Patent Application
20050210829
This relates to decorative panels used in window and door units and in particular to a wood composite panel having increased resistance to movement due to moisture penetration and humidity changes.
Many of the current raised panels used in doors and in decorative windows provide inadequate resistance to moisture penetration. Ambient moisture caused by humidity and precipitation collects between the panel and the glazing cap, which holds the panel within the door. In some instances, moisture penetrates the panel and causes swelling of the panel. Expansion of the panel through swelling can bow the panel and even force the panel out of engagement with the stiles and rails of the door. Additionally, swelling and contraction of the panel causes undesirable cracking of the panel including the veneer and decreases the aesthetic appeal of a door. Moreover, cracking of the veneer allows additional moisture into the panel that causes increased swelling and cracking. Further, the moisture that collects between the glazing cap and the panel also may damage the stiles and rails of the door, eventually requiring replacement of the entire door. Further still, because the panel swells, it is difficult to seal the panel within the frame to protect against moisture. As the panel swells within the frame, the panel shears the sealant.
Many door assemblies and decorative windows use solid wood raised panels. Wood is porous and moisture (e.g. precipitation or humidity) easily penetrates the solid wood panels causing swelling and cracking. Varnish and staining treatments are sometimes applied to the outward facing surfaces of the raised panel after assembly of the door to protect against moisture. Typically, the edges of solid wood panels are covered by the glazing cap during assembly. One disadvantage of this method of manufacture is that the panel edges are not varnished or stained because they are covered by the glazing cap. As moisture collects between the glazing cap and the panel it penetrates the panel through the edges to cause swelling. Another disadvantage of this type of door is the extra manufacturing step necessary to stain or varnish the door. Additionally, the solid wood panel is susceptible to undesirable swelling and contraction caused by humidity changes.
Another type of door assembly uses a composite construction including wood strands or laminates. Flat wooden strands are saturated with resin and adhered together to form a substrate. A flat veneer is applied over the substrate to provide an appealing exterior. The relatively large size of the wooden strands (e.g. up to 20 inches long and 3 inches wide) provides for a rough outer substrate surface. One disadvantage of using a wood strand or laminate substrate is the rough surface deforms thin pliable veneers used to provide profiled decorative surfaces. The rough surface presses through the pliable veneer causing undesirable surface texturing. Moreover, thicker veneers are less pliable and crack when pressed onto a profiled substrate used to form raised panels.
What is needed is a composite panel that overcomes the shortcomings of previous panels. What is further needed is a composite panel that overcomes swelling due to moisture penetration and humidity changes, and provides a smooth profiled substrate for pliable veneer application.
A composite panel includes a fiberboard substrate including wood fiber and a waterproof resin. The panel includes at least one veneer disposed over a first face of the fiberboard substrate. In one example, a second veneer is disposed over a second face of the fiberboard substrate. A waterproof adhesive is disposed between the at least one veneer and the fiberboard substrate.
Several options for the composite panel follow. In one option, the first face of the fiberboard substrate has a profiled surface. In another option, the at least one veneer is pliable and assumes a profile corresponding to the profiled surface of the fiberboard substrate when disposed over the fiberboard substrate. In yet another option, the waterproof resin includes phenol formaldehyde. In still another option, the waterproof resin includes methyl di-isocyanate. Optionally, the waterproof adhesive includes cyanuramide. In another option, the waterproof adhesive includes polyurethane. In still another option, the waterproof adhesive includes urethane.
A door assembly includes a door having at least one panel cavity. In one option, an insulation core is disposed within the at least one panel cavity. At least one panel is disposed within the at least one panel cavity and coupled to the door. The at least one panel comprises a fiberboard substrate including wood fiber and a waterproof resin and having at least one profiled face. The at least one panel further includes a first veneer coupled to the at least one profiled face with a waterproof adhesive. In one option, the first veneer has a profile corresponding to the at least one profiled face of the fiberboard substrate. In another option, the at least one panel includes a second veneer, wherein the second veneer is coupled to another face of the fiberboard substrate with the waterproof adhesive, and the second veneer is substantially adjacent to the insulation core.
Several options for the door assembly follow. In one option, door assembly includes a glazing cap coupled to the door and engaged against the at least one panel to retain the at least one panel within the at least one panel cavity. In another option, a sealant is disposed between the at least one panel and the glazing cap. In still another option, the second veneer is slidably coupled to the insulation core, and the second veneer, fiberboard substrate and first veneer are moveable relative to the insulation core. Optionally, the door assembly includes a second panel having a second fiberboard substrate including wood fiber and waterproof resin, wherein a third veneer is coupled along at least one surface to a face of the second fiberboard substrate, and a fourth veneer is coupled along at least one surface to another face of the second fiberboard substrate and the fourth veneer is substantially adjacent to the insulation core. In one option, at least one bracket is coupled to the at least one panel and to the second panel. In another option, at least one glass pane is disposed within the insulation core and the at least one panel.
A method of making a panel includes compressing a fiberboard substrate including wood fiber and a waterproof resin, wherein the fiberboard substrate includes at least one face. A waterproof adhesive is applied to at least one surface of a first veneer. At least one surface of the first veneer is coupled to the at least one face of the fiberboard substrate. In one example, the waterproof adhesive is applied to at least one surface of a second veneer. Optionally, the at least one surface of the second veneer is coupled to another face of the fiberboard substrate.
Several options for the method follow. In one option, applying the waterproof adhesive to the at least one surface of the veneer includes applying an adhesive including cyanuramide. In another option, the waterproof adhesive includes urethane. In still another option, the at least one face of the fiberboard substrate is milled to provide at least one profiled face. Optionally, the first veneer is pliable and assumes a profile substantially corresponding to the at least one profiled face when pressed against the at least one face of the fiberboard substrate.
The decorative panel disclosed herein is subject to less overall movement and decay relative to other panels. The combination of wood fiber and waterproof resin used in the substrate and the waterproof adhesive between the substrate and the veneer substantially prevents penetration of water into the panel, a cause of undesirable expansion, cracking and decay. Additionally, the substrate materials and the waterproof adhesive lessen expansive and contractive movement of the panel due to humidity changes. Further the small size of the wood fibers used in the substrate provides a smooth surface for application of a veneer. Pliable veneers applied over a profiled substrate using the materials and techniques described herein, assume the profile of the substrate. Because the substrate is smooth the pliable material does not have an undesirable texture caused with rough substrates. Moreover, in another example, because the panel is subject to less expansion, sealants are successfully applied between the panel and the glazing cap to aid in preventing water leakage. Moisture is less likely to collect between the panel and the stiles and rails of the door assembly and damage the door. Further, the decorative panel provides a long lasting appealing finish due to its resistance to movement, thereby reducing maintenance concerns.
The composite panel disclosed herein comes preinstalled in door assemblies and decorative windows. In another option, the composite panel is useful as a replacement panel for existing doors and decorative windows. In yet another option, the composite panel is useful for indoor and outdoor applications.
These and other embodiments, aspects, advantages, and features of the present invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art by reference to the following description of the invention and referenced drawings or by practice of the invention. The aspects, advantages, and features of the invention are realized and attained by means of the instrumentalities, procedures, and combinations particularly pointed out in the appended claims and their equivalents.
In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.
In one option, the waterproof adhesive 206 used to couple the first veneer 200 and the second veneer 202 to the fiberboard substrate 204 is a Type 1 rated waterproof adhesive.
The waterproof adhesive 206 includes but is not limited to cyanuramide, a compound sold or distributed under the trademark MELAMINE™ registered to Melamine Chemicals, Inc. In another option, the waterproof adhesive includes urethane, polyurethane or the like. One example of a waterproof adhesive 206 is a glue having the trade name MUF 4301 made by National Casein, and including MELAMINE™. Another example of a waterproof adhesive 206 capable of being used alone or mixed with an additional adhesive is WP 2200 made by National Casein. In one example, MUF 4301 waterproof adhesive is mixed with WP 2200 waterproof adhesive at about a 95% to 5% volume ratio, respectively.
The fiberboard substrate 204 of the composite panel 100 includes wood fibers and a waterproof resin. In one example, the fiberboard substrate 204 is constructed with wood fibers created in a fiberizing process that pulls wood apart into fibers. In one option, fiberizing generates wood fibers having a range of lengths between about 0.5 to 8 millimeters. In another option, the wood fibers are the length of one or four cells. The wood fibers used in fiberboard substrate 204 include but are not limited to soft wood fibers, hard wood fibers, or a mixture of soft wood and hard wood fibers.
The waterproof resin used to bond the wood fibers together, in one example, is a phenolic resin (e.g. phenol formaldehyde or the like). In another example, the waterproof resin includes methyl di-isocyanate. In one option, the waterproof resin is sprayed on the wood fibers and the mixture of wood fiber and waterproof resin is tumbled to evenly distribute the resin among the fibers. The mixture is then compressed into a board. Optionally, the mixture of wood fiber and waterproof resin is heated during compression.
In one example, the fiberboard substrate 204 has a density of between about 45 lbs./ft3 to 80 lbs./ft3. In another example, the fiberboard substrate 204 has a lineal expansion of about 0.58% in 50% to 90% relative humidity, where the substrate 204 has a thickness between about 0.375 inches and 1.5 inches. Application of the waterproof resin to the wood fibers binds the wood fibers together to create the fiberboard substrate 204. In one example, the waterproof resin provides at least some measure of waterproofing to the fiberboard substrate 204. In another example, the waterproof resin and the waterproof adhesive 206 cooperate to make the composite panel 100 substantially waterproof. Optionally, the combination of the waterproof adhesive and the waterproof resin substantially prevents penetration by moisture (e.g. precipitation or humidity) into the composite panel 100. In another option, the mixture of the wood fibers and the waterproof resin makes the fiberboard substrate 204 resistant to expansive and contractive movement caused by humidity changes.
Several options for the method follow. In one option, the waterproof adhesive applied to the at least one surface of the veneer includes MELAMINE™. The waterproof adhesive includes urethane, in another option. Compressing of the fiberboard substrate includes heating the substrate, in still another option. In yet another option, coupling the at least one surface of the veneer to the at least one face of the fiberboard substrate includes heating the waterproof adhesive.
The door assembly 700 includes a door 701 having stiles 704A, B, C, D and rails 706A, B, C, D. In one example, the door assembly 700, including stiles 704A, B, C, D and rails 706A, B, C, D is constructed from wood. The stiles 704A, B, C, D and rails 706A, B, C, D include aluminum, steel, or the like, in another example. In yet another example, the stiles 704A, B, C, D and rails 706A, B, C, D are constructed with composite materials, for example, laminated wood strands, wood fibers, or the like. Optionally, the door 701 includes a handle 708, for example a door knob. The door assembly 700 includes a frame for installation of the door assembly 700 within a surface (e.g. a wall), in another option.
In yet another example, a panel assembly including an insulation core 302 and one panel 100 is retained within a clad door assembly. The clad door assembly is similar to the door assemblies described above in some respects. The clad door assembly includes a second panel integral to the clad door. In one option, the clad door including the second panel is constructed to include aluminum, steel or the like. The insulation core 302 is disposed within the clad door so it engages the integral second panel. The panel 100 is then inserted into the clad door against the insulation core 302 and a glazing cap 902 or the like is used to retain the panel assembly within the door.
Several options for the method 1000 follow. In one option, the first panel and the insulation core are retained within the at least one panel cavity by coupling a glazing cap to the door and engaging the glazing cap against the veneer of the first panel. In another option, the first panel and the insulation core are retained within the at least one panel cavity with a glazing bead coupled to the frame (e.g. with nails) and engaged against the veneer of the first panel. In yet another option, sealant is interposed between the glazing cap and the veneer of the first panel.
The decorative panel disclosed herein is subject to less overall movement and decay relative to other panels. The combination of wood fiber and waterproof resin used in the substrate and the waterproof adhesive between the substrate and the veneer substantially prevents penetration of water into the panel, the main cause of undesirable expansion, cracking and decay. Additionally, the substrate materials and the waterproof adhesive lessen expansive and contractive movement of the panel due to humidity changes. Further the small size of the wood fibers used in the substrate provides a smooth surface for application of a veneer. Pliable veneers applied over a profiled substrate using the materials and techniques described herein, assume the profile of the substrate. Because the substrate is smooth the pliable material does not have an undesirable texture caused with rough substrates. Moreover, because the panel is subject to less expansion, in one example sealants are applied between the panel and the glazing cap to aid in preventing water leakage. Moisture is less likely to collect between the panel and the stiles and rails of the door and damage the door. Further, the panel provides a long lasting appealing finish due to its resistance to movement, thereby reducing maintenance concerns.
The composite panel disclosed herein comes preinstalled in door assemblies and decorative windows. In another option, the composite panel is useful as a replacement panel for existing doors and decorative windows. In yet another option, the composite panel is useful for indoor and outdoor applications.
It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. It should be noted that embodiments discussed in different portions of the description or referred to in different drawings can be combined to form additional embodiments of the present application. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
