# US 2019/0169838 A1 · Class-a fire-protected finger-jointed lumber products, and methods of and automated factory for producing the same

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- Number: US 2019/0169838 A1
- Document ID: US20190169838A1
- Status: Published application
- Kind: A1
- Application number: 15/829,940
- Filed: 2017-12-03
- Published: 2019-06-06
- Earliest claimed: 2017-12-02
- Assignees: M-Fire Suppression, Inc.
- Applicants: M-Fire Suppression, Inc.
- Inventors: Stephen Conboy
- Web page: https://patentgrep.com/patent/US20190169838A1

## CPC

- B27M 1/08: by multi-step processes
- B05B 9/00: Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour (B05B11/00 takes precedence)
- B05C 3/10: the articles being moved through the liquid or other fluent material (conveying articles through baths B65G, e.g. B65G49/02)
- B05C 9/08: for applying liquid or other fluent material and performing an auxiliary operation
- B27D 1/10: Butting blanks of veneer; Joining same along edges; Preparatory processing of edges, e.g. cutting {(see also B27M3/002 and B27M3/0026)}
- B27D 3/00: Veneer presses; Press plates; Plywood presses (presses in general B30B {; presses for wood fibre sheets B27N3/08, B27N3/24, B27N3/26})
- B27K 1/02: Apparatus
- B27K 3/04: Impregnating in open tanks
- B27K 3/52: Impregnating agents containing mixtures of inorganic and organic compounds
- B27N 3/02: from particles
- B27N 3/04: from fibres
- B27N 3/143: {Orienting the particles or fibres}
- B27N 7/005: {Coating boards, e.g. with a finishing or decorating layer}
- B27N 9/00: Arrangements for fireproofing (fireproofing materials C09K21/00)
- B32B 3/06: for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking}
- B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)}
- B32B 3/14: characterised by a face layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)}
- B32B 3/18: characterised by an internal layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)}
- B32B 7/03: with respect to the orientation of features (direction of fibres or filaments B32B5/12)
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 13/10: of wood; of wood particle board
- B32B 21/02: {the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard}
- B32B 21/042: {of wood (B32B21/13 takes precedence)}
- B32B 21/13: all layers being exclusively wood
- B32B 21/14: comprising wood board or veneer
- B65B 11/00: Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material (bundling articles by applying narrow strips or bands of flexible material B65B13/00)
- B65B 11/004: {in blanks, e.g. sheets precut and creased for folding }
- B65B 13/02: Applying and securing binding material around articles or groups of articles, e.g. using strings, wires, strips, bands or tapes
- B65B 35/50: Stacking one article, or group of articles, upon another before packaging
- B65G 17/00: Conveyors having an endless traction element, e.g. a chain, transmitting movement to a continuous or substantially-continuous load-carrying surface or to a series of individual load-carriers; Endless-chain conveyors in which the chains form the load-carrying surface
- B65G 23/02: Belt- or chain-engaging elements
- E04B 1/26: the supporting parts consisting of wood
- E04B 1/94: against fire ({fire protection of partitions E04B2/7403, E04B2/7409; supporting constructions for ceilings having the capability of expansion in case of fire E04B9/08}; fire-fighting A62C, {e.g. fire prevention or containment A62C2/00}; impregnation of wood or similar materials B27K; {fireproof paints C09D5/18; fireproofing materials C09K21/00; flame-resistant papers D21H5/0002; coverings or linings, e.g. for walls or ceilings, in general E04F13/00}; fireproof doors E06B5/16; {firebreak devices for pipes or the like passing through walls F16L5/04; protection of pipes by means of non-inflammable material F16L57/04})
- E04B 1/944: {covered with fire-proofing material}
- E04C 2/16: of fibres, chips, vegetable stems, or the like
- E04C 3/122: {Laminated}
- E04C 3/14: with substantially solid, i.e. unapertured, web ({E04C3/127,} E04C3/17, E04C3/18 take precedence)
- E04C 3/16: with apertured web, e.g. trusses (E04C3/17, E04C3/18 take precedence)
- E04C 3/17: with non-parallel upper and lower edges, e.g. roof trusses
- E04C 3/30: Columns; Pillars; Struts (not designed for end loading E04C3/02; posts, masts, as independent structures E04H12/00)
- E04C 3/36: of materials not covered by groups E04C3/32 or E04C3/34; of a combination of two or more materials
- E04C 3/42: of wood, e.g. units for rafter roofs (E04C3/46 takes precedence)
- E04H 1/04: Apartment houses arranged in two or more levels
- E04H 5/02: Buildings or groups of buildings for industrial purposes, e.g. for power-plants or factories (buildings forming part of cooling plants E04H5/10)
- F26B 25/14: Chambers, containers, receptacles of simple construction
- F26B 25/16: mainly closed, e.g. drum
- B05D 1/02: performed by spraying
- B05D 1/18: performed by dipping
- B05D 7/06: to wood
- B27K 2240/30: Fireproofing
- B32B 2255/08: on wood layer
- B32B 2255/26: Polymeric coating
- B32B 2255/28: Multiple coating on one surface
- B32B 2260/026: Wood layer
- B32B 2260/046: Synthetic resin
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2419/00: Buildings or parts thereof
- B32B 2419/06: Roofs, roof membranes
- B32B 2607/00: Walls, panels
- C09K 21/04: containing phosphorus
- E04B 1/943: {elongated}
- E04B 2/70: with elongated members of wood
- E04B 5/12: with wooden beams (E04B5/14 takes precedence)
- E04B 7/024: {the trusses or frames supporting load-bearing purlins, e.g. braced purlins (battens, supports for battens E04D12/00)}
- E04B 2001/2644: {Brackets, gussets or joining plates}
- E04B 2103/04: of plastics, fibrous material or wood
- B27M: WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
- B05B: SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES (spray-mixers with nozzles B01F25/72; processes for applying liquids or other fluent materials to surfaces by spraying B05D)
- B05C: APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (spraying apparatus, atomising apparatus, nozzles B05B; plant for applying liquids or other fluent materials to objects by electrostatic spraying B05B5/08)
- B27D: WORKING VENEER OR PLYWOOD (applying liquids or other fluent materials to surface in general B05; grinding, sanding, or polishing of wood B24; applying adhesives or glue to surfaces of wood B27G11/00; manufacture of veneer B27L5/00)
- B27K: PROCESSES, APPARATUS OR SELECTION OF SUBSTANCES FOR IMPREGNATING, STAINING, DYEING, BLEACHING OF WOOD OR SIMILAR MATERIALS, OR TREATING OF WOOD OR SIMILAR MATERIALS WITH PERMEANT LIQUIDS, NOT OTHERWISE PROVIDED FOR (applying liquids or other fluent materials to surfaces in general B05; coating wood or similar material B44D); CHEMICAL OR PHYSICAL TREATMENT OF CORK, CANE, REED, STRAW OR SIMILAR MATERIALS
- B27N: MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL (containing cementitious material B28B; shaping of substances in a plastic state B29C; fibreboards made from fibrous suspensions D21J; drying F26B17/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B65B: MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING (bundling and pressing devices for cigars A24C1/44; devices for tensioning and securing binders adapted to be supported by the article or articles to be bound B25B25/00; applying closure members to bottles, jars or similar containers B67B1/00-B67B6/00; concurrent cleaning, filling and closing of bottles B67C7/00; emptying bottles, jars, cans, casks, barrels or similar containers B67C9/00)
- B65G: TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS (packaging B65B; handling thin or filamentary materials, e.g. paper sheets or thread, B65H; cranes B66C; portable mobile or lifting or hauling appliances, e.g. hoists, B66D; devices for lifting or lowering goods for loading or unloading purposes, e.g. fork-lift trucks, B66F9/00; emptying bottles, jars, casks, barrels or similar containers, not otherwise provided for, B67C9/00; delivering or transferring liquids B67D; filling or discharging vessels for liquefied, solidified or compressed gases F17C; pipe-line systems for fluids F17D)
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- E04H: BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL (foundations E02D)
- F26B: DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM (drying devices for combines A01D41/133; racks for drying fruit or vegetables A01F25/12; drying foodstuffs A23; drying hair A45D20/00; body-drying implements A47K10/00; drying household articles A47L; drying gases or vapours B01D; chemical or physical processes for dewatering or like separating liquids from solids B01D43/00; centrifugal apparatus B04; drying ceramics C04B33/30; drying yarns or fabrics in association with some other form of treatment D06C; drying frames for laundry without heating or positive air circulation, domestic laundry-or spin-driers, wringing or hot pressing laundry D06F; furnaces, kilns, ovens F27)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE

## Abstract

A method of producing packaged bundles of Class-A fire-protected lumber for use in wood-framed building construction. The method involved maintaining a dipping tank in a lumber factory, containing a water-based clean fire inhibiting chemical (CFPC) liquid at a depth sufficient to cover pieces of raw lumber while being treated during dip-coating operations. Untreated lumber pieces are submerged into the dipping tank, piece by piece, in an automated manner to coat all surfaces of the lumber pieces in CFIC liquid, and then removed from the dipping tank to produce pieces of Class-A fire-protected lumber having a CFIC liquid coating. The Class-A fire-protected lumber pieces are automatically wet stacked, packaged and wrapped into a packaged bundle, and allowed to dry.

## Claims

### Claim 1

A method of producing Class-A fire-protected finger-jointed lumber from an automated factory having a production line with a plurality of stages, said method comprising the steps of:
(a) providing a reservoir tank containing a supply of clean fire inhibiting chemical (CFIC) liquid that is supplied to a dipping tank deployed in a CFIC liquid dip-coating stage installed between (i) a lumber planing/dimensioning stage supplied by a finger-jointing stage, and (ii) an automated stacking, packaging, and wrapping stage installed at the end of said production line;
(b) loading untreated short-length lumber into a controlled-drying stage so to produce suitably dried short-length lumber for supply to said finger-jointing stage;
(c) supplying dried short-length lumber to said finger-jointing stage for producing pieces of extended-length finger-jointed lumber;
(d) transporting produced pieces of extended-length finger-jointed lumber into said planing/dimensioning stage, so that the finger-jointed lumber is planed/dimensioned into pieces of dimensioned finger-jointed lumber;
(e) automatically transporting and submerging the dimensioned finger-jointed lumber pieces through said dipping tank for sufficient coating in CFIC liquid, while being transported by a transport mechanism; and
(f) automatically removing the wet dip-coated pieces of dimensioned finger-jointed lumber from said dipping tank, and stacking, packing and wrapping the dip-coated pieces together and said automated stacking, packaging, and wrapping stage so as to produce a packaged bundle of Class-A fire-protected finger-jointed lumber.

### Claim 2 (depends on 1)

The method of claim 1, which further comprises:
(g) painting the ends of each packaged bundle of Class-A fire-protected finger-jointed lumber, using a paint containing clean fire-inhibited chemicals (CFIC), and applying trademarks to said packaged bundle of Class-A fire-protected finger-jointed lumber.

### Claim 3

An automated lumber production factory comprising:
a production line supporting a finger-jointing stage, a planing and dimensioning stage, a clean fire inhibiting chemical (CFIC) dip-coating stage, and a stacking, packaging and wrapping stage, arranged in the named order;
wherein said production line supports an automated production process including the steps of:
(a) fabricating finger-jointed lumber pieces at said finger-jointing stage;
(b) planing and dimensioning said finger-jointed lumber pieces at said planing and dimensioning stage;
(c) after being planed and dimensioned, automatically conveying said finger-jointed lumber pieces from said planing and dimensioning stage to said CFIC dip-coating stage;
(d) dip-coating said finger-jointed lumber pieces in a supply of clean fire inhibiting chemical (CFIC) liquid contained in a dipping tank maintained at said CFIC dip-coating stage, so as to produce Class-A fire-protected finger-jointed lumber pieces in a high-speed manner; and
(e) stacking, packaging and wrapping a bundle of said Class-A fire-protected finger-jointed lumber pieces.

### Claim 4 (depends on 3)

The automated lumber production factory of claim 3, wherein each said finger-jointed lumber piece is a finger-jointed lumber stud, and each said bundle of Class-A fire-protected finger-jointed lumber pieces is a bundle of Class-A fire-protected finger-jointed lumber studs for use in wood-framed building construction.

### Claim 5

An automated lumber factory system for fabricating Class-A fire-protected finger-jointed lumber products along a production line, said automated lumber factory system comprising:
a finger-jointing stage for fabricating finger-jointed lumber pieces from shorter-length lumber pieces;
a planing and dimensioning stage for continuously planing and dimensioning said finger-jointed lumber pieces;
a CFIC dip-coating stage for dip-coating said finger-jointed lumber pieces in a supply of clean fire inhibiting chemical (CFIC) liquid contained in a dipping tank maintained at said CFIC dip-coating stage, so as to produce Class-A fire-protected finger-jointed lumber pieces in a high-speed manner;
a stacking, packaging and wrapping stage for automatically stacking, packaging and wrapping a bundle of said Class-A fire-protected finger-jointed lumber pieces; and
a conveying subsystem for automatically conveying said finger-jointed lumber pieces (i) from said planing and dimensioning stage to said CFIC dip-coating stage, (ii) through said CFIC dip-coating stage, and (iii) from said CFIC dip-coating stage to said stacking, packaging, and wrapping stage.

### Claim 6 (depends on 5)

The automated lumber factory system of claim 5, wherein said conveying subsystem comprises several sets of chain-driven transport rails, spaced apart and extending from said planing and dimensioning stage towards said dipping tank, and then running inside and along the bottom of said dipping tank, and then running out of said dipping tank, towards said stacking, packing and wrapping stage.

### Claim 7

A lumber dip-coating stage for installation and operation between a planing and dimensioning stage and a stacking, packaging and wrapping stage deployed along a production line in a factory producing Class-A fire-protected lumber, said lumber dip-coating stage comprising:
a supply tank containing a volume of clean fire inhibiting chemical (CFIC) liquid for use in dip-coating finger-jointed lumber pieces so as to produce Class-A fire-protected finger-jointed lumber pieces;
a dipping reservoir having a width dimension to accommodate the width of finger-jointed lumber pieces transported through said dipping reservoir while being fully immersed and submerged in CFIC liquid contained in said dipping reservoir, so as to coat said finger-jointed lumber pieces during transport through said dipping reservoir;
a conveyor subsystem supporting several sets of chain-driven transport rails, extending from said planing and dimensioning stage towards said dipping reservoir, and then running inside and along said dipping reservoir, and then running out thereof towards said stacking, packing and wrapping stage;
a level sensor for sensing the level of CFIC liquid in the dipping reservoir during production line operation;
a liquid pump for pumping CFIC liquid from said supply tank into said dipping reservoir in response to level sensing by said level sensor, so to maintain the liquid level in said dipping reservoir during production line operation; and
a controller for controlling said conveyor subsystem and said liquid pump during production line operation.

### Claim 8 (depends on 7)

The lumber dip-coating stage of claim 7, which further includes liquid heaters, circulation pumps and controls for (i) maintaining the temperature of CFIC liquid solution in said dipping reservoir, and (ii) while controlling the circulation of CFIC liquid around submerged pieces of finger-jointed lumber being transported through said dipping reservoir.

### Claim 9 (depends on 8)

The lumber dip-coating stage of claim 8, wherein said controller is programmed to control one or more CFIC liquid dip-coating parameters selected from the group consisting of (i) the temperature of CFIC liquid contained in said dipping reservoir, (ii) the level of fluid above finger-jointed lumber pieces being transported through said dipping reservoir in a submerged manner, and (iii) speed of lumber moving through said dipping reservoir, so as to control the degree of absorption of CFIC liquid within the surface fibers of said finger-jointed lumber pieces while being rapidly transported through said dipping reservoir, and allows for the rapid formation of a surface coating, or surface barrier, on the surface of each piece of CFIC liquid dipped lumber.

### Claim 10 (depends on 7)

The lumber dip-coating stage of claim 7, wherein said stacking, packaging and wrapping stage comprises equipment for automatically receiving CFIC-coated finger-jointed lumber pieces while still dripping and wet from CFIC liquid dipping operations, and stacking a predetermined number of CFIC-coated finger-jointed lumber pieces into a lumber package, and then wrapping the package of CFIC-coated finger-jointed lumber pieces with a sheet of wrapping material that covers at least the top portion and half way down each side of said lumber package, and then banding the wrapped lumber package with banding.

### Claim 11

A method of producing packaged bundles of Class-A fire-protected lumber for use in wood-framed building construction, said method comprising the steps of:
(a) maintaining a dipping tank in a lumber factory, wherein said dipping tank contains a water-based clean fire inhibiting chemical (CFPC) liquid at a depth sufficient to cover pieces of raw lumber while being treated during dip-coating operations;
(b) loading a bundle of untreated raw lumber into said lumber factory for Class-A fire-protection treatment;
(c) drying the raw untreated lumber in said bundle to an adequate moisture content;
(d) submerging dried raw untreated lumber pieces into said dipping tank, piece by piece, to coat all surfaces of the lumber pieces in CFIC liquid, and then removing the dip-coated lumber pieces from said dipping tank so to as to produce pieces of Class-A fire-protected lumber with a CFIC liquid coating; and
(e) wet stacking, packaging and wrapping the Class-A fire-protected lumber pieces into a packaged bundle, while the Class-A fire-protected lumber pieces are still wet with CFIC liquid coating.

### Claim 12 (depends on 11)

The method of claim 11, which further comprises:
(f) painting the edges of said packaged bundle of Class-A fire-protected lumber with a Class-A fire-protection paint containing CFIC material.