Log Segmentation and Lamination for Consistent Structural Lumber

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Solution Overview

Problem

Existing lumber production processes face inefficiencies in utilizing lower-valued tree stem materials, leading to waste and suboptimal utilization, particularly in the conversion of conifer logs into high-grade products, and there is a need for improved methods to enhance value and reduce waste during the production of dimensional lumber.

Innovation Solution

A process involving the division of logs into consistent longitudinal lengths, followed by precise cutting and grading of sticks, which are then moisture-controlled and assembled into laminated beams using finger-jointed shooks, optimizing the production of high-grade laminated lumber products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If logs are broken down into smaller sections to increase production output, then productivity improves, but the spread of properties increases leading to more downgrading

Engineering Contradiction:

Improveproduction outputVSAvoidproperty consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The log is divided into multiple smaller sections (e.g., 50x7mm from a 100x50mm log) to increase the total number of usable pieces. By systematically segmenting the log and applying consistent cutting patterns, the process maximizes output while maintaining acceptable property ranges across all sections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention adjusts cutting parameters such as section length, width, and thickness to optimize the distribution of properties across all sections. By carefully controlling these parameters, the process ensures that even when logs are broken into smaller sections, the property spread remains within acceptable ranges for structural lumber production.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If traditional dimensional lumber production methods are used, then processing simplicity is maintained, but utilization of lower-valued log material is suboptimal

Engineering Contradiction:

Improveprocessing simplicityVSAvoidmaterial utilization

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The log is pre-surfaced and pre-cut to standardized dimensions before being divided into final sections. This preliminary preparation ensures that even lower-valued log material can be effectively utilized by establishing consistent reference surfaces and dimensions early in the process, maximizing the usable yield from each log.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cutting and processing system is designed to handle various log sizes and grades using the same equipment and procedures. This universal approach allows lower-valued logs to be processed through the same system as higher-valued logs, ensuring maximum utilization of all material regardless of initial quality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If logs are processed into traditional dimensional lumber, then structural requirements are met, but waste is generated from defects and downgraded material

Engineering Contradiction:

Improvestructural propertiesVSAvoidwaste from defects

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

Each section is evaluated and processed according to its specific properties and defect distribution. By applying local quality control measures tailored to each section's characteristics, the process maximizes the usable material from areas with minor defects while maintaining structural integrity requirements for the final product.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Sections with defects that would normally be downgraded or discarded are repositioned and reconfigured in the lamination process to create structural beams. The defect distribution is strategically managed so that weaknesses in individual sections are compensated by the composite structure, converting potentially wasted material into useful structural components.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentEP3953119B1A production process for manufacture of a laminate

Publication Date: 2026.03.11 WOOD ENG TECH LTD

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AI summary

This invention relates to a process for the division of an individual input source log into discrete longitudinal lengths for subsequent processing. The process comprises receiving an individual input source log, dividing the input source log into one or a plurality of output log portions of a predetermined length, wherein at least a portion of said output log portions resultant from said division are of a substantially equal or substantially constant or consistent longitudinal length, and wherein said substantially equal or substantially constant or consistent longitudinal length output log portions are procured as a feed stream of log material for a subsequent processing step. This process provides for the processing of logs and subsequent assembly into an end product formed from a composite of sticks derived from said processed logs.