Method of manufacturing a decorative substrate and decorative substrate produced thereby

• US 20040088946A1
• Filed: 11/12/2002
• Published: 05/13/2004
• Est. Priority Date: 11/12/2002
• Status: Active Grant

• Current Assignee: Masonite Corporation (Owens Corning)
• Original Assignee: Masonite Corporation (Owens Corning)
• Inventors: Liang, Bei-Hong, Hardwick, Geoffrey B., Coghlan, Henry, Luetgert, Karine, Walsh, John Peter
• Granted Patent: US 7,195,686 B2
• Time in Patent Office: Days
• US Class Current: 52/782.1
• CPC Class Codes: B27N 7/005 Coating boards, e.g. with a finishing or decorating layer
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 37/06 characterised by the heating method
• CPC Class Codes: B32B 37/10 characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1023 Surface deformation only [e.g., embossing]
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 156/1044 of parallel stacked sheets only
• CPC Class Codes: Y10T 428/31982 Wood or paper

Abstract

A method of forming a composite article is disclosed that involves providing a press having first and second platens, a cellulosic fiber substrate having a first thickness, and a layer of material such as a wood veneer, foil, or non-creped paper, where the layer of material has a thickness less than the thickness of the cellulosic fiber substrate. A layer of bonding material is placed onto the cellulosic fiber substrate or the layer of material, and the layer of material is placed onto the cellulosic fiber substrate so that the bonding material is between the layer of material and the cellulosic fiber substrate. The cellulosic fiber substrate and layer of material are placed between the first and second platens, and at least one of the first and second platens is moved toward the other of the first and second platens to deform the cellulosic fiber substrate and layer of material into a predetermined configuration while bonding the layer of material to the cellulosic fiber substrate without cracking or wrinkling the layer of material.

Claims

1. A method of forming a composite article comprising the steps of:

providing a press having first and second platens;

providing a first cellulosic fiber substrate having a first thickness;

providing a layer of material selected from the group consisting of wood veneers, foils, and non-creped papers;

interposing a bonding material between the cellulosic fiber substrate and the layer of material;

placing the layer of material onto the cellulosic fiber substrate;

placing the cellulosic fiber substrate and layer of material between the first and second platens; and

moving at least one of the first and second platens toward the other of the first and second platens to deform the cellulosic fiber substrate and layer of material into a predetermined configuration while bonding the layer of material to the cellulosic fiber substrate without cracking or wrinkling the layer of material.

2. A composite article formed by the steps of:

providing a press having first and second platens;

providing a cellulosic fiber substrate having a first thickness;

providing a layer of material selected from the group consisting of wood veneers, foils, and non-creped papers, the layer of material having a thickness less than the thickness of the cellulosic fiber substrate;

placing a bonding material onto one of the cellulosic fiber substrate or the layer of material;

placing the layer of material onto the cellulosic fiber substrate so that the bonding material is between the layer of material and the cellulosic fiber substrate;

placing the cellulosic fiber substrate and layer of material between the first and second platens; and

moving at least one of the first and second platens toward the other of the first and second platens to deform the cellulosic fiber substrate and layer of material into a predetermined configuration while bonding the layer of material to the cellulosic fiber substrate without cracking or wrinkling the layer of material.

3. A composite article comprising a layer of MDF having a first surface and a layer of veneer bonded to the first surface, the first surface having been deformed under the application of heat and pressure while in contact with the layer of veneer to form a sharp edge in said layer of veneer.

4. A method of forming a composite article comprising the steps of:

providing a press;

providing an MDF substrate having first and second sides;

overlaying a flat sheet of wood veneer on the first side;

placing the MDF substrate and wood veneer overlay into the press;

closing the press to simultaneously deform the MDF substrate and wood veneer and bond the wood veneer to the MDF substrate to create a composite article.

5. The method of claim 4 including the additional steps of removing the composite article from the press and moistening the wood veneer.

6. The method of claim 5 wherein said step of moistening the wood veneer comprises the step of applying water to the wood veneer.

7. The method of claim 4 wherein said step of deforming the MDF substrate comprises the step of forming at least one linear depression in the MDF substrate.

8. The method of claim 7 wherein the step of laying a flat sheet of wood veneer in the press over the first side comprises the steps of providing a flat sheet of wood veneer having a grain direction and laying the flat sheet of wood veneer in the press over the first side with the grain direction parallel to the at least one linear depression.

9. The method of claim 4 including the additional step of applying a layer of adhesive to one of the MDF substrate and the flat sheet of veneer.

10. The method of claim 4 wherein the step of providing a flat sheet of wood veneer comprises the step of providing a flat sheet of wood veneer having a backing.

11. The method of claim 4 wherein the step of providing a flat sheet of wood veneer comprises the step of providing a flat sheet of wood veneer having a meltable adhesive layer.

12. The method of claim 8 wherein the step of providing a flat sheet of wood veneer comprises the step of providing a flat sheet of wood veneer having a meltable adhesive layer.

13. The method of claim 4 wherein the step of providing a flat sheet of wood veneer comprises the step of providing a flat sheet of wood veneer comprising a plurality of narrow strips.

14. A composite article comprising a deformed sheet of MDF and an uncracked, deformed layer of wood veneer bonded to the deformed sheet of MDF, the uncracked, deformed layer of wood veneer having a moisture content of less than about 4 percent.

15. The composite article of claim 14 wherein said moisture content of less than about 4 percent is a moisture content of less than about 2 percent.

16. The composite article of claim 14 including a layer of bonding material between the sheet of MDF and the wood veneer.

17. A method of forming a molded panel having a natural wood surface comprising the steps of:

providing a press having first and second platens for deforming sheets of wood composite material;

heating and moisturizing a sheet of wood composite material;

providing a flat sheet of wood veneer;

applying a layer of bonding material to one of the heated and moisturized sheet of wood composite material and the flat sheet of wood veneer;

placing the flat sheet of wood veneer onto the heated and moisturized sheet of wood composite material;

placing the veneer and the heated and moisturized sheet of wood composite material into the press between the first and second platens;

applying pressure to the veneer and moisturized sheet of wood composite by moving at least one of the first and second platens toward the other of the first and second platens to deform and bond the MDF and the wood veneer into a finished article;

removing the finished article from the press; and

wetting the finished article to raise the moisture content of the wood veneer.

18. The method of claim 17 wherein said step of applying pressure includes the step of heating the veneer and moisturized sheet of wood composite.

19. The method of claim 18 wherein the step of applying pressure to the veneer and moisturized sheet of wood composite comprises the steps of applying pressure at a first level for a first period of time, decreasing the pressure to a second level for a second period of time and increasing the pressure to a third level greater than said first level for a third period of time.

20. The method of claim 19 wherein said step of decreasing the pressure to a second level includes the step of degassing the veneer and moisturized sheet of wood composite material.

21. The method of claim 18 wherein the step of applying pressure to the veneer and moisturized sheet of wood composite comprises the steps of applying pressure at a first level for a first period of time and applying pressure at a second level greater than said first level for a second period of time.

22. A method of forming a composite article having a finished surface comprising the steps of:

providing an MDF substrate having first and second sides and a surface area;

laying a sheet of material having the surface area on the first side;

placing the MDF substrate and sheet of material into a press;

closing the press to simultaneously deform the MDF substrate and the sheet of material and bond the sheet of material to the MDF without forming wrinkles in the sheet of material.