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Abstract

A system is described for processing an entire tree into wood fiber material for molding the constituent wood elements into custom molded wood products. A delimber removes limbs and leaves from the trunk, a debarker removes bark from the trunk of the delimbed tree, and a splitter separating sequence is constructed and arranged for separating the debarked trunk into elongate pieces of substantially equal cross-sectional area. A graduated roller mill having a sequence of pairs of compressor rollers with the rollers of each pair spaced successively closer together receives the elongate pieces of wood and extrudes and delivers thin sheets of wood at the output end. Liquid squeezed from the wood sheets is collected and separated into resins and water. A shredder shreds and fragments the wood sheet wood fibers into a loosely bonded mat of substantially separate striated wood fibers. The mat is cut or chopped into wood fibers of substantially uniform length. The constituent elements of the tree are reconstituted in a slurry for custom molding. The resulting wood material product is a new material composite of a uniform length isotropically distributed lignocellulose fiber phase and resin and plastic phase of natural tree wood resins and additive plastic resins binding the lignocellulose fibers in a composite matrix.

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First Claim