1 A method of manufacturing a lineal component, consisting of a laminate material applied to a core material or substrate that can be machined to produce a desirable product in which the exposed surfaces will be of the same or complimentary color and/or with an otherwise desirable appearance or mechanical property or properties. This method of manufacturing is comprised of all of the following steps except that step B may be used with or without step C, or step C may be used with or without step B.
- A} Producing or providing a substrate consisting of an acceptable material for the core of the product, such as but not limited to, low grade wood or wood product, particleboard, fiberboard of an acceptable density, plywood, plastic, foam, metal, composite or engineered material or other material suitable for a core.
- B} Machining out pockets in the end of the substrate, of a size and shape as required to accept the installation or pouring of the filler strip or strips, or filler material. Said pocket may be on the end or ends of the substrate, or on any face of the substrate, in any location, as required by the final use or design of the end product.
- C} Machining the end or ends or face or faces or any end and face combination, of the substrate to provide an appropriate surface to adhere the filler strip or filler material to these ends or faces, without the necessity of machining a pocket, whenever appropriate.
- D} Machining, extruding, casting, stamping, molding or otherwise producing plugs, strips or other shapes to fill the pockets machined out in step B, or casting, pouring or otherwise applying a liquid or semi-liquid material in the pockets machined out on step B, or other method for filling the pocket with a suitable material, for the purpose of producing fillers for the pockets described in this patent.
- E} Gluing the plugs, strips or shapes produced in step D, or pouring an appropriate filler material such as epoxy or other castable materials, into the pocket or pockets produced in step B, or on to the end or ends, or face or faces of the substrate. Said strips, shapes or liquid material may be glued or poured between individual pieces of substrate, to produce a lineal component of extended length, for more effective and or efficient manufacture. The lineal component may be used as a single component or may be cut down into individual components as required to produce the final product or products.
- F} Machining the substrate thus produced so that it is of a profile that can accept the laminating, profile wrapping, pressing or other application method of the coating material.
- G} Applying the thin veneer, foil, paper, metal, plastic, composite or other material to the substrate after the filler material has been applied and the thus formed substrate has been machined.
- H} Machining through or along the thin veneer, foil, paper, metal, plastic, composite or other material thus exposing the filler material to produce the desired visual, or mechanical result.