Door skin, a method of etching a plate, and an etched plate formed therefrom

Patent metadata

Field	Value
Publication number	US-9719288-B2
Application number	US-201615238024-A
Country	US
Kind code	B2
Filing date	Aug 16, 2016
Priority date	Jan 17, 2003
Publication date	Aug 1, 2017
Grant date	Aug 1, 2017

Abstract

The present invention relates to a door skin comprising an exterior surface having outer portions lying on a first plane, spaced grooves recessed from the plane of the outer portions, and tonal portions having a planar area and a plurality of spaced depressions recessed from the plane of said planar area. The present invention is also directed to a method of etching a plate, for use with a molded die set, for embossing a wood grain pattern in the door skin, and the etched plate formed therefrom.

First claim

What is claimed is:

1. A stained molded door skin, comprising a molded component having a stained exterior surface comprising molded grooves and molded tonal portions stained with a stain, the molded grooves of the stained molded door skin configured with variable depths and lengths with respect to one another and variably spaced with respect to one another to collectively simulate an appearance of a naturally appearing wood grain tick pattern, the molded tonal portions of the stained molded door skin comprising depressions retaining a sufficient amount of the stain to simulate an appearance of darkened naturally occurring wood grain background tone, wherein the stained exterior surface further comprises outer portions lying between the molded grooves.

2. A molded construction component having a stainable exterior surface comprising molded grooves and molded tonal portions, the molded grooves of the molded construction component configured with variable depths and lengths relative to one another and variably spaced with respect to one another to collectively simulate an appearance of a naturally appearing wood grain tick pattern, the molded tonal portions of the molded construction component comprising depressions configured to receive and retain sufficient stain to simulate an appearance of darkened naturally occurring wood grain background tone.

3. The molded construction component of claim 2 , wherein a first area of the exterior surface has a first density of the molded tonal portions, wherein a second area of the exterior surface has a second density of the molded tonal portions, and wherein the first density differs from the second density so that when stain is received and retained in the molded tonal portions the first and second areas simulate naturally occurring wood background tones having different degrees of darkness.

4. The molded construction component of claim 2 , wherein the molded grooves have a greater depth than the depressions.

5. The molded construction component of claim 2 , wherein the molded construction component comprises a sheet molding compound, polystyrene, polypropylene, or a combination thereof.

6. The molded construction component of claim 2 , wherein the molded construction component comprises medium density fiberboard, hardboard, or a combination thereof.

7. The molded construction component of claim 2 , wherein the stainable exterior surface further comprises outer portions lying between the molded grooves.

8. The molded construction component of claim 7 , wherein the outer portions are planar with one another, and wherein the grooves are recessed from the outer portions by between about 0.005 inch to about 0.015 inch.

9. The molded construction component of claim 2 , wherein the molded tonal portions form an outer planar area.

10. The molded construction component of claim 9 , wherein bases of the depressions are recessed between about 0.001 inch and about 0.003 inch from the outer planar area.

11. A stained construction component having a stained exterior surface comprising molded grooves and molded tonal portions stained with a stain; the molded grooves of the stained construction component configured with variable depths and lengths with respect to one another and variably spaced with respect to one another to collectively simulate an appearance of a naturally appearing wood grain pattern, the molded tonal portions of the stained construction component comprising depressions retaining a sufficient amount of the stain to simulate an appearance of darkened naturally occurring wood grain background tone.

12. The stained construction component of claim 11 , wherein a first area of the exterior surface has a first density of the molded tonal portions retaining a first amount of the stain to provide a first tone, wherein a second area of the exterior surface has a second density of the molded tonal portions retaining a second amount of the stain to provide a second tone, and wherein the first tone differs from the second tone to simulate multiple naturally occurring wood background tones of different degrees of darkness.

13. The stained construction component of claim 11 , wherein the molded grooves have a greater depth than the depressions.

14. The stained construction component of claim 11 , wherein the molded construction component comprises a sheet molding compound, polystyrene, polypropylene, or a combination thereof.

15. The stained construction component of claim 11 , wherein the molded construction component comprises medium density fiberboard, hardboard, or a combination thereof.

16. The stained construction component of claim 11 , wherein the molded grooves extend substantially parallel to one another.

17. The stained construction component of claim 11 , wherein the stained exterior surface further comprises outer portions lying between the molded grooves.

18. The stained construction component of claim 17 , wherein the outer portions are planar with one another, and wherein the grooves are recessed from the outer portions by between about 0.005 inch to about 0.015 inch.

19. The stained construction component of claim 11 , wherein the molded tonal portions form an outer planar area.

20. The stained construction component of claim 19 , wherein bases of the depressions are recessed between about 0.001 inch and about 0.003 inch from the outer planar area.

Assignees

• Masonite Corp

Inventors

• Luetgert Karine A
• Richter Mark E
• Immell William R
• Huhn Stephen G

Classifications

• B29C59/022

  characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor · CPC title

• B44B5/026

  Dies (B44B5/028 takes precedence) · CPC title

• Y10T428/24479

  including variation in thickness · CPC title

• Y10T428/24595

  and varying density · CPC title

• E06B3/7001 Primary

  Coverings therefor; Door leaves imitating traditional raised panel doors, e.g. engraved or embossed surfaces, with trim strips applied to the surfaces · CPC title