underside of the wood element). Naturally, any of these alternative ultrasonic transducer positions or configurations can also be used in systems that supply ultrasonic energy to multiple wood elements from one, two, three, or more directions.

[0086] In some implementations, in some examples, one or more of the illustrated ultrasonic transducers 584a, 584b, 586a, and 586b can be moved or repositioned to supply ultrasonic energy to the wood element from one or more of these other directions or positions. On the other hand, although the ultrasonic transducer described above with reference to Figure 9 is shown within an environment 580 including a press 588, it will be understood that any ultrasonic transducer or configuration described with reference to either Figure 9 or this specification can be used in embodiments that do not include a press or an area that does 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 transducers supply ultrasonic energy to the multiple wood elements 594. In some examples, the conveyor 595 may continue to move while the ultrasonic transducers supply ultrasonic energy to the multiple wood elements 594. In some examples, the speed of the conveyor 595 may be adjusted (e.g., decelerated) for a period of time while the sound wave transducers supply ultrasonic energy to the multiple wood elements 594. In some examples, one or more ultrasonic transducers may remain stationary relative to the movement of the conveyor 595. In some examples, one or more ultrasonic transducers may be configured to move, for example, relative to the conveyor 595, relative to a target position 596, or relative to the multiple wood elements 594.

[0088] The press 588 can transmit one or more compressive forces to multiple wood elements 594. In some examples, the press 588 can transmit a downward compressive force to multiple wood elements 594. In some examples, the press 588 can transmit one or more lateral compressive forces (e.g., a compressive force from the left, a compressive force from the right, or a compressive force from both the left and right). In some examples, the press 588 can transmit compressive forces from in front of multiple wood elements 594, behind multiple wood elements 594, or from both the front and rear of multiple wood elements 594. It is also possible to combine the compressive forces applied in this way. For example, according to some embodiments, the press 588 can transmit a downward compressive force and one or more additional compressive forces (e.g., from the left, from the right, from both left and left, from the front, from the back, from both front and rear, from each of the left, right, front and rear, or from other directions) to multiple wood elements 588. In some examples, the press 588 may be nearly 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 on a wood element 594, or to move relative to multiple wood elements 594.

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

[0090] In some examples, one or more ultrasonic transducers can be integrated with a press and simultaneously supply ultrasonic energy to multiple wood elements while the press transmits one or more compressive forces to multiple wood elements (or, depending on the embodiment, before, after, or in the aforementioned combination). Figure 10A is a conceptual diagram 600 of an exemplary press 602 and an exemplary ultrasonic transducer 604 integrated with the press 602 and usable to manufacture composite wood products using ultrasonic energy. In some embodiments, the ultrasonic transducer 604 and the press 602 can simultaneously supply ultrasonic energy and compressive force to multiple wood elements 606, respectively. The example in Figure 10A shows wood elements 606 on a conveyor 608 (in this example, two vertically stacked wooden veneers, but any wood elements discussed herein can be used as substitutes), and the conveyor 608 can move the multiple wood elements 606 to target positions 609 below the press 602 and ultrasonic transducer 604.

[0091] The press 602 can apply a downward compressive force 610 to multiple wood elements 606 when the wood elements 606 are in a target position 609, and simultaneously, the ultrasonic transducer 604 can supply ultrasonic energy to the multiple wood elements. The press 602 includes a surface 612 from which the compression 610 can be applied to the multiple wood elements 606. In some examples, the ultrasonic transducer 604 can be positioned coplanar with the surface 612 of the press 602 from which the compressive force 610 can be applied to the multiple wood elements 606. In some examples, the ultrasonic transducer 604 can be positioned recessed relative to the surface 612 of the press 602 from which the compressive force 610 can be applied to the multiple wood elements 606. In this example, the press 602 and the ultrasonic transducer 604 can supply compressive force and ultrasonic energy in a first direction (for example, downward relative to the target position 609 in this example). In some examples, the press 602 and the ultrasonic transducer 604 can supply compressive force and ultrasonic energy at different times, respectively. For example, the ultrasonic transducer 604 can first supply ultrasonic energy to multiple wood elements, and then the press 602 can apply compressive force to the multiple wood elements. Alternatively, the press 602 may first apply compressive force to the multiple wood elements, and then the ultrasonic transducer 604 may supply ultrasonic energy to the multiple wood elements. In some examples, the press 602 and the ultrasonic transducer 604 can supply compressive force and ultrasonic energy simultaneously, or at different times, respectively.

[0092] Figure 10B is a conceptual diagram 620 showing an exemplary press 622 and one or more exemplary ultrasonic transducers 624a, 624b integrated with the press 622 and usable to manufacture composite wood products using ultrasonic energy. In some embodiments, the ultrasonic transducers 624a, 624b and the press 622 can each simultaneously supply ultrasonic energy and one or more compressive forces to a plurality of wood elements 626. An example in Figure 10B shows four ultrasonic transducers 624a integrated with the press 622 and arranged to supply ultrasonic energy toward the plurality of wood elements 626 in a first direction (for example, downward from an upper position of the plurality of wood elements in this example) when the plurality of wood elements 626 are in a target position 627. The example in Figure 10B shows a single ultrasonic transducer 624b integrated with a press 622 and configured to supply ultrasonic energy to the multiple wood elements 626 from a second direction (e.g., laterally, i.e., from right to left of the multiple wood elements in this example) when the multiple wood elements 626 are in a target position 627. The example in Figure 10B shows the wood elements 626 on a conveyor 628 that can move the multiple wood elements 626 to a target position 627 (four wood sheets arranged in a 2x2 (2x2 height x 2 width) configuration, but any wood elements discussed herein can be used instead).

[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 in a target position 627. The press 622 includes a first surface 631 from which the downward compressive force 630 can be applied 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 are moving to a target position 6. In this example, the lateral compressive force 632 may be a leftward compressive force applied by the press 622 from the right of the wood elements 626 when the wood elements are in a target position 627. The press 602 includes a second surface 633 from which the lateral force 632 can be applied to the wood elements 626. In some examples, the lateral compressive force may be a rightward compressive force applied by the press 622 (for example, using the press surface opposite the second surface 633 in Figure 10B) to the multiple wood elements 626 when the multiple wood elements are in 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, the press 622 can apply one or more downward forces (e.g., force 630) and one or more lateral forces (e.g., force 632, or any other lateral force as described above) simultaneously. In some examples, the press 622 can apply one or more downward forces and one or more lateral forces at different points in time. For example, the press 622 may first apply the downward force 630, and then apply the lateral force 632 (or any other lateral force). In another example, the press 622 may first apply the lateral force 632 (or any other lateral force), and then apply the downward force 630.

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

[0096] Figure 10C is a conceptual diagram 640 of an exemplary press 642 and one or more exemplary ultrasonic transducers 644a, 644b integrated into the press 642 and usable to manufacture composite wood products using ultrasonic energy. In some implementations, the ultrasonic transducers 644a, 644b and the press 642 can each simultaneously supply ultrasonic energy and one or more compressive forces to multiple wood elements 646. An example in Figure 10C shows three ultrasonic transducers 644a integrated into the press 642 and arranged to supply ultrasonic energy toward the multiple wood elements 646 in a first direction (for example, downward from the position on the multiple wood elements in this example) when the multiple wood elements 646 are in a target position 647. The example in Figure 10C shows three ultrasonic transducers 644b integrated with a press 642 and arranged to supply ultrasonic energy to the multiple wood elements 646 from a second direction (for example, from the forward position of the multiple wood elements 646 to the backward position when the wood elements are in the target position 647). The example in Figure 10C shows the wood elements 646 on a conveyor 648 that can move the multiple wood elements 646 to the target position 647 (four wood strips arranged in a 2x2 (height 2xwidth 2) configuration, but any wood elements discussed herein can be used instead).

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

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

[0099] In some examples, the ultrasonic transducer 644a can be positioned coplane with the first surface 651 of the press 642, which can apply a downward compressive force 650 to multiple wood elements 646. In some examples, the ultrasonic transducer 644a can be positioned recessed to the first surface 651 of the press 642. Similarly, in some examples, the ultrasonic transducer 644b can be positioned coplane with the second surface 653 of the press 642, which can apply a backward compressive force 652 to multiple wood elements 646. In some examples, the ultrasonic transducer 644b can be positioned recessed 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 supply one or more compressive forces and ultrasonic energy at different points in time, for example, in a manner similar to that described above with reference to Figure 10A.

[0100] Examples in Figures 10B and 10C demonstrate that ultrasonic energy can be supplied to multiple wood elements from two or more directions, according to several implementation configurations. For example, examples in Figures 10B and 10C show that ultrasonic energy can be supplied to multiple wood elements in a downward direction (e.g., from a position approximately above the multiple wood elements) and in other directions different from the downward direction (e.g., laterally from a position to the left or right of the wood elements, backward from a position in front of the wood elements, and forward from a position in the rear of the wood elements).

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

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

[0103] Figure 11B is a block diagram illustrating an environment 680 for manufacturing composite wood products using ultrasonic energy. The environment 680 includes a filler application area 104 and an ultrasonic energy supply area 106, respectively, with reference to Figure 1 and other figures, and includes components that can be included in areas 104 and 106, as well as a composite wood product processing area 682. In some examples, after multiple wood elements have been joined to form a composite wood product, the composite wood product may be subjected to processing carried out in the composite wood product processing area 682.

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

[0105] Examples of treatments applicable to composite wood products may include one or more sealants, flame retardants, insecticides or pest repellents, stains, paints, or other post-treatments, and such treatments may include supplying ultrasonic energy to the composite wood product, as described. In some examples, edge treatments may be applied to composite wood products, and such treatments may also include supplying ultrasonic energy to the composite wood product, as described. In some examples, ultrasonic energy can provide one or more advantages with respect to treatments similar to those described above with respect to fillers. For example, ultrasonic energy can stimulate the spreading or penetration of the treatment into the composite wood product or deeper penetration of the treatment, or it can stimulate better flow of the treatment to liquid or flowable treatment agents.

[0106] The composite wood product processing area 682 may include processing supply components that can apply processing to the composite wood product. In some examples, the processing application component may include one or more of the following: rollers, brushes, spray applicators, etc. In some examples, the processing application component may supply ultrasonic energy to the composite wood product (e.g., via one or more ultrasonic transducers). In some examples, the ultrasonic energy may be supplied by one or more ultrasonic transducers separate from the processing application component. Although not shown in Figure 11B for brevity, it will be understood that in some implementations, one or more of the compression force application areas 552 in Figure 8, the wood element preparation area 102 in Figure 1, and the defect inspection area 672 in Figure 11A may also be included in the environment 680.

[0107] Figure 11C is a block diagram of an environment 690 for manufacturing composite wood products using ultrasonic energy. The environment 690 includes a filler application area 104 and an ultrasonic energy supply area 106, as described above with reference to Figure 1 and other figures, respectively, and includes components that may be included in areas 104 and 106, as well as a pretreatment area 692. In some examples, a pretreatment may be applied to a plurality of wood elements, which may be carried out in the pretreatment area 692 and include supplying ultrasonic energy to the plurality of wood elements before applying filler 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 may include pretreatment supply components. According to some embodiments, the pretreatment of wood elements may include supplying ultrasonic energy at an ultrasonic energy level lower than the ultrasonic energy level used when joining the plurality of wood elements. For example, one or more ultrasonic transducers can supply ultrasonic energy to a plurality of wood elements as a pretreatment of the plurality of wood elements. In some examples, this pretreatment supply of ultrasonic energy can be supplied by one or more ultrasonic transducers that supply ultrasonic energy to multiple wood elements in the joining of wood elements. In some examples, this pretreatment supply of ultrasonic energy can be supplied by one or more ultrasonic transducers that are different from those that supply ultrasonic energy to multiple wood elements in the joining of wood elements. Although not shown in Figure 11C for brevity, it is understood that in some implementations, one or more of the compressive force application areas 552 in Figure 8, the wood element preparation area 102 in Figure 1, the defect inspection area 672 in Figure 11A, and the composite wood product processing area 682 in Figure 11B may also be included in the environment 690.

[0108] In some examples, an ultrasonic transducer including a roller element can be used to supply ultrasonic energy to multiple 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 may include a cylindrical body. In some embodiments, the roller element may include a spherical body. In some examples, the body of the roller element may include an outer surface configured to physically contact multiple wood elements while supplying ultrasonic energy. In some examples, the body of the roller element may include an outer surface configured to physically contact and roll over multiple wood elements while supplying ultrasonic energy. In some examples, the outer surface of the body of the roller element may be substantially smooth. In some examples, the outer surface of the body of the roller element may include multiple protrusions. In some examples, the outer surface of the body of the roller element may include multiple recessed shapes. In some examples, the outer surface of the body of the roller element may include one or more protrusions and one or more recessed shapes.

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

[0110] Multiple wood elements 710 can be arranged in close proximity to each other. For example, multiple wood elements 710 may be stacked vertically, arranged horizontally, or arranged in any suitable manner. In the example shown in Figure 12A, the wood elements, which are wooden veneer in this example, may be arranged in a 2x2 configuration. In some examples, multiple wood elements 710 include one or more elements 712 to which filler has been applied by an applicator 702. In some examples, multiple wood elements 710 include one or more elements 712 to which filler has been applied, and one or more wood elements to which filler has not been applied. Also, in some examples, multiple wood elements 710 do not include filler. Multiple wood elements 710 may be placed on a conveyor 714, or moved on the conveyor 714 in direction 716. The conveyor 714 may move the multiple wood elements 710 to a target position 717 relative to an ultrasonic transducer 704, a roller element 706, or both the ultrasonic transducer 704 and the roller element 706.

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

[0112] In some examples, the roller element 706 may include a cylindrical body 726, the outer surface 728 of the cylindrical body 726 may be configured to physically contact one or more wood elements of the multiple wood elements 710 while ultrasonic energy is being supplied to the multiple wood elements 710. For example, the roller element 706 may rotate around 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 multiple wood elements 710. In the example shown in Figure 12A, it can be seen that as the roller element 706 rolls across the top surface of the multiple wood elements 710, the outer surface 728 will contact two wood elements of the multiple wood elements 710 (for example, two elements on the top surface of a 2x2 stack).

[0113] Figure 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 Figure 12A. The ultrasonic transducer 730 can generate ultrasonic energy that can be directed from the ultrasonic transducer 730 to the roller element 732 by exemplary ultrasonic horn 734, and the ultrasonic horn 734 can be coupled to the ultrasonic transducer 730 and configured to direct 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 can generally have a spherical shape. The outer surface 738 of the spherical body 736 may be in physical contact with one or more wood elements 737 of a plurality of wood elements. Similar to the roller element 706 in Figure 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 such as 739a, 739b, 739c, 739d, 739e, 739f, 739g, 739h, 7391, 739j, etc., similar to, for example, the ball used in early computer mice rolling 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 may be a roller. In some examples, the support member 740 may be a pad, cushion, fastener, 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 those 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 in Figure 12A.

[0114] In some examples, ultrasonic energy can be supplied to multiple wood elements via roller elements 706 or 732. In various embodiments, the ultrasonic energy may have a frequency in the range of 10 kHz to 20 MHz. In some examples, the ultrasonic energy may 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, the ultrasonic energy can be radiated from the outer surface 728 or 738 to multiple wood elements 710. According to various implementations, the ultrasonic energy can be transmitted from the roller elements 706 or 732 to multiple wood elements 710 by one or more ultrasonic longitudinal waves, ultrasonic radiated waves, or ultrasonic transverse waves. In some examples, while ultrasonic energy is being supplied, at least a portion of the outer surface 728 or 738 may remain in physical contact with at least one of the multiple wood elements 710. In some examples, ultrasonic energy will continue to be supplied even when the outer surface 728 or 738 is not in physical contact with any of the multiple wood elements 710 at one or more of the following times: before, after, or both before and after the outer surface 728 or 738 comes into contact with the wood element.

[0115] In some examples, systems comprising ultrasonic transducers 704 or 730 and roller elements 706 or 732, respectively, can stimulate the bonding of wood elements by providing ultrasonic energy to multiple wood elements 710. Referring to other systems for manufacturing composite wood products using ultrasonic energy, as described above, the supplied ultrasonic energy provides various mechanical stimuli (e.g., vibrational stimuli at the molecular and macroscopic levels) to the multiple wood elements 710 and filler, thermal stimuli to the multiple wood elements 710, and diffusive stimuli to the filler. Furthermore, the friction generated between the wood elements by the supply of ultrasonic energy can further stimulate bonding. The ultrasonic treatment pressure (e.g., pressure from the ultrasonic) resulting from the supply of ultrasonic energy will also stimulate the bonding of multiple wood elements. Advantageously, the ultrasonic transducers 704 or 730 and roller elements 706 or 732 can continuously stimulate multiple wood elements 710 and filler, respectively, which will beneficially assist in bonding.

[0116] The roller element 706 or 732 may include any suitable material. In some examples, the roller element 706 or 732 includes titanium. In some examples, the roller element 706 or 732 includes aluminum. In some examples, the roller element 706 or 732 can provide compressive force to multiple wood elements 710 when its outer surface 728 or 738 rolls over the wood elements. In some examples, the roller element 706 or 732 may not provide compressive force to multiple wood elements when its 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 when the roller element 706 or 732 rolls over multiple wood elements 710. Figure 12C is a conceptual diagram showing an environment 742 for manufacturing composite wood products using ultrasonic energy. According to some implementations, the exemplary ultrasonic transducer 743 includes an exemplary horn 744 and an exemplary roller element 745, which can represent the transducer 704 or 730, the horn 718 or 734, and the roller element 706 or 732 in Figures 12A and 12B, respectively. In some implementations, an exemplary motion controller 746 can control the motion of the transducer 743. In some examples, the motion controller 746 can control the movement of the transducer 743 and, furthermore, the movement of the horn 744 and the roller element 745. The motion controller 746 may include one or more motors (for example, a servo motor, a stepping motor, a linear motor, a direct drive motor, an AC motor, or a DC motor), and may also include a motion control module that provides one or more signals to one or more motors to control the movement of the ultrasonic transducer 743. In the example in Figure 12C, the motion controller 746 is shown separately from the ultrasonic transducer 743, but in some implementations, the motion controller 746 may be integrated 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 roller element 745) to move linearly 748 (for example, forward, backward, or in each of the forward and backward directions). 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 roller element 745) to move in a two-dimensional pattern, such as a pattern covering the surface of one or more wood elements of a plurality of wood elements (for example, moving in a two-dimensional plane). In some examples, the motion controller 746 can command the ultrasonic transducer 743 to move in a three-dimensional pattern (for example, moving in three-dimensional space). Figure 12C shows a pattern 749 intended to demonstrate that ultrasonic transducers (and, in some examples, horns 744 and roller elements 745 by extension) can move in any direction in three-dimensional space, and for simplification, arrows to and from the page are not shown in pattern 749. In some examples, ultrasonic transducers 743 (and, in some examples, horns 744 and roller elements 745) can be configured to move in multi-axis motion systems such as two-axis or three-axis motion systems.

[0119] In some examples, the motion controller 746 may include one or more of the following: a processing component, a communication module, memory, a power supply module, and one or more sensors. Although not shown in Figure 12C for simplification, in some examples, the motion controller 746 may include one or more of the following: a processing component 872, a communication module 874, memory 876, a power supply module 878, and one or more sensors 880, as shown in Figure 15B. These can be used to provide the motion control functions described above, as will be 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 may be configured to move across a two-dimensional grid set to a given height (or width, or depth), or it may be configured to move across two-dimensional grids set to various heights (or widths, or depths) (for example, to move in three-dimensional space). Referring again to Figure 12C, the ultrasonic transducer 743 can be configured to move along or across the motion guide 747. In some examples, the motion guide 747 may be one or more rails, sliders, or tracks. In some examples, the motion guide 747 may be a two-dimensional grid. In some examples, the operating 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 nearly stationary as the roller element rolls over multiple wood elements. In some implementations, the horn may be configured to extend or contract as the roller element rolls over multiple wood elements.

[0122] In some examples, both the horn and roller elements may be considered part of the ultrasonic transducer, and according to some examples, such a part of the ultrasonic transducer may be in physical contact with the wood elements or filler while ultrasonic energy is being supplied to multiple wood elements. In some examples, the horn or roller elements may not be considered part of the ultrasonic transducer.

[0123] In some examples, whether the roller element includes a cylindrical body or a spherical body, the outer surface of each body can include a variety of features. In some examples, the outer surface of the cylindrical body 728 or the spherical body 738 may be substantially smooth, may include a number of protrusions, may include a number of recessed shapes, or may include one or more protrusions and one or more recessed shapes.

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

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

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

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

[0128] The second projection 808 includes a substantially flat outer surface 809. As can be seen from the top view 802 of Figure 14B, the base of the second projection 808 has a square shape, similar to the outer surface 809 of the second projection 808, but any other suitable shape (e.g., elliptical, circular, rectangular, triangular, rhombus, diamond, or other suitable shape) can be used as a substitute for the base or outer surface 809 of the projection 808 having a substantially flat outer surface 809. In some examples, the base and outer surface 809 of the second projection 808 may have different shapes, including any combination of the shapes described above.

[0129] The third projection 810 has an outer surface containing a point 811. In some examples, the point 811 may be the vertex of the projection 810. In some examples, the third projection 810 may have a roughly "pyramid" shape. As can be seen from the top view 802 of Figure 14B, the base of the third projection 810 has a square shape, but any other suitable shape (e.g., ellipse, circle, rectangle, triangle, rhombus, diamond, or other suitable shape) can be used alternatively for the base of the projection 810 having an outer surface containing a point.

[0130] The fourth projection 812 has an outer surface including a ridge 813. As can be seen from the upper surface 802 in Figure 14B, the base of the fourth projection 812 has a rectangular shape, but any other suitable shape (e.g., elliptical, circular, square, triangular, rhombic, diamond, or other suitable shape) can be used alternatively for the base of the projection 812 having an outer surface including a ridge.

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

[0132] Figure 14C is a front view 820 and Figure 14D is a side view 820, showing an exemplary portion of an exemplary roller element 824 including a plurality of exemplary 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 an outer surface 825 into which the recesses 826, 828, 830, 832, 834 are positioned. 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 in Figure 14D, the base of the first recess 826 is circular, but other suitable shapes (e.g., elliptical, square, rectangular, triangular, rhombus, diamond, or other suitable shapes) may be used alternatively 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 Figure 14D, the base of the second recess 828 has a square shape, similar to the outer surface 829 of the second recess 828, but other suitable shapes (e.g., elliptical, circular, rectangular, triangular, rhombus, diamond, or other suitable shapes) may be used alternatively 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 any combination of the shapes described above.

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

[0135] The fourth recess 832 has an outer surface including a ridge 833, or a concave ridge or an inverted ridge. As can be seen from the top view 822 of Figure 14D, the base of the fourth recess 832 has a rectangular shape, but any other suitable shape (e.g., elliptical, circular, square, triangular, rhombic, diamond, or other suitable shape) can be used alternatively for the base of the recess 832 having an outer surface including a ridge.

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

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

[0138] In some examples, the apparatus, systems, and methods described herein may be used to supply varying or different amounts of ultrasonic energy to multiple wood elements, or to transmit ultrasonic energy to multiple wood elements or to one or more target regions or target locations within them, or to provide a combination thereof. In some examples, a first amount of ultrasonic energy may be supplied to multiple wood elements, and then a second amount of ultrasonic energy may be requested from the multiple wood elements. In some embodiments, the first amount of ultrasonic energy may have a higher intensity than the second amount of ultrasonic energy. In some embodiments, the first amount of ultrasonic energy may have a lower intensity than the second amount of ultrasonic energy. In some examples, the first amount of ultrasonic energy may be supplied to multiple wood elements over a first period, and then the second amount of ultrasonic energy may be supplied to multiple wood elements over a second period different from the first period (e.g., longer or shorter than the first duration).

[0139] In some examples, a first amount of ultrasonic energy can be supplied to multiple wood elements or to a first target location within them, and then a second amount of ultrasonic energy can be supplied to multiple wood elements or to a second target location within them. In some examples, the ultrasonic transducer may remain stationary throughout both the supply of the first amount of ultrasonic energy to the first target location and the supply of the second amount of ultrasonic energy to the second target location. In some examples, the ultrasonic transducer, or one or more parts of the ultrasonic transducer, may move or be moved during the supply of the first amount of ultrasonic energy to the first target location, during the supply of the second amount of ultrasonic energy to the second target location, or during the time it takes to supply the first and second amounts. As described above, this may include supplying various combinations of different amounts of ultrasonic energy to multiple wood elements or to different locations within them over different periods of time.

[0140] Figure 15A is a conceptual diagram 850 showing an example control module 852 and an ultrasonic transducer 854 that supply ultrasonic energy to multiple wood element examples 856 for manufacturing composite wood products using ultrasonic energy. According to some examples, the exemplary control module 852 can provide one or more control signals 857 to the exemplary ultrasonic transducer 854 to control one or more of the following: the amount of ultrasonic energy, the intensity of the ultrasonic energy, the duration of the ultrasonic energy, the transmission depth of the ultrasonic energy, and the target position for the transmission of the ultrasonic energy. In general, the control module 852 may be used with any of the exemplary ultrasonic systems described herein and may be used to provide one or more of the aforementioned control signals 857 to one or more ultrasonic transducers in any of the exemplary 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 Figure 15A.

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

[0142] Figure 15B is a block diagram 870 of the exemplary control module 852 shown in Figure 15A. The control module 852 includes a processing component 872, a communication module 874, a memory 876 (for example, containing stored data in some examples), and a power supply module 878. The processing component 872 may, in some examples, include one or more microcontrollers, microprocessors, or digital signal processors that can execute instructions stored in the memory 876 and perform tasks for the control module 852. The communication module 874 may, in some examples, include a transmitter that transmits information directly, via a wired connection, and in some examples, via wired or wireless communication over 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., 3G / 4G / 5G networks, a combination of the above)).

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

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

[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 supplying ultrasonic energy. In some examples, one or more sensors 880 can sense ambient environmental parameters, such as temperature, humidity, atmospheric pressure, air quality, or one or more 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 one or more external sensors, and such input can provide the control module 852 with information about 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 supplying ultrasonic energy.

[0146] The ultrasonic energy supply control module 882 can be used to manage or control the manner in which ultrasonic energy is supplied to multiple wood elements 856. For example, the ultrasonic energy supply control module 882 can generate one or more control signals 857 as shown in Figure 15A. In various examples, the ultrasonic energy supply 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 the manner in which ultrasonic energy is supplied. For simplicity, Figure 15B shows the ultrasonic energy supply control module 882 as a standalone module, but in some implementations, the module 882 may be contained within the processing component 872. In Figure 15A, the control module 852 is shown in a separate enclosure from the transducer 854, but in some examples, the control module 852, or one or more parts of the control module 852, can be located within the transducer 854.

[0147] Referring again to Figure 15A, the control module 852 can instruct the ultrasonic transducer 854, for example via one or more control signals 857, to supply varying amounts of ultrasonic energy to multiple wood elements 856, the multiple wood elements 856 including wood elements 858a, 858b, and 858c arranged longitudinally in the same manner as the wood elements in Figure 4. In some examples, the control module 852 can instruct the ultrasonic transducer 854, for example via one or more control signals 857, to supply ultrasonic energy to various positions or parts of the multiple wood elements 856.

[0148] The control module can be instructed to supply a first amount of ultrasonic energy 860 to a first position or part of a plurality of wood elements, such as wood elements 858a, 858b, and 858c. This can stimulate the joining of wood elements 858a, 858b, and 858c, for example. The control module can then be instructed to supply a second amount of ultrasonic energy 862, such as a smaller amount of ultrasonic energy, to a second position or part of a plurality of wood elements, such as wood element 858d, which can stimulate the joining of element 858d to element 858c. Each of elements 858a, 858b, and 858c may be one type of wood element, such as wood strand, and element 858d may be another type of wood element, such as wood veneer. The wood veneer 858d is more delicate than, for example, the wood strands 858a, 858b, and 858c, and can therefore benefit from a smaller amount of ultrasonic energy 860 supplied when stimulating bonding to the element 858c. In some examples, the control module 852 may include the motion controller 746 shown in Figure 12C, which can provide motion control functions to the ultrasonic transducer 854.

[0149] In a typical embodiment, a system for manufacturing a composite wood product includes an applicator configured to apply a filler to multiple wood elements and an ultrasonic transducer configured to supply ultrasonic energy to the multiple wood elements, wherein the ultrasonic energy has a frequency in the range of 10 kHz to 20 MHz.

[0150] The embodiment may include one or more of the following: Multiple wood elements can be joined to form a composite wood product. The applicator may include an adhesive applicator, and the filler may include an adhesive. The filler does not have to include an adhesive. The filler may include plastic. The filler may include metal. Multiple wood elements can be positioned close to each other before the ultrasonic transducer supplies ultrasonic energy to the multiple wood elements. The applicator can apply the filler to the multiple wood elements at the same time that the ultrasonic transducer supplies ultrasonic energy to the multiple wood elements. The ultrasonic transducer can supply ultrasonic energy to the multiple wood elements before the applicator applies the filler to the multiple wood elements. The ultrasonic transducer can supply ultrasonic energy to the multiple wood elements after the applicator has applied the filler to the multiple wood elements. The system may include a press configured to apply compressive force to the multiple wood elements. The press may apply compressive force to the multiple wood elements before the ultrasonic transducer supplies ultrasonic energy to the multiple wood elements. The press can apply compressive force to multiple wood elements while simultaneously supplying ultrasonic energy to multiple wood elements via an ultrasonic transducer. The press can apply compressive force to multiple wood elements after the ultrasonic transducer has supplied ultrasonic energy to the multiple wood elements. The ultrasonic energy may have a frequency in the 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 system may further include a defect inspection component, the ultrasonic transducer may be further configured to supply an additional amount of ultrasonic energy to the composite wood product, and the defect inspection component may be configured to inspect defects in the composite wood product. The defect inspection component may include a camera. The system may further include a defect inspection component and a second ultrasonic transducer, the second ultrasonic transducer may be configured to supply ultrasonic energy to the composite wood product, and the defect inspection component may be configured to inspect defects in the composite wood product.The defect inspection component may include a camera. The ultrasonic transducer can further be configured to supply ultrasonic energy to multiple wood elements before the applicator applies the filler to the multiple wood elements. By supplying ultrasonic energy to multiple wood elements before the applicator applies the filler to the multiple wood elements, the multiple wood elements can be cleaned. The system may further include a processing applicator configured to process a composite wood product, and the ultrasonic transducer can further be configured to supply an additional amount of ultrasonic energy to the composite wood product. The system may further include a processing applicator and a second ultrasonic transducer, the processing applicator can be configured to apply the process to the composite wood product, and the second ultrasonic transducer can be configured to supply ultrasonic energy to the composite wood product. The ultrasonic transducer can be selected from the group of Langevin transducers, ring transducers, cymbal transducers, dome transducers, horn transducers, pyramid transducers, wedge transducers, and spherical transducers. The ultrasonic transducer can generate ultrasonic energy as a square wave. An ultrasonic transducer can generate ultrasonic energy as a sine wave. An ultrasonic transducer can generate ultrasonic energy as a wave selected from a group consisting of trapezoidal waves and triangular waves. An ultrasonic transducer can generate ultrasonic energy as a continuous waveform. An ultrasonic transducer can generate ultrasonic energy as a pulsed waveform. The system may further include a conveyor configured to transport multiple wood elements. The system may further include a funnel configured to guide multiple wood elements onto the conveyor. The system may further include a chamber configured to accommodate multiple wood elements.

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

[0152] The embodiment 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 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 that includes a point. At least one of the plurality of protrusions may have an outer surface that includes a ridge. Multiple wood elements can be joined to form a composite wood product. The applicator may include an adhesive applicator, and the filler may include an adhesive. The filler does not have to include an adhesive. The filler may include plastic. The filler may include metal. Multiple wood elements can be positioned close to each other before the roller element supplies ultrasonic energy to the multiple wood elements. The applicator can apply the filler to the multiple wood elements at the same time that the roller element supplies ultrasonic energy to the multiple wood elements. The roller element can supply ultrasonic energy to multiple wood elements before the applicator applies the filler to the multiple wood elements. The roller element can supply ultrasonic energy to the multiple wood elements after the applicator has applied the filler to the multiple wood elements. The system may further include a press configured to apply compressive force to the multiple wood elements. The press may apply compressive force to the multiple wood elements before the roller element supplies ultrasonic energy to the multiple wood elements. The press can apply compressive force to the multiple wood elements at the same time that the roller element supplies ultrasonic energy to the multiple wood elements. The press can apply compressive force to the multiple wood elements after the roller element has supplied ultrasonic energy to the multiple wood elements. The ultrasonic energy may have a frequency in the 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 system may further include a defect inspection component, the roller element may be further configured to supply ultrasonic energy to a composite wood product, and the defect inspection component may be configured to inspect defects in the composite wood product. The defect inspection component may include a camera. The roller element may be configured to supply ultrasonic energy to multiple wood elements before the applicator applies filler to multiple wood elements. Multiple wood elements can be cleaned by supplying ultrasonic energy to multiple wood elements before the applicator applies filler to multiple wood elements. The system may further include a processing applicator configured to process a composite wood product, and the roller element may be further configured to supply ultrasonic energy to the composite wood product. The ultrasonic transducer can generate ultrasonic energy as a square wave. The ultrasonic transducer can generate ultrasonic energy as a sine wave. The ultrasonic transducer can generate ultrasonic energy as a wave selected from a group consisting of trapezoidal waves and triangular waves. The ultrasonic transducer can generate ultrasonic energy as a continuous waveform. The ultrasonic transducer can generate ultrasonic energy as a pulsed waveform. This system may further include a conveyor configured to transport multiple timber elements. This system may further include a funnel configured to guide multiple timber elements onto the conveyor. This system may further include a chamber configured to accommodate multiple timber elements.

[0153] In a typical embodiment, a system for manufacturing a composite wood product includes an applicator configured to apply a filler to a plurality of wood elements, and an ultrasonic transducer configured to generate ultrasonic energy, the ultrasonic energy having a frequency in the 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 ultrasonic energy to the roller element, the roller element configured to supply ultrasonic energy to a plurality of wood elements, wherein when ultrasonic energy is supplied, a portion of the outer surface of the spherical body remains in physical contact with at least one of the plurality of wood elements.

[0154] The embodiment 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 that includes a point. At least one of the plurality of protrusions may have an outer surface that includes a ridge. Multiple wood elements can be joined together to form a composite wood product. The applicator may include an adhesive applicator, and the filler may include an adhesive. The filler does not have to include an adhesive. The filler may include plastic. The filler may include metal. Multiple wood elements can be positioned close to each other before the roller element supplies ultrasonic energy to the multiple wood elements. The applicator can apply the filler to the multiple wood elements at the same time that the roller element supplies ultrasonic energy to the multiple wood elements. A roller element can supply ultrasonic energy to multiple wood elements before an applicator applies filler to multiple wood elements. A roller element can supply ultrasonic energy to multiple wood elements after an applicator has applied filler to multiple wood elements. The system may further include a press configured to apply compressive force to multiple wood elements. The press may apply compressive force to multiple wood elements before the roller element supplies ultrasonic energy to multiple wood elements. The press may apply compressive force to multiple wood elements simultaneously with the roller element supplying ultrasonic energy to multiple wood elements. The press may apply compressive force to multiple wood elements after the roller element has supplied ultrasonic energy to multiple wood elements. The ultrasonic energy may have a frequency within the frequency range of 15 kHz to 1 MHz. The ultrasonic energy may have a frequency within the frequency range of 20 kHz to 100 kHz.The system may further include a defect inspection component, the roller element may be further configured to supply ultrasonic energy to a composite wood product, and the defect inspection component may be configured to inspect for defects in the composite wood product. The defect inspection component may include a camera. The roller element may be configured to supply ultrasonic energy to multiple wood elements before an applicator applies filler to multiple wood elements. Multiple wood elements can be cleaned by supplying ultrasonic energy to multiple wood elements before an applicator applies filler to multiple wood elements. The system may further include a processing applicator configured to process a composite wood product, and the roller element may be further configured to supply ultrasonic energy to the composite wood product. The ultrasonic transducer can generate ultrasonic energy as a square wave. The ultrasonic transducer can generate ultrasonic energy as a sine wave. The ultrasonic transducer can generate ultrasonic energy as a wave selected from a group consisting of trapezoidal waves and triangular waves. The ultrasonic transducer can generate ultrasonic energy as a continuous waveform. The ultrasonic transducer can generate ultrasonic energy as a pulsed waveform. This system may further include a conveyor configured to transport multiple timber elements. This system may further include a funnel configured to guide multiple timber elements onto the conveyor. This system may further include a chamber configured to accommodate multiple timber elements.

[0155] The above description provides examples of several embodiments. Other embodiments not expressly described above are also possible, such as embodiments based on modifications and / or variations of the features described above. For example, the above techniques may be carried out in a different order, including one or more additional steps and / or excluding one or more specified steps. Similarly, devices, systems, and methods may include one or more additional features, exclude one or more specified features, and / or include specified features or steps combined in a way different from those presented above. A feature or step described singly may be carried out as multiple such features or steps. Similarly, a feature or step described plural may be carried out as a single example of such features or steps. Furthermore, steps and techniques described above as being carried out by some devices and / or systems may be carried out alternatively or additionally by other devices and / or systems described above, or other devices and / or systems not expressly described. The drawings are for illustrative purposes only and may not show some embodiments in detail. Modifications of size, arrangement, shape, angle, curvature, and / or relative positional features are possible. Therefore, other embodiments are also included in the scope of the following claims.

Claims

1. A method for manufacturing composite wood products, Apply filler to multiple wood elements, A compressive force is applied to the plurality of wood elements by a press having a first surface that applies a compressive force to the plurality of wood elements. The plurality of wood elements are joined together to form a composite wood product, and the joining includes supplying ultrasonic energy to the plurality of wood elements. The ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz. The ultrasonic energy is supplied by an ultrasonic transducer integrated with the press, and the ultrasonic transducer is positioned directly on the first surface of the press so as to be flush with the first surface.

2. A method for manufacturing composite wood products, Apply filler to multiple wood elements, A compressive force is applied to the plurality of wood elements by a press having a first surface that applies a compressive force to the plurality of wood elements. The plurality of wood elements are joined together to form a composite wood product, and the joining includes supplying ultrasonic energy to the plurality of wood elements. The ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz. The ultrasonic energy is supplied by an ultrasonic transducer integrated with the press, the ultrasonic transducer being positioned recessed relative to the first surface of the press, in this method.

3. A method for manufacturing composite wood products, Apply filler to multiple wood elements, The plurality of wood elements are subjected to 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, The plurality of wood elements are joined together to form a composite wood product, and the joining includes supplying ultrasonic energy to the plurality of wood elements. The ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz. The ultrasonic energy is supplied by a first ultrasonic transducer integrated with the press, and the first ultrasonic transducer is positioned directly on the first surface of the press so as to be flush with the first surface.

4. A method for manufacturing composite wood products, Apply filler to multiple wood elements, The plurality of wood elements are subjected to 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, The plurality of wood elements are joined together to form a composite wood product, and the joining includes supplying ultrasonic energy to the plurality of wood elements. The ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz. The ultrasonic energy is supplied by a first ultrasonic transducer integrated with the press, the first ultrasonic transducer being positioned recessed relative to the first surface of the press, in this method.

5. A method for manufacturing composite wood products, Apply filler to multiple wood elements, A roller element having a spherical body, wherein a roller element having a surface that applies compressive force to the plurality of wood elements applies compressive force to the plurality of wood elements, The plurality of wood elements are joined together to form a composite wood product, and the joining includes supplying ultrasonic energy to the plurality of wood elements. The ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz. The ultrasonic energy is supplied via the roller element by an ultrasonic transducer in this method.

6. A method for manufacturing composite wood products, Apply filler to multiple wood elements, A roller element having a surface that applies compressive force to the plurality of wood elements applies compressive force to the plurality of wood elements, The plurality of wood elements are joined together to form a composite wood product, and the joining includes supplying ultrasonic energy to the plurality of wood elements. The ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz. The ultrasonic energy is supplied by the ultrasonic transducer through the roller element. A method in which an operation controller controls one or more of the operations of the ultrasonic transducer and the roller.

7. A method for manufacturing composite wood products, Apply filler to multiple wood elements, A roller element having a surface that applies compressive force to the plurality of wood elements applies compressive force to the plurality of wood elements, The plurality of wood elements are joined together to form a composite wood product, and the joining includes supplying ultrasonic energy to the plurality of wood elements. The ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz. The ultrasonic energy is supplied by the ultrasonic transducer through the roller element. The ultrasonic energy comprises a first amount of ultrasonic energy and a second amount of ultrasonic energy. The first amount of ultrasonic energy is supplied to a first depth of the plurality of wood elements. The second amount of ultrasonic energy is supplied to the second depth of the plurality of wood elements. The second depth differs from the first depth, The second amount of ultrasonic energy is obtained in a manner different from the first amount of ultrasonic energy.

8. A method for manufacturing composite wood products, A filler containing metal is applied to multiple wood elements. A roller element having a surface that applies compressive force to the plurality of wood elements applies compressive force to the plurality of wood elements, The plurality of wood elements are joined together to form a composite wood product, and the joining includes supplying ultrasonic energy to the plurality of wood elements. The ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz. The ultrasonic energy is supplied via the roller element by an ultrasonic transducer in this method.

9. A method for manufacturing composite wood products, Apply filler to multiple wood elements, A roller element having a surface that applies compressive force to the plurality of wood elements applies compressive force to the plurality of wood elements, The aforementioned multiple wood elements are joined together to form a composite wood product. The joining includes supplying ultrasonic energy to the plurality of wood elements, The ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz. The ultrasonic energy is supplied by the ultrasonic transducer through the roller element. A method for inspecting defects in the composite wood product, wherein the inspection includes supplying ultrasonic energy to the composite wood product.

10. A method for manufacturing composite wood products, Apply filler to multiple wood elements, A roller element having a surface that applies compressive force to the plurality of wood elements applies compressive force to the plurality of wood elements, The aforementioned multiple wood elements are joined together to form a composite wood product. The joining includes supplying ultrasonic energy to the plurality of wood elements, The ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz. The ultrasonic energy is supplied by the ultrasonic transducer through the roller element. Before applying the filler to the multiple wood elements, the multiple wood elements are pre-treated, and the pre-treatment includes supplying ultrasonic energy to the multiple wood elements to clean them. method.

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

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

13. The method according to any one of claims 1 to 10, wherein the filler includes plastic.

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

15. The method according to any one of claims 1 to 10, wherein the plurality of wood elements are arranged in close proximity to each other before joining the plurality of wood elements.

16. The method according to any one of claims 1 to 10, wherein the ultrasonic energy is supplied to the plurality of wood elements after the filler material has been applied to the plurality of wood 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 wood elements before supplying the ultrasonic energy to the plurality of wood elements.

18. The method according to any one of claims 1, 2, 5 to 10, wherein the ultrasonic energy is supplied to the plurality of wood elements at the same time as the compressive force is applied to the plurality of wood elements.

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

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

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

22. Further including inspecting for defects in the aforementioned composite wood product, The method according to any one of claims 1 to 8, wherein the inspection comprises supplying ultrasonic energy to the composite wood product.

23. The method further includes pre-treating the plurality of wood elements before applying the filler, The method according to any one of claims 1 to 9, wherein the pretreatment includes supplying ultrasonic energy to the plurality of wood elements.

24. The method according to claim 23, wherein the pretreatment includes supplying ultrasonic energy to the plurality of wood elements and cleaning the plurality of wood elements.

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

26. The method according to claim 1 or 2, wherein both the compressive force and the ultrasonic energy are supplied to the plurality of wood elements in the same direction.

27. The method according to claim 26, wherein the same direction is downward.

28. The method according to claim 26, wherein the same direction is the lateral direction.

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

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

31. The method according to claim 30, wherein the first projection among the plurality of projections is at least one of a projection having a rounded outer surface, a projection having a substantially flat outer surface, a projection having an outer surface including a point, a projection having an outer surface including a ridge, or a projection having an outer surface having 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. The method according to claim 32, wherein the first recess among 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, or a recess having a surface having 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 projection 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 wood elements when the roller element rolls over the plurality of wood elements.

36. The ultrasonic energy is supplied via the roller element by the ultrasonic transducer and the guiding element. The method according to any one of claims 5 to 10, wherein the guiding element connects the roller element to the ultrasonic transducer and guides the ultrasonic energy from the ultrasonic transducer to the roller element.

37. The method according to claim 36, wherein the guiding element includes an ultrasonic horn.

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

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

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

41. A system for manufacturing composite wood products, A filler applicator for applying filler to multiple wood elements, A roller element that applies compressive force to the plurality of wood elements, having a spherical body and a surface that applies the compressive force to the plurality of wood elements, An ultrasonic transducer that supplies ultrasonic energy to the plurality of wood elements via a roller element in order to join the plurality of wood elements to form a composite wood product, wherein the ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz, An ultrasonic transducer and an motion controller that controls one or more of the movements of the roller elements, A system equipped with this feature.

42. A system for manufacturing composite wood products, A filler applicator for applying filler to multiple wood elements, A roller element that applies compressive force to the plurality of wood elements, having a surface to which the compressive force is applied to the plurality of wood elements, and the surface having a plurality of protrusions, An ultrasonic transducer that supplies ultrasonic energy to the plurality of wood elements via a roller element in order to join the plurality of wood elements to form a composite wood product, wherein the ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz, An ultrasonic transducer and an motion controller that controls one or more of the movements of the roller elements, A system equipped with this feature.

43. A system for manufacturing composite wood products, A filler applicator for applying filler to multiple wood elements, A roller element that applies compressive force to the plurality of wood elements, having a surface to which the compressive force is applied to the plurality of wood elements, and the surface having a plurality of recesses, An ultrasonic transducer that supplies ultrasonic energy to the plurality of wood elements via a roller element in order to join the plurality of wood elements to form a composite wood product, wherein the ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz, An ultrasonic transducer and an motion controller that controls one or more of the movements of the roller elements, A system equipped with this feature.

44. A system for manufacturing composite wood products, A filler applicator for applying filler to multiple wood elements, A roller element that applies compressive force to the plurality of wood elements, having a surface on which the compressive force is applied to the plurality of wood elements, wherein the surface has at least one projection and at least one recess, An ultrasonic transducer that supplies ultrasonic energy to the plurality of wood elements via a roller element in order to join the plurality of wood elements to form a composite wood product, wherein the ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz, An ultrasonic transducer and an motion controller that controls one or more of the movements of the roller elements, A system equipped with this feature.

45. A system for manufacturing composite wood products, A filler applicator for applying filler to multiple wood elements, A roller element that applies compressive force to the plurality of wood elements, the roller element having a surface to which the compressive force is applied to the plurality of wood elements, An ultrasonic transducer that supplies ultrasonic energy to the plurality of wood elements via a roller element in order to join the plurality of wood elements to form a composite wood product, wherein the ultrasonic energy has a frequency within the frequency range of 10 kHz to 20 MHz, A pre-treatment supply component that pre-treats the plurality of wood elements before applying the filler, An ultrasonic transducer and an motion controller that controls one or more of the movements of the roller elements, A system equipped with this feature.

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