Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Patent
1987-06-10
1989-03-14
Dawson, Robert A.
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
52455, 156245, 156292, 264119, B32B 3120
Patent
active
048121886
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND OF THE INVENTION
The present invention relates to a method of producing imitated panelled doors and similar panelling elements, which appear with a frame portion and a front surface plane, and one or more partial area portions with recessed surface planes. In the old prior art such panelling element consisted of a frame of joined board portions forming one or more openings in which were inserted infilling panels, the edge portions of these as well as optionally the adjacent edges of the frame board portions being profiled for forming characteristic subframe patterns. The other sides of the infilling panels may well be flush with the outer sides of the frame portion, but in the transition areas along the edges of the panels the outer side will be recessed compared to the plane of the outer side of the frame portion.
In recent times many attempts have been made to produce such doors, furniture doors, or panelled elements with such as appearance, but by using a modernized technique whereby e.g. the frame boards are replaced by a continuous body of chipboard or similar materials. It has even been proposed that both the frame and the panel portions can be glued as separate covering elements onto a through-going base plate member. Truly it is hereby possible to provide imitated panelled doors or panel elements substantially cheaper than by the original method, but still substantial production costs have been involved relative to the modern alternative which consists of the so-called smooth doors. However, the decorative effect of a "panelled door" is so pronounced that it justifies a somewhat higher production price than for a simple smooth door.
It is the purpose of the invention to provide a method by which a door or panel element can be produced as an imitated element of the panelled type in a very inexpensive manner.
The invention is based on the consideration that the infilling panels or at least the characteristic border portions between these and the surrounding frame portion may very well be produced by a simple die pressing of an originally planar plate member when this is adapted to resist the die pressing without the occurring of visually unacceptable deformations in the surface of the plate manner. On the other hand, this condition is highly essential in practice, and the problem is that an acceptable surface made from either a wooden veneer or paper suitable for painting is difficult to shape by die pressing. It is possible that the very idea of a pattern embossing is not new, as e.g. a chip board is locally compressible, but prior attempts in this direction have not lead to practically usable results.
By the invention a method is developed by which the panelling element is constructed in a manner known per se by covering a frame structure with a relatively thin cover plate, but whereby it has been found possible to die press such a cover plate, which is specially produced for the purpose for obtaining an outer surface appearance which perfectly corresponds to the said panelling pattern. It is hereby essential that the thin plate member can be die pressed while being coated by veneer or paper and that the plate therefore, may be a wood-like character so that it does not later show warping tendencies.
In accordance with the present invention, a method of producing door or other panel elements having a relief surface is provided by a combination of construction the elements as a frame work which is provided with wood-like thin covering plates with the covering plates being utilized with an associated paper or veneer coatings which have been subjected to a previous die pressing for forming a relief surface.
However, it has been found that by using already known thin plate materials it is very difficult to obtain satisfying results, and on this background the invention also provides for a new plate material, adapted to the purpose or, more correctly, a method of producing such covering plate members based on such a pre-fabricated plate material.
In order to produce the above described plate
REFERENCES:
patent: Re26376 (1968-04-01), Caron et al.
patent: 2120137 (1938-06-01), Mason
patent: 2682083 (1954-06-01), Patton
patent: 4265067 (1981-05-01), Palmer
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