Method of forming wood-veneered product

Details Method of forming wood-veneered product Method of forming wood-veneered product

1999-12-29

2001-05-15

Weisberger, Richard (Department: 1774)

Stock material or miscellaneous articles

Structurally defined web or sheet

Including sheet or component perpendicular to plane of web...

C428S098000, C428S106000, C428S119000, C156S182000, C156S304100, C156S304500, C156S325000

Reexamination Certificate

active

06231947

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a method of forming a wood-veneered product, and more particularly to a method of forming a wood-veneered product that reduces waste of high-quality veneer.
BACKGROUND
Recent environmental regulations and depletion of old-growth forests have made it increasingly difficult and expensive to obtain high-quality lumber for use in wood products. Such products include doors, windows, furniture, cabinets, and millwork. This is particularly a problem for wood products that are stained rather than painted, because stain is less likely than paint to cover irregularities in wood.
One way to address the difficulty and expense of obtaining high-quality lumber is to use a veneer. Veneered parts are created by affixing a higher-quality veneer, such as high-grade or clear wood, over a lower-quality core, such as medium density fiberboard (MDF), particleboard, plywood, laminated veneer lumber (LVL), or finger-jointed stock. Veneered parts more efficiently utilize high-quality wood, reducing wood requirements and associated costs.
In the manufacture of some wood products, such as doors and windows, veneered parts must be reshaped, and portions of the veneer and core may be removed. For example, in forming a window, a portion of a window stile or rail may be cut away to accommodate a pane of glass. Unfortunately, the portions of wood that are removed often must be discarded, because they cannot be used for any other purpose. The costs associated with discarding such wood may be considerable. In particular, the cost of veneer typically increases faster than the size of the veneer, because larger veneers must be obtained from larger, scarcer trees.
SUMMARY OF THE INVENTION
The present invention addresses these and other shortcomings by providing a method of forming a wood-veneered product that reduces waste of high-quality veneer. The method includes (1) providing a veneer having a main portion formed of wood and an edge portion joined to the main portion, the edge portion being formed of a material different from the wood of the main portion, (2) providing a core having an edge portion and a surface for receiving the veneer, (3) affixing the veneer to the surface of the core, so that the edge portion of the veneer is adjacent the edge portion of the core, and (4) shaping the veneer and core, so that the edge portion of the veneer is removed, to form the wood-veneered product. The method reduces waste, because it reduces the amount of wood required for the main portion of the veneer. The core and veneer may include various materials of various sizes. The core and veneer may be formed and joined in various ways.
The present invention also provides a wood-veneered product that includes (1) a veneer having a main portion formed of wood and an edge portion joined to the main portion, and (2) a core having an edge portion and a surface for receiving the core. The edge portion of the veneer is formed of a different material than the main portion of the veneer, and the veneer is affixed to the surface of the core so that the edge portion of the veneer is adjacent the edge portion of the core.
Many other features, advantages, and objects of the invention will become apparent to those versed in the art upon reference to the accompanying drawings and detailed description, in which preferred embodiments incorporating the principles of the invention are disclosed as illustrative examples.


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