Door skin, a method of etching a plate, and an etched plate formed therefrom
AssigneeMasonite Corporation
InventorsKarine A. Luetgert, Mark E. Richter, William R. Immell, Stephen G. Huhn
Life of this patent
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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.
Claims50
A molded door skin, comprising:
- an exterior surface having outer portions lying on a first plane;
- spaced grooves recessed from the plane of said outer portions;
- tonal portions having a planar area and a plurality of spaced depressions recessed from the plane of said planar area.
A method of etching a wood grain pattern into a plate, comprising the steps of:
- providing an image of a piece of wood having ticks and background tones;
- providing a metal plate;
- applying acid resist on a surface of the plate;
- laser ablating the resist according to a tick image derived from the image;
- applying acid to the plate according to the tick image to a form ticks having a first height;
- repeating said applying acid resist, said laser ablating and said applying acid steps to form some ticks having a second height, wherein the second height differs from the first height;
- applying acid resist on the surface of the etched plate;
- laser ablating the resist according to a tonal image derived from the image;
- and
- applying acid to the plate, thereby etching the plate and forming the tonal pattern in the plate.
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An etched plate for forming a wood grain pattern into a composition material, comprising:
- an etched metal plate having lower portions lying on a first plane;
- spaced ticks extending from the plane of said lower portions;
- tonal areas having a plurality of channels, said channels defining a plurality of spaced protrusions.
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Dependencies are inferred from the claim text.