Masonite Corporation

Allan J Luck

John T Clarke

Michael R Hoffman

Roger F Sutton

Robert O Blomquist

Fibreboard panels and the like, useful as drawer fronts, cabinet doors, table tops, furniture parts, moldings, baseboards and the like are formed of compressed fibre panels or strips with an edge treatment forming a contoured or profiled edge surface. The wood fibres on the edge surface are heat seared and die pressed together to form a heat seared sealed surface of skin which does not require subsequent filling and further mechanical surfacing and which is more easily finished by the application of liquid decorating materials, paints, stains, printing inks and various colorants. The cellulosic fibrous blanks are mechanically pre-shaped to provide a contoured profile edge which is subjected to heat and pressure from a heated die which sears and seals together the fibres forming a skin over the profiled edge surface. The skin formation results in a reduction of time and labor that is required for any final finishing operations and provides a better appearance for the entire surface of the fibreboard piece.

Edge treatment for fibreboard panels and the like

A fiberboard is manufactured having relatively high density skins on a relatively low density core by including a skin forming chemical in at least the surface fibers of a consolidated mat, having a density of less than 35 pounds per cubic foot, and then hot-pressing the consolidated mat at a temperature of at least 525.degree. F. to form a board having high density surface skins. In accordance with another embodiment of the present invention, a skin forming chemical is used to form a skin on higher density mats having a density of 35 pounds/ft..sup.3 or greater. The skin formed on the higher density mats has strength and density properties which are not as significantly different from the core material as is the skin formed over the low density core material of the first embodiment, but the skin on the higher density mats also improves the board strength, stiffness paint holdout and design fidelity properties.

Product containing high density skins on a low density core and method

A fiberboard is manufactured having relatively high density skins on a relatively low density core by including urea in at least the surface fibers of a consolidated mat, having a density of less than 35 pounds per cubic foot, and then hot-pressing the consolidated mat at a temperature of at least 525.degree. F. to form a board having high density surface skins. In accordance with another embodiment of the present invention, urea is used to form a skin on higher density mats having a density of 35 pounds/ft..sup.3 or greater. The skin formed on the higher density mats has strength and density properties which are not as significantly different from the core material as is the skin formed over the low density core material of the first embodiment, but the skin on the higher density mats also improves the board strength, stiffness, paint holdout and design fidelity properties.

Product containing high density skins

Multi-sided decorative moldings and furniture parts are manufactured by drying or hot-pressing a cellulosic fiber-containing mat to consolidate said mat into a unitary blank, cutting the blank to a size larger than interior dimensions of a closed mold in each of its three dimensions and with at least two generally shaped or profiled edge surfaces disposed between a top surface and a bottom surface of the blank. The cut blank is then molded at a temperature of at least 200.degree. F. for a period of time sufficient to permanently transfer the interior shape and design of the mold cavity to every surface of the blank.

Post-press molding of man-made boards to produce contoured furniture

A cellulosic fiber containing board is molded at a temperature of at least 525.degree. F. to provide a relatively high density skin on at least one surface. A fibrous composition, including cellulosic fibers, is consolidated to form a consolidated blank. The consolidated blank is then cut to a shape larger in at least two of its three dimensions than corresponding dimensions of a mold cavity when said mold is in a closed position. Urea is then included in at least a surface layer of fibers of the blank in an amount of at least 5% based on the dry weight of the fibers contacted with urea, and thereafter the cut blank is molded to form a contoured product having a skin on at least one surface thereof. The skin is formed by hot-pressing a consolidated cellulosic fiber-containing board including urea in at least its surface fibers, at a temperature of at least 525.degree. F. The composition of the skin has not been determined but is different than the composition of cellulosic material thereunder. In one embodiment, the consolidated cellulosic fiber-containing board has a density of less than 35 pounds/ft..sup.3 to provide a skin of higher density and substantially better structural properties. In accordance with another embodiment, a consolidated board having a density of at least 35 pounds/ft..sup.3 is provided with a skin which is not as significantly different from the core material as is the skin formed over the low density core material of the first embodiment, but the skin on the higher density mats also improves the board strength, stiffness, paint holdout and design fidelity properties.

A cellulosic fiber containing board is molded at a temperature of at least 525.degree. F. to provide a relatively high density skin on at least one surface. A fibrous composition, including cellulosic fibers, is consolidated to form a blank having a density of less than 35 pounds/cubic foot. The blank is then cut to a shape larger in at least two of its three dimensions than corresponding dimensions of a mold cavity when said mold is in a closed position. Urea is then included in at least a surface layer of fibers of the blank in an amount of at least 5% based on the dry weight of the fibers contacted with urea, and thereafter the cut blank is molded to form a contoured product having a skin on at least one surface thereof, the skin defined by a thickness of material on said surface of said product having a density greater than the material on which the skin is formed.

Fibreboard panels and the like, useful as drawer fronts, cabinet doors, table tops, furniture parts, moldings, baseboards and the like are formed of compressed fibre panels or strips with an edge treatment forming a contoured or profiled edge surface. The wood fibres on the edge surface are heat seared and die pressed together to form a heat seared sealed surface of skin which does not require subsequent filling and further mechanical surfacing and which is more easily finished by the application of liquid decorating materials, paints, stains, printing inks and various colorants. The cellulosic fibrous blanks are mechanically preshaped to provide a contoured profile edge which is subjected to heat and pressure from a heated die which sears and seals together the fibres forming a skin over the profiled edge surface. The skin formation results in a reduction of time and labor that is required for any final finishing operations and provides a better appearance for the entire surface of the fibreboard piece.

A mineral wool board is manufactured having relatively high density skins by including urea in at least the surface fibers of a consolidated mineral wool fiberboard containing cellulosic fibers and/or starch and then hot-pressing the consolidated board at a temperature of at least 525.degree. F. to form a board having high density surface skins.

Mineral wool product containing high density skins and method of

Six-sided furniture parts are manufactured by pressing a cellulosic fiber-containing mat to consolidate said mat into a unitary blank, cutting the blank to a size larger than interior dimensions of a closed mold in every dimension and with two to four generally shaped or profiled edges disposed between a top surface and a bottom surface of the blank. The cut blank is then molded at a temperature of at least 500.degree. F. for a period of time sufficient to permanently transfer the interior shape and design of the mold cavity to every surface of the blank.

Post press molding of man-made boards to produce contoured furniture

A method of molding a cellulosic fiber containing board at a temperature of at least 525.degree. F. to provide a relatively high density skin on at least one surface. A fibrous composition, including cellulosic fibers, is consolidated to form a blank having a density of less than 35 pounds/cubic foot. The blank is then cut to a shape larger in at least two of its three dimensions than corresponding dimensions of a mold cavity when said mold is in a closed position. Urea is then included in at least a surface layer of fibers of the blank in an amount of at least 5% based on the dry weight of the fibers contacted with urea, and thereafter the cut blank is molded to form a contoured product having a skin on at least one surface thereof, the skin defined by a thickness of material on said surface of said product having a density greater than the material on which the skin is formed.

A fiberboard is manufactured having relatively high density skins on a relatively low density core by including a skin forming chemical in at least the surface fibers of a consolidated mat, having a density of less than 35 pounds per cubic foot, and then hot-pressing the consolidated mat at a temperature of at least 525.degree. F. to form a board having high density surface skins.

A fiberboard is manufactured having relatively high density skins on a relatively low density core by including urea in at least the surface fibers of a consolidated mat, having a density of less than 35 pounds per cubic foot, and then hot-pressing the consolidated mat at a temperature of at least 525.degree. F. to form a board having high density surface skins.

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Marengo, IL, United States of America

Allan J Luck