Interlocking system for waney lumber

Abstract

A hollow core composite wood product comprising four elongated pieces of lumber, at least two of which are waney pieces of lumber. The elongated pieces are profiled to remove both longitudinally extending edges on one side thereof such that each of said elongated pieces has longitudinally extending indented portions on one side. The indented portions are shaped so as to be complementary to and engageable with the indented portions of adjacent pieces. The pieces are positioned adjacent to one another such that the indented portions are engaged with one another and the pieces together define a longitudinally extending cavity in the center of the hollow core composite wood product. The indented portions of said first pieces are bonded to the indented portions of said second pieces by an adhesive. The indented portions are shaped such that adjacent pieces fit into a self-aligning, interlocking engagement, preventing lateral movement of the pieces relative to one another. This enables the hollow core composite product to be pressed in a conventional one-dimensional press.

1 . A hollow core composite wood product comprising: 
 a) two first elongated pieces of waney lumber, wherein each of said first pieces is profiled such that first and second longitudinally extending edges of a first side thereof have been removed such that each of said first pieces has indented portions extending longitudinally along said first side, said first elongated pieces of lumber additionally having a second side opposite said first side;    b) two second elongated pieces of lumber, wherein each of said second pieces is profiled such that first and second longitudinally extending edges of a first side thereof have been removed such that each of said second pieces has indented portions extending longitudinally along said first side, said second elongated pieces of lumber additionally having a second side opposite said first side;    wherein each of said indented portions of said first pieces is shaped so as to be complementary to and engageable with one of said indented portions of said second pieces;    wherein said first and second pieces are positioned adjacent to one another such that each of said indented portions of said first pieces is engaged with one of said indented portions of said second pieces, such that said first sides of said first and second pieces together define a longitudinally extending cavity in a center of said hollow core composite wood product, and such that said second sides of said first and second pieces together define an outside surface of said hollow core composite product;    wherein engagement of said indented portions of said first pieces with said indented portions of said second pieces prevents lateral movement of said first and second pieces relative to one another when force is applied to said second sides of said first pieces in a direction substantially perpendicular to said second sides of said first pieces and toward a center of said hollow core composite wood product; and    wherein said indented portions of said first pieces are bonded to said indented portions of said second pieces by an adhesive.    
   
   
       2 . The hollow core composite wood product of  claim 1 , wherein said first pieces are made from waney lumber and wherein said first and second edges thereof are waney edges.  
   
   
       3 . The hollow core composite wood product of  claim 1 , wherein a width of said second sides of said first pieces is substantially equal to that of said hollow core composite wood product.  
   
   
       4 . The hollow core composite wood product of  claim 1 , wherein said indented portions of said first pieces each have a longitudinally extending protrusion and said indented portions of said second pieces each have a longitudinally extending groove and wherein said groove is operative to receive said protrusion.  
   
   
       5 . The hollow core composite wood product of  claim 1 , wherein said hollow core composite wood product has a square or substantially rectangular cross-section.  
   
   
       6 . The hollow core composite wood product of  claim 1 , wherein at least one of said first and second pieces is finger jointed.  
   
   
       7 . The hollow core composite wood product of  claim 1 , wherein said hollow core composite wood product is cut in four by cutting each of said first and second pieces longitudinally in two to provide four L-shaped corner products.  
   
   
       8 . The hollow core composite wood product of  claim 1 , wherein said hollow core composite wood product is cut in two by cutting each of said first pieces longitudinally in two to provide two corbels.  
   
   
       9 . A method for making a hollow core composite wood product, comprising: 
 (a) providing two first elongated pieces of lumber, each of said pieces having a first side and second side opposite said first side;    (b) providing two second elongated pieces of lumber, each of said pieces having a first side and second side opposite said first side;    (c) profiling each of said first pieces such that first and second longitudinally extending edges of a first side thereof are removed such that each of said first pieces has indented portions extending longitudinally along said first side;    (d) profiling each of said second pieces such that first and second longitudinally extending edges of a first side thereof are removed such that each of said second pieces has indented portions extending longitudinally along said first side;    (e) applying an adhesive to said indented portions of said first and second pieces;    (f) positioning said first and second pieces such that each of said indented portions of first pieces is engaged with one of said indented portions of said second pieces, such that said first sides of said first and second pieces together define a longitudinally extending cavity in a center of said hollow core composite wood product, and such that said second sides of said first and second pieces define an outer surface of said hollow core composite product;    (g) applying a force to each of said second sides of said first pieces, said force being applied in a direction substantially perpendicular to said second sides of said first pieces and toward a center of said hollow core composite wood product;    wherein each of said indented portions of said first pieces is shaped so as to be complementary to and engageable with one of said indented portions of said second pieces;    wherein said engagement of said indented portions of said first pieces with said indented portions of said second pieces prevents lateral movement of said first and second pieces relative to one another when said force is applied to said second sides of said first pieces.    
   
   
       10 . The method of  claim 9 , wherein said first pieces are made from waney lumber and wherein said first and second edges thereof are waney edges.  
   
   
       11 . The method of  claim 9 , wherein said second pieces are made from waney lumber and wherein said first and second edges thereof are waney edges.  
   
   
       12 . The method of  claim 9 , wherein a width of said second sides of said first pieces is substantially equal to that of said hollow core composite wood product.  
   
   
       13 . The method of  claim 9 , wherein said indented portions of said first pieces each have a longitudinally extending protrusion and said indented portions of said second pieces each have a longitudinally extending groove and wherein said groove is operative to receive said protrusion.  
   
   
       14 . The method of  claim 9 , wherein said hollow core composite wood product has a substantially square or rectangular cross-section.  
   
   
       15 . The method of  claim 9 , wherein said first and second pieces are finger jointed.  
   
   
       16 . The method of  claim 9 , wherein said providing steps include sawing logs into lumber, kiln drying, finger-jointing and planing said first and second pieces.  
   
   
       17 . The method of  claim 9 , wherein said force is applied by a one-dimensional press.  
   
   
       18 . The method of  claim 9 , further comprising the following step: after applying said force, cutting each of said first and second pieces longitudinally in two to provide four L-shaped corner products.  
   
   
       19 . The method of  claim 9 , further comprising the following step: after applying said force, cutting each of said first pieces longitudinally in two to provide two corbels.