Decorative skirting (base) board or crown molding
AssigneeMasonite Corporation
InventorsDavid Paxton, Steven K. Lynch
Life of this patent
Estimating the term…
Abstract
A molded skirting board, crown molding, or other decorative moldings simulating natural wood millwork, and a method of molding a loose cellulosic mat, in a single pressing step, to provide one or more relatively high density, skirting boards without requiring preliminary pressing, or other pre-shaping step, such as scalping. The molded articles are molded in a conventional, multi-opening fiberboard press to produce multiple, interconnected parts in a single pressing step process, while achieving excellent transfer of mold detail (embossing fidelity) without visually noticeable fiber fracture. A corrugated or L-shaped, hidden stiffening/positioning member spaces the article from a wall or ceiling to simulate thick, heavier, natural wood millwork.
Claims35
A wood composite article, simulating natural wood millwork, molded from a mat of refined cellulosic fibers and sufficient binder to adhere the cellulosic fibers together into a structurally sound article having specific gravity in the range of 0.96 to about 1.08, said article including first and second planar longitudinal edges at opposite ends of said article adapted to contact a substrate, said first planar edge being integral with a planar portion of said article, and said second planar edge being integral with a contoured portion of said article, said planar portion of said article being integral with said contoured portion of said article.
A method of manufacturing a molded wood composite article comprising:
- disposing a mat of cellulosic fibers and a resin binder over an essentially horizontal lower mold cavity die having first and second ends and multiple, repeating planar surface portions and multiple, repeating contoured surface portions extending between said first and second ends that form a cavity in said die;
- and
- pressing said mat between said cavity die and mold core die that has planar and contoured surface portions corresponding to the planar and contoured cavity die surfaces, under sufficient heat and pressure to structurally consolidate the mat into a multiple of wood composite articles, having a specific gravity of about 0.96 to about 1.08, in a single pressing and being separable along surface portions corresponding to said cavity die contoured surface portions.
A method of manufacturing a molded wood composite article comprising:
- disposing a mat of cellulosic fibers and a resin binder over an essentially horizontal lower mold cavity die having multiple, repeating planar surface portions and multiple, repeating contoured surface portions that form a cavity in said die;
- and
- pressing said mat between said cavity die and mold core die that has planar and contoured surface portions corresponding to the planar and contoured cavity die surfaces, under sufficient heat and pressure to structurally consolidate the mat into a multiple of wood composite articles, having a specific gravity of about 0.96 to about 1.08, in a single pressing;
- and
- separating the plurality of articles into individual articles.
Dependencies are inferred from the claim text.