Decorative wooden articles and method of fabricating

• US 20030059639A1
• Filed: 09/27/2001
• Published: 03/27/2003
• Est. Priority Date: 09/27/2001
• Status: Active Grant

• Current Assignee: O'Sullivan Industries, Inc.
• Original Assignee: O'Sullivan Industries, Inc.
• Inventors: Worsley, David Russell
• Granted Patent: US 6,593,006 B2
• Time in Patent Office: Days
• US Class Current: 428/537.1
• CPC Class Codes: B05D 2401/32 applied as powders
• CPC Class Codes: B05D 3/0209 Multistage baking
• CPC Class Codes: B05D 3/0254 After-treatment
• CPC Class Codes: B05D 3/0263 with IR heaters
• CPC Class Codes: B05D 3/0272 with ovens
• CPC Class Codes: B05D 3/067 Curing or cross-linking the coating
• CPC Class Codes: B05D 3/068 using ionising radiations (gamma, X, electrons)
• CPC Class Codes: B05D 7/06 to wood
• CPC Class Codes: B32B 21/04 comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/042; next to a bituminous or tarry layer B32B11/042; next to a water setting substance layer B32B13/10; next to a metal layer B32B15/10; next to a glass layer B32B17/062; next to a layer formed of natural mineral fibres or particles B32B19/042; next to a cellulosic plastic layer B32B23/044
• CPC Class Codes: B44C 5/043 containing wooden elements
• CPC Class Codes: Y10T 428/24438 Artificial wood or leather grain surface
• CPC Class Codes: Y10T 428/253 Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/31982 Wood or paper
• CPC Class Codes: Y10T 428/31986 Regenerated or modified
• CPC Class Codes: Y10T 428/31989 Of wood
• CPC Class Codes: Y10T 428/31993 Of paper

Abstract

A method of fabricating a decorative wood article includes the steps of applying a decorative overlay onto at least one surface of a wood article, applying a radiation curable powder coating onto the outer surface of the overlay, heating the applied radiation curable powder coating at a temperature sufficient to melt and flow the powder coating, and exposing the applied powder coating to radiation energy to cure the powder coating and form a film on the outer surface of the decorative overlay.

Claims

1. A method of fabricating a decorative wood article, said method comprising the steps of:

applying a decorative overlay onto at least one surface of a wood article, the decorative overlay having a top surface;

applying a radiation curable powder coating onto the outer surface of the overlay;

heating the applied radiation curable powder coating at a temperature sufficient to melt and flow the applied powder coating; and

exposing the powder coating to radiation energy to cure the powder coating and form a film on the top surface of the decorative overlay.

2. A method in accordance with claim 1 further comprising the step of heating the wood article prior to applying the powder coating.

3. A method in accordance with claim 1 wherein heating the applied radiation curable powder coating comprises the step of heating the applied radiation curable powder coating at about 150°

F. to about 250°

F. to melt and flow the powder coating.

4. A method in accordance with claim 2 wherein heating the wood article prior to applying the powder coating comprises the step of heating the wood article to at about 140°

F. to about 170°

F. prior to applying the powder coat.

5. A method in accordance with claim 1 wherein applying a decorative overlay comprises the step of applying a decorative overlay, comprising paper, wood veneer, vinyl, ink, a foil or a heat transfer foil, onto at least one surface of the wood article.

6. A method in accordance with claim 1 wherein the wood article comprises wood, particleboard, fiberboard, or medium density fiberboard.

7. A method in accordance with claim 1 wherein applying a radiation curable powder coating comprises the step of applying a radiation curable powder coating by an electrostatic application method onto the outer surface of the decorative overlay.

8. A method in accordance with claim 1 wherein the cured powder coating film has a dry film thickness of about 0.5 mils to about 25 mils.

9. A method in accordance with claim 1 wherein the cured powder coating film has a dry film thickness of about 1.0 mils to about 10 mils.

10. A method in accordance with claim 1 wherein exposing the powder coating to radiation energy comprises exposing the powder coating to at least one of UV light and electron beam radiation.

11. A decorative wood article fabricated by a process comprising:

applying a decorative overlay onto at least one surface of a wood article, the decorative overlay having an outer surface;

applying a radiation curable powder coating onto the outer surface of the overlay;

heating the applied radiation curable powder coating at a temperature sufficient to melt and flow the applied radiation curable powder coating; and

exposing the applied powder coating to radiation energy to cure the powder coating and form a film on the outer surface of the decorative overlay.

12. A decorative wood article in accordance with claim 11 wherein the process further comprises heating the wood article prior to applying the powder coating.

13. A decorative wood article in accordance with claim 11 wherein heating the applied radiation curable powder coating comprises heating the applied radiation curable powder coating at about 150°

F. to about 250°

F. to melt and flow the powder coating.

14. A decorative wood article in accordance with claim 12 wherein heating the wood article prior to applying the powder coating comprises heating the wood article to at about 140°

F. to about 170°

F. prior to applying the powder coat.

15. A decorative wood article in accordance with claim 11 wherein the decorative overlay comprises paper, wood veneer, vinyl, ink, a foil or a heat transfer foil.

16. A decorative wood article in accordance with claim 11 wherein the wood article comprises wood, particleboard, fiberboard, or medium densityfiber board.

17. A decorative wood article in accordance with claim 11 wherein applying a radiation curable powder coating comprises applying a radiation curable powder coating by an electrostatic application method onto the outer surface of the decorative overlay.

18. A decorative wood article in accordance with claim 11 wherein the cured powder coating film has a dry film thickness of about 0.5 mils to about 25 mils.

19. A decorative wood article in accordance with claim 11 wherein the cured powder coating film has a dry film thickness of about 1.0 mils to about 10 mils.

20. A decorative wood article in accordance with claim 11 wherein exposing the powder coating to radiation energy comprises exposing the powder coating to at least one of UV light and electron beam radiation.