REPAIR OF WOODEN ARTICLES

• US 3,844,863 A
• Filed: 05/16/1973
• Issued: 10/29/1974
• Est. Priority Date: 08/06/1970
• Status: Expired due to Term

• Current Assignee: David M. Forsythe, William J. Runckel
• Original Assignee: David M. Forsythe, William J. Runckel
• Inventors: Forsythe, David M., Runckel, William J.
• Primary Examiner(s): Whitby, Edward G.
• Application Number:
  US05/360,810
• Time in Patent Office: 531 Days
• Field of Search: 264/36 117/2R 156/94,98 260/9,17.2 144/31R,31B
• US Class Current: 156/98
• CPC Class Codes: B27G 1/00 Machines or devices for removing knots or other irregularities or for filling-up holes filling up cracks or holes in a veneer cutting block B27L5/00; caulking decks B63B5/065
• CPC Class Codes: C08L 2205/02 containing two or more polymers of the same C08L -group
• CPC Class Codes: C08L 97/007 Cork
• CPC Class Codes: C08L 97/02 Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N
• CPC Class Codes: C09D 5/34 Filling pastes materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12
• CPC Class Codes: Y10T 428/20 Patched hole or depression
• CPC Class Codes: Y10T 428/24347 From both sides

Abstract

A method of repairing a wooden article having an aperture or hole therein such as a knothole, or the result of routing out a defect in the article. The aperture is filled with a filler composition having a flowable liquid consistency, and which is a mixture of cork particles and resin. Because of the consistency of the filler composition, it flows out through gravity completely to fill the peripheral boundaries of the aperture. Through buoyancy, the cork particles tend to stratify in the repaired region prior to hardening of the filler composition. The cork, being a closed cell material, does not absorb the resin. On hardening, a filler plug is formed having a machinability and other characteristics closely matching that of natural wood.

Claims

1. A METHOD OF MANUFACTURING A REPAIRED PLYWOOD PANEL COMPRISING PREPARING A HOLE IN THE OUTER VENEER OF A PANEL IN THE REGION OF THE REPAIR, FILLING SAID HOLE WITH A LIQUID FILLER COMPOSITION COMPRISI G FROM 3 TO 10 PERCENT BY WEIGHT COMMINUTED CORK, AND PERMITTING SAID FILLER COMPOSITION TO HARDEN WITHIN SAID HOLE, WITH SUCH ACCOMPANIED WITH STRATIFICATION RESULTING IN THE CORK RISING TO FORM A LAYER ADJACENT THE OUTER SURFACE OF THE VENEER HAVING A SUBSTANTIALLY GREATER AMOUNT OF CORK THAN AN UNDERLYING LAYER AT THE BOTTOM OF THE HOLE, TO PRODUCE A FILLED REPAIRED REGION.

2. A method of repairing a wooden article having an aperture therein comprising introducing into said aperture a filler composition having a flowable liquid consistency which filler composition is a mixture of Mediterranean cork particles and thermosetting resin, with flowing of said filler composition filling the peripheral boundaries of said aperture, and permitting said filler composition to harden within said aperture with such accompanied with stratification resulting in the cork rising to form a layer adjacent the outer surface of the article having a substantially greater amount of cork than an underlying layer at the bottom of the aperture, to produce a filled repaired region.

3. A method of repairing a wooden article having an aperture therein which aperture opens to a surface of the article, the method comprising introducing into said aperture a filler composition having a flowable liquid consistency, which filler composition is a mixture of Mediterranean cork particles and thermosetting resin, permitting said composition through gravity to flow so as to fill the peripheral boundaries of the aperture, and then letting the composition harden to form a hardened filler plug of cork material encased in resin, and removing material from the article where it surrounds said plug and from said plug to produce a surface extending across the plug with exposed cork particles in the region of said plug.

4. The method of claim 3, wherein said article is a plywood panel including an outer veneer and a core with a glue line uniting the outer veneer to the core, said aperture is in the outer veneer and extends through said glue line to expose the wood of the core, and said filler composition on being introduced into said aperture flows over the wood of said core and on hardening bonds to the core.

5. A method of repairing a wooden article having an aperture therein opening to a surface of the article comprising introducing into said aperture a filler composition having a flowable liquid consistency, which filler composition is a mixture of Mediterranean cork particles and thermosetting resin with the particles comprising from about 3 to 10 percent by weight cork particles, permitting said composition through gravity to flow so as to fill the peripheral boundaries of said aperture, and subsequently letting the composition harden to form a hardened filler plug of cork particles encased in resin, said hardening occurring after stratification of the cork particles which results by reason of their tendency to rise to the surface of the filler composition on the composition initially being introduced to said aperture, and removing material from the article where it surrounds said plug and the plug to produce a surface extending across the plug with exposed cork particles.