Method for making composite panels and engineered mouldings

Abstract

A method of fabrication with the formation of a receiving panel which defines a plurality of spaced-apart parallel plows extending longitudinally. The panel has an open surface along which the plows are exposed and an opposing surface from which the plows are not accessible. The plows may be formed by adhering substrates to a separate veneer layer to define the plows between the substrates. It is preferable that the veneer layer be formed of wood, but the substrates can be formed of a less expensive material, such as composite material. Once the receiving panel has been fabricated, it is bowed to form an arc about an axis parallel to the plows. This can be done by passing the panel, carried by a belt, between two rollers that are configured to define between them a profile corresponding to the arc of the panel. While the panel is in this bowed condition, strips, made of wood, are inserted in the plows. The strips can be formed by opposing laminations that are not adhered to each other. An adhesive is applied to an interface between the strips and the surfaces of the plows and edge strips. The panel is then caused to return to an unbowed condition. The composite panel can be cut through the strips to form a plurality of segments that can be used as engineered mouldings. Cutting can be done by passing the composite panel through a rip saw having a plurality of parallel blades.