Manufactured Wood Boards Having a Distressed Appearance

• US 20100304089A1
• Filed: 05/26/2009
• Published: 12/02/2010
• Est. Priority Date: 05/26/2009
• Status: Abandoned Application

• Current Assignee: Spectrum Towers, LLC
• Original Assignee: Spectrum Towers, LLC
• Inventors: Magnusson, Tryggvi
• Application Number:
  US12/471,869
• Publication Number:
  US 20100304089A1
• Time in Patent Office: Days
• US Class Current: 428/158
• CPC Class Codes: B27M 1/003 Mechanical surface treatment
• CPC Class Codes: B27M 1/02 by compressing
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/042 of wood B32B21/13 takes precedence
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B44C 5/043 containing wooden elements
• CPC Class Codes: Y10T 428/24496 Foamed or cellular component

Abstract

The present invention is a wood-based product utilized in forming various structures and other items. The product includes a piece of wood disposed on the exposed surface of the product that has been embossed with a desired pattern to give the product a desired appearance, such as a distressed or weathered appearance. The wood piece used in the product is embossed at a sufficient temperature and pressure to create the desired appearance in the wood piece. Additionally the product can be formed completely or only partially from the wood piece.

Claims

1. A wood-based product formed by a process comprising the steps of:

a) placing a piece of wood in a forming device; and

b) embossing a desired pattern on the piece of wood.

2. The product of claim 1 further comprising the step of attaching the piece of wood to a suitable core member prior to placing the piece of wood in the forming device.

3. The product of claim 2 wherein the step of attaching the piece of wood to a suitable core member comprises attaching the piece of wood to multiple core members.

4. The product of claim 3 wherein the core members are selected from one or more of the group consisting of:

a resin material or wood-based composite material.

5. The product of claim 4 wherein the core members are formed from HDF.

6. The product of claim 1 wherein the step of embossing the piece of wood comprises embossing the piece of wood at a pressure in excess of 300 psi.

7. The product of claim 6 wherein the step of embossing the piece of wood comprises embossing the piece of wood at a pressure of between 300 psi and 800 psi.

8. The product of claim 1 wherein the step of embossing the piece of wood comprises embossing the piece of wood at a temperature in excess of 100°

C.

9. The product of claim 8 wherein the step of embossing the piece of wood comprises embossing the piece of wood at a temperature in excess of 150°

C.

10. The product of claim 2 wherein the wood has a thickness of between about 0.60 mm to about 6.00 mm.

11. A method for forming a decorative wood piece, the method comprising the steps of:

a) providing a wood piece formed of a suitable material;

b) placing a piece of wood in a forming device including a heated embossing member; and

c) embossing a desired pattern on the piece of wood.

12. The method of claim 11 wherein the step of embossing the piece of wood comprises heating the embossing member to a temperature in excess of 100°

C.

13. The method of claim 11 wherein the step of embossing the piece of wood comprises engaging the embossing member with the piece of wood at a pressure of between 300 psi and 800 psi.

14. The method of claim 11 wherein the step of providing the piece of wood comprises providing a veneer sheet of wood having a thickness of between about 0.60 mm to about 6.00 mm.

15. The method of claim 11 wherein the step of providing the piece of wood comprises providing a piece of wood having a thickness in the range of about 0.60 mm to about 25.4 mm.