Method for manufacturing a laminated log and the laminated log

Abstract

A method for manufacturing a laminated log having a solid insulating material layer located between internal and external plank layers of natural wood, with a plurality of compression limiter members located into respective through hole extending through the solid insulating material layer and extending between the internal and external layers to control and preferably prevent excessive compression of the insulating member during the bonding under relatively high pressure of all layers at the same time. After the layers are bonded, the laminated log typically runs through a molder device which gives the exterior surface a rounded edge to make it look like a natural log. The log manufactured using the above method is also part of the present invention.

I claim: 
     
         1 . A method for manufacturing a laminated log, said laminated log defining along a longitudinal axis thereof an interior surface, an opposite exterior surface, and first and second intermediate surfaces extending between said interior and exterior surfaces, said method comprising the steps of:
 forming a laminate having a solid insulating material layer located between an internal wooden plank layer and an external wooden plank layer, with a plurality of compression limiter members being located between said internal and external plank layers inside respective through holes extending through said solid insulating material layer between said internal and external wooden plank layers, said through holes being spaced apart from one another along said longitudinal axis of said laminated log;   applying a layer of bonding agent between each adjacent said layers; and   applying and maintaining pressure against said interior and exterior surfaces of said laminate during a predetermined time duration and within controlled environmental temperature and humidity level ranges to allow setting of said bonding agent layers and adhesion of each said layer to adjacent said layers.   
     
     
         2 . The method of  claim 1 , wherein, in the step of forming a laminate, said plurality of compression limiter members are sized to control a compression rate of said solid insulating material layer during the step of applying and maintaining pressure. 
     
     
         3 . The method of  claim 2 , wherein, in the step of forming a laminate, said plurality of compression limiter members are of a length extending between said internal and external wooden plank layers substantially slightly less than or equal to a thickness of said solid insulating material layer. 
     
     
         4 . The method of  claim 3 , wherein, in the step of forming a laminate, each one of the plurality of compression limiter members substantially entirely fills the respective one of said through holes. 
     
     
         5 . The method of  claim 1 , wherein, in the step of forming a laminate, said through holes are substantially equally spaced apart from one another along said longitudinal axis of said laminated log. 
     
     
         6 . The method of  claim 1 , further including the step of facing at least one of said interior, exterior, and first and second intermediate surfaces. 
     
     
         7 . The method of  claim 6 , wherein the step of facing includes facing at least two of said interior, exterior, and first and second intermediate surfaces. 
     
     
         8 . The method of  claim 7 , wherein the step of facing includes simultaneously facing said at least two of said interior, exterior, and first and second intermediate surfaces. 
     
     
         9 . The method of  claim 1 , wherein the step of forming a laminate includes forming a laminate wherein at least one of said internal and external wooden plank layers includes at least two superposed adjacent wooden planks with a layer of bonding agent therebetween. 
     
     
         10 . The method of  claim 9 , wherein the step of forming a laminate includes forming a laminate wherein each said internal and external wooden plank layer includes at least two superposed adjacent wooden planks with a layer of bonding agent therebetween. 
     
     
         11 . The method of  claim 6 , wherein the step of facing includes forming at least one complementary pair of longitudinal tongue and groove joinery on respective said first and second intermediate surfaces. 
     
     
         12 . The method of  claim 6 , wherein the step of facing includes forming a rounded surface on at least one of said interior and exterior surfaces. 
     
     
         13 . The method of  claim 1 , wherein the step of applying and maintaining pressure includes applying and maintaining uniform pressure against said entire interior and exterior surfaces of said laminate. 
     
     
         14 . The method of  claim 13 , wherein, in the step of applying and maintaining pressure, the uniform pressure being within a range varying from about 50 psi to about 120 psi. 
     
     
         15 . The method of  claim 14 , wherein, in the step of applying and maintaining pressure, the uniform pressure being about 100 psi. 
     
     
         16 . A laminated log manufactured according to the method of  claim 1 .