Reverse molded plant-on panel component, method of manufacture, and method of decorating a door therewith

Patent metadata

Field	Value
Publication number	US-9284772-B2
Application number	US-201314043304-A
Country	US
Kind code	B2
Filing date	Oct 1, 2013
Priority date	Apr 20, 2000
Publication date	Mar 15, 2016
Grant date	Mar 15, 2016

Abstract

A reverse molded, plant-on decorative panel component comprises a panel portion lying on a first plane, a skirt portion, and a contoured portion. The skirt portion has a first surface adapted to be exteriorly disposed and an opposite second surface adapted to be interiorly disposed in order to be adhesively secured to a planar surface. The contoured portion extends outwardly from and surrounds the panel portion and interconnects and is integral with the panel portion and the skirt portion. The skirt portion extends peripherally about the contoured portion.

First claim

We claim as follow:

1. A reverse molded wood composite door skin having an exterior surface adapted to be exteriorly disposed and an opposite interior surface adapted to be interiorly disposed, comprising:
at least one panel portion, said exterior surface of said at least one panel portion extending in a first plane;
a skirt portion having a first thickness and a first specific gravity, said exterior surface of said skirt portion extending in a second plane, said interior surface of said skirt portion adapted to be adhesively secured to a planar support surface; and
a contoured wall surrounding said panel portion and interconnecting and integral with said panel portion and said skirt portion, said skirt portion extending peripherally about said contoured wall, said contoured wall including first and second contoured portions, said first contoured portion being adjacent said skirt portion and being reverse molded so that said exterior surface thereof extends outwardly relative to said second plane to an outermost convex top having a rounded apex that is farther outward from the first and second planes than any other part of the contoured wall, said second contoured portion being positioned between said first contoured portion and said panel portion and having said exterior surface thereof extending inwardly relative to said first plane, said outermost convex top of said rounded apex having a second thickness that is less than said first thickness and a second specific gravity that is greater than said first specific gravity.

2. A reverse molded wood composite door skin in accordance with claim 1 , wherein said reverse molded wood composite door skin includes less than 5% by weight resin binder.

3. A reverse molded wood composite door skin in accordance with claim 2 , wherein said resin binder is homogeneously distributed throughout said reverse molded wood composite door skin.

4. A reverse molded wood composite door skin in accordance with claim 3 , wherein said reverse molded wood composite door skin is reverse molded from a mat of refined cellulosic fibers and sufficient binder to adhere said refined cellulosic fibers together into a structurally sound article, and wherein said structurally sound article does not include a thermoplastic coating material an outer surface thereof, and does not include a resin-impregnated paper overlay.

5. A reverse molded wood composite door skin in accordance with claim 4 , wherein said mat of refined cellulosic fibers is made by a dry process and has a smooth planar back surface.

6. A reverse molded wood composite door skin in accordance with claim 1 , wherein said first contoured portion extends outwardly 5-10 mm from said second plane.

7. A reverse molded wood composite door skin in accordance with claim 1 , wherein said reverse molded wood composite door skin is reverse molded from a mat of refined cellulosic fibers and sufficient binder to adhere the cellulosic fibers together into a structurally sound article, and wherein the cellulosic mat includes at least 40% by weight softwood fibers, based on the total weight of cellulosic fibers in said article.

8. A reverse molded wood composite door skin in accordance with claim 7 , wherein said softwood fibers comprise at least one member selected from the group consisting of pine, spruce and a mixture thereof.

9. A reverse molded wood composite door skin in accordance with claim 8 , wherein said cellulosic fibers are about 100% by weight said softwood fibers.

10. A reverse molded wood composite door skin in accordance with claim 1 , wherein said contoured wall extends outwardly said second plane at an angle in a range of 25-35°.

11. A reverse molded wood composite door skin in accordance with claim 1 , wherein said contoured wall extends outwardly said second plane at an angle in a range of 30-35°.

12. A reverse molded wood composite door skin in accordance with claim 1 , wherein said skirt portion is separable from said contoured wall.

13. A reverse molded wood composite door skin in accordance with claim 1 , wherein said reverse molded wood composite door skin is between about 0.10 inch and about 0.25 inch thick.

14. A reverse molded wood composite door skin in accordance with claim 1 , wherein said first plane is positioned outward relative to said second plane.

15. A reverse molded wood composite door skin in accordance with claim 14 , wherein said first and second planes are parallel to one another.

16. A reverse molded wood composite door skin having an exterior surface adapted to be exteriorly disposed and an opposite interior surface adapted to be interiorly disposed, said reverse molded wood composite door skin comprising:
at least one planar panel portion, said exterior surface of said at least one planar panel portion extending in a first plane;
a major planar portion having a first thickness and a first specific gravity, said exterior surface of said major planar portion extending in a second plane that is different than said first plane, said interior surface of said major planar portion adapted to be adhesively secured to a support surface;
a contoured portion surrounding said planar panel portion and being surrounded by the major planar portion, said contoured portion interconnecting and integral with said planar panel portion and said major planar portion, said exterior surface of said contoured portion extending outwardly from and relative to said first plane and interconnecting and integral with said major planar portion and said planar panel portion, said contoured portion being reversed molded so that said exterior surface thereof extends outwardly relative to said second plane to an outermost convex top portion having a rounded apex that is farther outward from the first and second planes than any other part of the contoured portion, said rounded apex having a second thickness that is less than said first thickness and a second specific gravity that is greater than said first specific gravity.

17. A reverse molded wood composite door skin in accordance with claim 16 , wherein said contoured portion includes a plurality of raised planar steps interposed between said major planar portion and said convex top portion.

18. A reverse molded wood composite door skin in accordance with claim 16 , wherein said contoured portion includes first and second contoured portions, and wherein said first contoured portion includes said convex top portion and is proximate said major planar portion and said second contoured portion is proximate said planar panel portion.

19. A reverse molded wood composite door skin in accordance with claim 18 , wherein said first contoured portion extends outwardly relative to said planar panel portion and said second contoured portion extends inwardly relative to said planar panel portion.

20. A reverse molded wood composite door skin in accordance with claim 16 , wherein said second specific gravity of said rounded apex of said contoured portion is in a range of 1.02 to 1.08, and wherein said first specific gravity of said major planar portion is in a range of 0.98 to 1.00.

21. A reverse molded wood composite door skin in accordance with claim 16 , wherein said reverse molded wood composite door skin is between about 0.10 inch and about 0.25 inch thick.

22. A reverse molded wood composite door skin in accordance with claim 16 , wherein said first plane is positioned outward relative to said second plane.

23. A reverse molded wood composite door skin

Assignees

• Masonite Corp

Inventors

• Lynch Steven K
• Schafernak Dale E
• Luetgert Karine
• Liang Bei-Hong
• Braddock Lee

Classifications

• B44C5/0453

  produced by processes involving moulding · CPC title

• B44C5/043

  containing wooden elements · CPC title

• B44C5/0461

  used as wall coverings · CPC title

• B44C3/046

  using a modelling surface, e.g. plate · CPC title

• Y10T428/24628

  Nonplanar uniform thickness material · CPC title