Miter-foldable saturated paper-based overlay system and method for fabricating the same

An overlay system comprising:

• a wood substrate having a first side and a second side opposite said first side, said second substrate side having a miter cut operative to permit said substrate to be folded at said miter cut such that said first substrate side is miter-folded so as to present an edge between two non-coplanar surfaces;
• a saturated paper sheet having a first side coextensive with and adhesively contacting said miter-folded first substrate side, and having a second side opposite said adhered first saturated paper sheet side, said adhered saturated paper sheet directly adhered to said wood substrate prior to miter-cutting so as to permit formation of a miter-folded edge, and thereby being adhered upon miter-folding to said edge between said non-coplanar surfaces of said first side of said miter-folded saturated paper sheet substrate, said saturated paper sheet substrate being saturated prior to adhesion thereof to said first substrate side using a latex saturant comprised of a blend of two components, a first component selected from the group consisting of an acrylic and an ethylene vinyl acetate, and a second component selected from the group consisting of polyvinyl chloride, styrene acrylate, vinyl acetate, and methyl methacrylate, said first and second components having T.sub.g values which differ by at least 30, and said saturant further comprising a thickener and a release agent, said saturated paper sheet being further hot calendered to a Sheffield smoothness of less than 100 prior to adhering said sheet to said wood substrate, and said second side of said saturated paper sheet substrate thereby presenting a continuous paper surface across said miter-folded edge.