Methods of designing embossing dies and making wood composite products
AssigneeMasonite Corporation
InventorsDennis H. Vaders, Nian-hua Ou
Life of this patent
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Abstract
Methods are provided for the design of backing dies utilized with front, decorative embossing dies for the simultaneous production and embossing of wood composite panels. The methods apply where more than one decorative pattern is embossed onto the wood composite panels during a single press cycle. The cross-sectional area or volume of the panels impressed with each different decorative pattern forms the basis for the methods of the design. Included are methods of forming wood composite panels using dies made according to the disclosed die design methods.
Claims50
A method of die set design for use in the production of composite products produced by the simultaneous consolidation and embossing of at least two embossing patterns onto raw material during one press cycle of a single press, where the embossing patterns vary with respect to product width, but not with respect to product length, said method comprising the steps of:
- (a) designing at least two decorative embossing patterns on at least one first embossing die,
- (b) designing a second die corresponding to each said first die, each corresponding first and second die forming a die set, each second die being designed to cooperate with each first die to format least one finished composite product having a substantially uniform desired nominal thickness and wherein said composite product may include product sections, each section embossed with a different embossing pattern,
- (c) calculating the cross-sectional area of each section of each finished composite product of (b) impressed with a different decorative embossing pattern,
- (d) designating a preferred die set or die set portion defining a preferred cross-sectional area from the cross-sectional areas determined in (c), all other die sets or die set portions being considered non-preferred and
- (e) adjusting the second die of each non-preferred die set or die set portion to produce a product section having the preferred cross-sectional area.
In a method of die set design for use in the production of wood composite products produced by the simultaneous consolidation and embossing of at least two embossing patterns onto raw wood composite material during one press cycle of a single press, where the embossing patterns vary with respect to product width, but not with respect to product length, the method including the steps of designing at least two decorative embossing patterns on at least one first embossing die, designing a second die corresponding to each said first die, each corresponding first and second die forming a die set, each second die being designed to cooperate with each first die to form at least one finished composite product wherein said composite product may include product sections, each section embossed with a different embossing pattern, the improvement comprising the steps of:
- (a) calculating the cross-sectional area of each section of each finished composite product impressed with a different decorative embossing pattern,
- (b) designating a preferred die set or die set portion defining a preferred cross-sectional area from the cross-sectional areas determined in (a), all other die sets or die set portions being considered non-preferred and
- (c) adjusting the second die of each non-preferred die set or die set portion to produce a product section having the preferred cross-sectional area.
A method of die set design for use in the production of composite products produced by the simultaneous consolidation and embossing of at least two embossing patterns onto raw material during one press cycle of a single press, where the embossing patterns vary with respect to product width and with respect to product length, said method comprising the steps of:
- (a) designing at least two decorative embossing patterns on at least one first embossing die,
- (b) designing a second die corresponding to each said first die, each corresponding first and second die forming a die set, each second die being designed to cooperate with each first die to format least one finished composite product having a substantially uniform desired nominal thickness and wherein said composite product may include product sections, each section embossed with a different embossing pattern,
- (c) calculating the volume of each section of each finished composite product of (b) impressed with a different decorative embossing pattern,
- (d) designating a preferred die set or die set portion defining a preferred volume from the volumes determined in (c), all other die sets or die set portions being considered non-preferred and
- (e) adjusting the second die of each non-preferred die set or die set portion to produce a product section having the preferred volume.
In a method of making wood composite products produced by the simultaneous consolidation and embossing of two or more embossing patterns onto raw wood composite material during one press cycle of a single press, where the embossing patterns vary with respect to product width, but not with respect to product length, the method including the steps of designing at least two decorative embossing patterns on at least one first embossing die, designing a second die corresponding to each said first die, each corresponding first and second die forming a die set, each second die being designed to cooperate with each first die to form at least one finished composite product wherein said composite product may include product sections, each section embossed with a different embossing pattern, the improvement comprising the steps of:
- (a) calculating the cross-sectional area of each section of each finished composite product impressed with a different decorative embossing pattern,
- (b) designating a preferred die set or die set portion defining a preferred cross-sectional area from the cross-sectional areas determined in (a), all other die sets or die set portions being considered non-preferred,
- (c) adjusting the second die of each non-preferred die set or die set portion to produce a product section having the preferred cross-sectional area and (d) simultaneously forming product sections utilizing die sets designed by steps (a) through (c) above.
In a method of making wood composite products produced by the simultaneous consolidation and embossing of two or more embossing patterns onto raw wood composite material during one press cycle of a single press, where the embossing patterns vary with respect to product width and with respect to product length, the method including the steps of designing at least two decorative embossing patterns on at least one first embossing die, designing a second die corresponding to each said first die, each corresponding first and second die forming a die set, each second die being designed to cooperate with each first die to format least one finished composite product wherein said composite product may include product sections, each section embossed with a different embossing pattern, the improvement comprising the steps of:
- (a) calculating the volume of each section of each finished composite product impressed with a different decorative embossing pattern,
- (b) designating a preferred die set or die set portion defining a preferred volume from the volumes determined in (a), all other die sets or die set portions being considered non-preferred,
- (c) adjusting the second die of each non-preferred die set or die set portion to produce a product section having the preferred volume and
- (d) simultaneously forming product sections utilizing die sets designed by steps (a) through (c) above.
Dependencies are inferred from the claim text.