US20050210829A1 - Wood composite panel - Google Patents
Wood composite panel Download PDFInfo
- Publication number
- US20050210829A1 US20050210829A1 US10/809,047 US80904704A US2005210829A1 US 20050210829 A1 US20050210829 A1 US 20050210829A1 US 80904704 A US80904704 A US 80904704A US 2005210829 A1 US2005210829 A1 US 2005210829A1
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- United States
- Prior art keywords
- panel
- veneer
- fiberboard substrate
- face
- door
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
- E06B3/70—Door leaves
- E06B3/72—Door leaves consisting of frame and panels, e.g. of raised panel type
- E06B3/74—Door leaves consisting of frame and panels, e.g. of raised panel type with wooden panels or frame
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- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
- E06B3/70—Door leaves
- E06B2003/7049—Specific panel characteristics
- E06B2003/7051—Specific panel characteristics of layered construction involving different materials
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- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
- E06B3/54—Fixing of glass panes or like plates
- E06B3/58—Fixing of glass panes or like plates by means of borders, cleats, or the like
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- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
- E06B3/54—Fixing of glass panes or like plates
- E06B3/58—Fixing of glass panes or like plates by means of borders, cleats, or the like
- E06B3/5807—Fixing of glass panes or like plates by means of borders, cleats, or the like not adjustable
- E06B3/5842—Fixing of glass panes or like plates by means of borders, cleats, or the like not adjustable fixed by a tongue-and-groove or mortise-and-tenon connection substantially parallel to the pane
Definitions
- 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.
- 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
- 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.
- thicker veneers are less pliable and crack when pressed onto a profiled substrate used to form raised panels.
- 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.
- 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.
- the first face of the fiberboard substrate has a profiled surface.
- 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.
- the waterproof resin includes phenol formaldehyde.
- the waterproof resin includes methyl di-isocyanate.
- the waterproof adhesive includes cyanuramide.
- the waterproof adhesive includes polyurethane.
- the waterproof adhesive includes urethane.
- a door assembly includes a door having at least one panel cavity.
- 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.
- the first veneer has a profile corresponding to the at least one profiled face of the fiberboard substrate.
- 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.
- 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.
- a sealant is disposed between the at least one panel and the glazing cap.
- 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.
- 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.
- at least one bracket is coupled to the at least one panel and to the second panel.
- 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.
- the waterproof adhesive is applied to at least one surface of a second veneer.
- the at least one surface of the second veneer is coupled to another face of the fiberboard substrate.
- applying the waterproof adhesive to the at least one surface of the veneer includes applying an adhesive including cyanuramide.
- the waterproof adhesive includes urethane.
- the at least one face of the fiberboard substrate is milled to provide at least one profiled face.
- 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.
- 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.
- the composite panel is useful as a replacement panel for existing doors and decorative windows.
- the composite panel is useful for indoor and outdoor applications.
- FIG. 1 is a front view illustrating a composite panel constructed in accordance with one embodiment.
- FIG. 2 is a cross-sectional view illustrating a composite panel constructed in accordance with one embodiment.
- FIG. 3 is a cross-sectional view illustrating a panel assembly constructed in accordance with another embodiment.
- FIG. 4 is a cross-sectional view illustrating a panel assembly constructed in accordance with yet another embodiment.
- FIG. 5 is a cross-sectional view illustrating a panel assembly constructed in accordance with still another embodiment.
- FIG. 6 is a block diagram illustrating a method for making a composite panel.
- FIG. 7 is a front view illustrating a door assembly constructed in accordance with one embodiment.
- FIG. 8 is a front view illustrating a door assembly constructed in accordance with another embodiment.
- FIG. 9 is a cross-sectional view illustrating a door assembly constructed in accordance with one embodiment.
- FIG. 10 is a block diagram illustrating a method for making a door assembly.
- FIG. 1 is a front view of a composite panel 100 for use in a door assembly or decorative window assembly.
- the composite panel includes a profiled face 102 .
- the profiled face 102 is convex and the center portion 104 of the face 102 forms the upper surface of the profiled face 102 .
- a skirt 106 surrounds the center portion 104 and the slopes 108 . The slopes 108 extend between the skirt 106 and the center portion 104 .
- the center portion 104 of the profiled face 102 is concave and forms a lower surface of the profiled face 102 .
- the profiled face 102 of the composite panel 100 includes multiple convex and/or concave portions.
- FIG. 2 is a cross-sectional view of the composite panel 100 showing a first veneer 200 and a second veneer 202 coupled to a fiberboard substrate 204 .
- the fiberboard substrate 204 includes a first face 208 and a second face 210 .
- the first face 208 is profiled.
- the second face 210 has a substantially planar geometry.
- the first veneer 200 and second veneer 202 are adhered to the first face 208 and the second face 210 , respectively with a waterproof adhesive 206 .
- at least the first veneer 200 is pliable, and when adhered to the first face 208 of the fiberboard substrate, the first veneer 200 wraps around the profile of the first face 208 .
- the pliable first veneer 200 wraps around the profile of the first face 208 without cracking.
- the first veneer 200 has a thickness between about 0.005 inches to 0.04 inches to make the first veneer 200 pliable and able to assume the profile and avoid cracking.
- the first veneer 200 provides the profiled face 102 of the composite panel 100 by assuming the profile of the first face 208 .
- the first veneer 200 and the second veneer are around 0.02 inches thick.
- the first veneer 200 and second veneer 202 include wood. Generally, a variety of woods are useable in the first veneer 200 and the second veneer 202 because of the low coefficient of expansion of the substrate 204 .
- the low coefficient of expansion aids in preventing shearing of the waterproof adhesive 206 between the veneer 200 , 202 and the fiberboard substrate 204 .
- the wood in the first veneer 200 and second veneer 202 is varnished, stained or the like.
- the first veneer 200 and second veneer 202 are prepainted.
- 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 MELAMINETM registered to Melamine Chemicals, Inc. In another option, the waterproof adhesive includes urethane, polyurethane or the like.
- a waterproof adhesive 206 is a glue having the trade name MUF 4301 made by National Casein, and including MELAMINETM.
- 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.
- 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.
- the fiberboard substrate 204 is constructed with wood fibers created in a fiberizing process that pulls wood apart into fibers.
- fiberizing generates wood fibers having a range of lengths between about 0.5 to 8 millimeters.
- 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.
- phenolic resin e.g. phenol formaldehyde or the like
- the waterproof resin includes methyl di-isocyanate.
- 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.
- the fiberboard substrate 204 has a density of between about 45 lbs./ft 3 to 80 lbs./ft 3 . 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 .
- the waterproof resin provides at least some measure of waterproofing to the fiberboard substrate 204 .
- the waterproof resin and the waterproof adhesive 206 cooperate to make the composite panel 100 substantially waterproof.
- 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 .
- 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.
- FIG. 3 is a cross-sectional view of a panel assembly 300 including two composite panels 100 .
- the panel assembly 300 includes an insulation core 302 .
- the insulation core 302 includes foamed polystyrene, or the like.
- polystyrene suitable for the insulation core 302 is a material sold under the trademark STYROFOAMTM and registered to the Dow Chemical Company.
- the second veneers 202 of the composite panels 100 have a corresponding surface area to the sides of the insulation core 302 .
- the second veneers 202 are substantially adjacent to the sides of the insulation core 302 .
- the second veneers 202 are slidably coupled to the sides of the insulation core 302 .
- the composite panels 100 (fiberboard substrates 204 , first veneers 200 and second veneers 202 ) are moveably coupled through the second veneers 202 to the insulation core 302 .
- the two composite panels 100 are constructed with the same materials.
- the two composite panels 100 include different materials or different ratios of materials in the fiberboard substrates 204 .
- the composite panels 100 include different first veneers 200 and/or second veneers 202 .
- the composite panels 100 include different profiled faces 102 , in another example.
- FIG. 4 is a cross-sectional view of another example of a panel assembly 400 including two composite panels 100 and an insulation core 302 .
- the composite panels 100 and the insulation core 302 include a glass cavity defined by the inner surfaces 403 of the composite panels 100 and the insulation core 302 .
- the panels 100 and insulation core 302 in one option, are dimensioned and configured to retain a glass pane 404 therein.
- at least one bracket 406 is coupled to the composite panels 100 and spans the insulation core 302 .
- the at least one bracket 406 has a substantially planar geometry, in yet another option.
- the at least one bracket 406 includes but is not limited to aluminum, steel or the like.
- the at least one bracket 406 maintains the spacing between the composite panels 100 .
- fasteners such as screws 408 or the like are driven into the inner surfaces 403 of the composite panels 100 to couple the at least one bracket 406 to the panels 100 .
- the at least one bracket 406 is coupled to the composite panels 100 with adhesives, nails or the like.
- the glass pane 404 engages the at least one bracket 406 , in yet another example, when disposed within the glass cavity defined by the inner surfaces 403 .
- the glass pane 404 is secured within the composite panels 100 and insulation core 302 , in one example, with beads 407 .
- the beads 407 are coupled to the composite panels 100 with nails, screws or the like.
- FIG. 5 is a cross-sectional view of still another example of a panel assembly 500 including two composite panels 100 and an insulation core 302 .
- panel assembly 500 is similar to panel assembly 400 .
- the composite panels 100 and insulation core 302 are dimensioned and configured to retain a glass pane 404 within a glass cavity defined by the inner surfaces 403 .
- At least one bracket 506 is coupled to the composite panels 100 , in one option.
- the at least one bracket 506 has an “L” shaped geometry.
- fasteners such as screws 408 or the like are driven into the composite panels 100 to couple the at least one bracket 506 to the panels 100 .
- the glass pane 404 engages the at least one bracket 506 when disposed within the glass cavity.
- the glass pane 404 engages the at least one bracket 506 and the inner surface 403 of the composite panel 100 , in still another example.
- the fiberboard substrate 204 of the composite panel 100 is more deformable than the at least one bracket 506 .
- the fiberboard substrate 204 absorbs pressure between the composite panel 100 and the glass pane 404 when the glass pane 404 is engaged against the inner surface 403 of the panel 100 .
- the glass pane 404 is secured within the composite panels 100 and insulation core 302 , in one example, with beads 407 .
- the beads 407 are coupled to the composite panels 100 with nails, screws or the like.
- FIG. 6 is a block diagram showing a method 600 for making a composite panel.
- a fiberboard substrate including wood fiber and a waterproof resin is compressed.
- the method 600 includes milling the at least one face of the fiberboard substrate to provide at least one profiled face.
- a waterproof adhesive is applied to at least one surface of a first veneer.
- the at least one surface of the first veneer is coupled to at least one face of the fiberboard substrate.
- at least the first veneer is pliable and assumes a profile substantially corresponding to the at least one profiled face of the fiberboard substrate when the veneer is pressed against the at least one profiled face.
- the waterproof adhesive is applied to at least one surface of a second veneer. The at least one surface of the second veneer is coupled to another face of the fiberboard substrate.
- the waterproof adhesive applied to the at least one surface of the veneer includes MELAMINETM.
- the waterproof adhesive includes urethane, in another option.
- Compressing of the fiberboard substrate includes heating the substrate, in still 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.
- FIG. 7 is a front view of a door assembly 700 .
- Door assembly 700 includes composite panels 702 A, B, C, D, E.
- corresponding panels are included on the opposite side of the door assembly 700 .
- the panels 702 A, B, C, D, E and corresponding panels are included in panel assemblies including an insulation core, described above.
- the panels 702 A, B, C, D, E include similar materials, in another option.
- the geometry of panels 702 A, B, C, D, E are varied, in yet another option, to provide different sizes and shapes of panels.
- panels 702 A, B, C, D, E have differing profiles to provide different decorative appearances for the panels.
- the door assembly 700 includes a door 701 having stiles 704 A, B, C, D and rails 706 A, B, C, D.
- the door assembly 700 including stiles 704 A, B, C, D and rails 706 A, B, C, D is constructed from wood.
- the stiles 704 A, B, C, D and rails 706 A, B, C, D include aluminum, steel, or the like, in another example.
- the stiles 704 A, B, C, D and rails 706 A, B, C, D are constructed with composite materials, for example, laminated wood strands, wood fibers, or the like.
- 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.
- FIG. 8 is a front view of door assembly 800 .
- door assembly 800 includes at least one glass pane 802 disposed within a door 801 .
- the door assembly 800 includes multiple glass panes 802 , in another example.
- the glass pane 802 is coupled to a panel 804 including a fiberboard substrate, waterproof adhesive and at least one veneer.
- the glass pane 802 is coupled to the panel 804 and a corresponding panel on the opposite side of the door 801 .
- a panel assembly similar to panel assembly 400 ( FIG. 4 ), includes the glass pane 802 disposed within the panels 804 and an insulation core, in another option.
- FIG. 9 is a cross-sectional view of a door assembly 900 including panel assembly 300 .
- panel assembly 300 is retained within a panel cavity of the door assembly 900 dimensioned and configured to house the panel assembly 300 .
- the panel assembly 300 is retained between stiles 901 .
- the panel assembly 300 is retained between stiles 901 and/or rails of a door.
- the panel assembly 300 is retained within the door assembly 900 with glazing caps 902 , in another example.
- the glazing cap 902 includes a deformable seat 904 .
- the deformable seat 904 includes vinyl, rubber or the like.
- the deformable seat 904 includes a tongue 906 dimensioned and configured to interference fit within a kerf 908 of the stile 901 , in yet another option.
- the tongue 906 includes at least one ridge 910 .
- the at least one ridge 910 is dimensioned and configured to engage a surface of the kerf 908 .
- engagement of the at least one ridge 910 applies a torsional force to the deformable seat 904 , forcing a retaining lip 912 to engage against the panel assembly 300 .
- the retaining lip 912 engages the first veneer 200 .
- the retaining lip includes a deformable bead 913 , in another option, to engage against the first veneer 200 .
- the retaining lip 912 and an opposing surface 914 of the stile 901 retain the panel assembly 300 within the door assembly 900 .
- a sealant 915 e.g. silicone
- the sealant 915 creates a seal between the glazing cap 902 and the panel assembly 300 to substantially prevent moisture penetration between the panel assembly 300 and the stiles 901 and/or rails of the door assembly 900 .
- the glazing cap 902 includes a decorative trim 916 coupled to the deformable seat 902 .
- the deformable seat 902 includes a vinyl barb 918 dimensioned and configured to interference fit within a kerf 920 of the deformable seat 902 .
- the decorative trim includes but is not limited to wood, wood composite, or the like.
- panel assembly 300 is retained within the door assembly 900 with glazing beads. Glazing beads are engaged to the panel assembly 300 , in one option, and nails or the like are driven through the glazing beads to retain the panel assembly 300 and glazing bead within the door assembly 900 .
- 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.
- 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.
- FIG. 10 is a block diagram illustrating a method 1000 for making a door assembly.
- a door is provided including at least one panel cavity dimensioned and configured to house at least one panel assembly.
- an insulation core is disposed within the at least one panel cavity.
- a first panel is disposed within the at least one panel cavity.
- the first panel includes a fiberboard substrate of wood fiber and a waterproof resin and a veneer coupled to the substrate with a waterproof adhesive.
- the first face of the insulation core is engaged against the first panel.
- the first panel and the insulation core are retained within the at least one panel cavity.
- a second panel is disposed within the at least one panel cavity.
- the second panel includes a fiberboard substrate of wood fiber and the waterproof resin, in one example, and a veneer coupled to the substrate with the waterproof resin.
- the method 1000 includes disposing at least one glass pane within at least one glass cavity in the first panel, the insulation core and the second panel.
- a bracket is coupled to the first panel and the second panel, in another option, along surfaces defining the at least one glass cavity of the first panel and the second panel.
- 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.
- 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.
- 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.
- 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.
- the composite panel is useful as a replacement panel for existing doors and decorative windows.
- the composite panel is useful for indoor and outdoor applications.
Abstract
A composite panel includes a fiberboard substrate including wood fiber and waterproof resin. At least one veneer is disposed over a first face of the fiberboard substrate. A waterproof adhesive is disposed between the veneer and the fiberboard substrate. In another example, a door assembly includes a door having at least one panel cavity. An insulation core is disposed within the at least one panel cavity and coupled to the door. At least one panel is disposed within the at least one panel cavity and coupled to the door. In one option, the at least one panel includes a fiberboard substrate including wood fiber and waterproof resin. The fiberboard substrate includes at least one face. A first veneer is coupled along at least one surface to the at least one face of the fiberboard substrate. In another option, a second veneer is coupled along at least one surface to another face of the fiberboard substrate. Optionally, the second veneer is substantially adjacent to the insulation core.
Description
- 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.
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FIG. 1 is a front view illustrating a composite panel constructed in accordance with one embodiment. -
FIG. 2 is a cross-sectional view illustrating a composite panel constructed in accordance with one embodiment. -
FIG. 3 is a cross-sectional view illustrating a panel assembly constructed in accordance with another embodiment. -
FIG. 4 is a cross-sectional view illustrating a panel assembly constructed in accordance with yet another embodiment. -
FIG. 5 is a cross-sectional view illustrating a panel assembly constructed in accordance with still another embodiment. -
FIG. 6 is a block diagram illustrating a method for making a composite panel. -
FIG. 7 is a front view illustrating a door assembly constructed in accordance with one embodiment. -
FIG. 8 is a front view illustrating a door assembly constructed in accordance with another embodiment. -
FIG. 9 is a cross-sectional view illustrating a door assembly constructed in accordance with one embodiment. -
FIG. 10 is a block diagram illustrating a method for making a door assembly. - 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.
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FIG. 1 is a front view of acomposite panel 100 for use in a door assembly or decorative window assembly. In one example, the composite panel includes a profiledface 102. In one option, the profiledface 102 is convex and thecenter portion 104 of theface 102 forms the upper surface of the profiledface 102. In another option, askirt 106 surrounds thecenter portion 104 and theslopes 108. Theslopes 108 extend between theskirt 106 and thecenter portion 104. In yet another option, thecenter portion 104 of the profiledface 102 is concave and forms a lower surface of the profiledface 102. Optionally, the profiledface 102 of thecomposite panel 100 includes multiple convex and/or concave portions. -
FIG. 2 is a cross-sectional view of thecomposite panel 100 showing afirst veneer 200 and asecond veneer 202 coupled to afiberboard substrate 204. In one example, thefiberboard substrate 204 includes afirst face 208 and asecond face 210. In one option, thefirst face 208 is profiled. In another option, thesecond face 210 has a substantially planar geometry. In another example, thefirst veneer 200 andsecond veneer 202 are adhered to thefirst face 208 and thesecond face 210, respectively with awaterproof adhesive 206. In yet another example, at least thefirst veneer 200 is pliable, and when adhered to thefirst face 208 of the fiberboard substrate, thefirst veneer 200 wraps around the profile of thefirst face 208. The pliablefirst veneer 200 wraps around the profile of thefirst face 208 without cracking. Thefirst veneer 200 has a thickness between about 0.005 inches to 0.04 inches to make thefirst veneer 200 pliable and able to assume the profile and avoid cracking. When coupled to thefiberboard substrate 204, thefirst veneer 200 provides the profiledface 102 of thecomposite panel 100 by assuming the profile of thefirst face 208. In one example, thefirst veneer 200 and the second veneer are around 0.02 inches thick. In another example, thefirst veneer 200 andsecond veneer 202 include wood. Generally, a variety of woods are useable in thefirst veneer 200 and thesecond veneer 202 because of the low coefficient of expansion of thesubstrate 204. The low coefficient of expansion aids in preventing shearing of thewaterproof adhesive 206 between theveneer fiberboard substrate 204. In another example, the wood in thefirst veneer 200 andsecond veneer 202 is varnished, stained or the like. In yet another example, thefirst veneer 200 andsecond veneer 202 are prepainted. - In one option, the
waterproof adhesive 206 used to couple thefirst veneer 200 and thesecond veneer 202 to thefiberboard 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 awaterproof adhesive 206 is a glue having the trade name MUF 4301 made by National Casein, and including MELAMINE™. Another example of awaterproof 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 thecomposite panel 100 includes wood fibers and a waterproof resin. In one example, thefiberboard 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 infiberboard 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, thefiberboard substrate 204 has a lineal expansion of about 0.58% in 50% to 90% relative humidity, where thesubstrate 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 thefiberboard substrate 204. In one example, the waterproof resin provides at least some measure of waterproofing to thefiberboard substrate 204. In another example, the waterproof resin and thewaterproof adhesive 206 cooperate to make thecomposite 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 thecomposite panel 100. In another option, the mixture of the wood fibers and the waterproof resin makes thefiberboard substrate 204 resistant to expansive and contractive movement caused by humidity changes. -
FIG. 3 is a cross-sectional view of apanel assembly 300 including twocomposite panels 100. In one example, thepanel assembly 300 includes aninsulation core 302. In one option, theinsulation core 302 includes foamed polystyrene, or the like. One example of polystyrene suitable for theinsulation core 302 is a material sold under the trademark STYROFOAM™ and registered to the Dow Chemical Company. In another example, thesecond veneers 202 of thecomposite panels 100 have a corresponding surface area to the sides of theinsulation core 302. In yet another example, thesecond veneers 202 are substantially adjacent to the sides of theinsulation core 302. Optionally, thesecond veneers 202 are slidably coupled to the sides of theinsulation core 302. In another option, the composite panels 100 (fiberboard substrates 204,first veneers 200 and second veneers 202) are moveably coupled through thesecond veneers 202 to theinsulation core 302. In yet another example, the twocomposite panels 100 are constructed with the same materials. In one option, the twocomposite panels 100 include different materials or different ratios of materials in thefiberboard substrates 204. In another option, thecomposite panels 100 include differentfirst veneers 200 and/orsecond veneers 202. Thecomposite panels 100 include different profiled faces 102, in another example. -
FIG. 4 is a cross-sectional view of another example of a panel assembly 400 including twocomposite panels 100 and aninsulation core 302. In one example, thecomposite panels 100 and theinsulation core 302 include a glass cavity defined by theinner surfaces 403 of thecomposite panels 100 and theinsulation core 302. Thepanels 100 andinsulation core 302, in one option, are dimensioned and configured to retain aglass pane 404 therein. In another option, at least onebracket 406 is coupled to thecomposite panels 100 and spans theinsulation core 302. The at least onebracket 406 has a substantially planar geometry, in yet another option. The at least onebracket 406 includes but is not limited to aluminum, steel or the like. In another example, the at least onebracket 406 maintains the spacing between thecomposite panels 100. In one option, fasteners such asscrews 408 or the like are driven into theinner surfaces 403 of thecomposite panels 100 to couple the at least onebracket 406 to thepanels 100. Optionally, the at least onebracket 406 is coupled to thecomposite panels 100 with adhesives, nails or the like. Theglass pane 404 engages the at least onebracket 406, in yet another example, when disposed within the glass cavity defined by theinner surfaces 403. Theglass pane 404 is secured within thecomposite panels 100 andinsulation core 302, in one example, withbeads 407. Thebeads 407 are coupled to thecomposite panels 100 with nails, screws or the like. -
FIG. 5 is a cross-sectional view of still another example of apanel assembly 500 including twocomposite panels 100 and aninsulation core 302. In some respects,panel assembly 500 is similar to panel assembly 400. As described above, thecomposite panels 100 andinsulation core 302 are dimensioned and configured to retain aglass pane 404 within a glass cavity defined by theinner surfaces 403. At least onebracket 506 is coupled to thecomposite panels 100, in one option. Optionally, the at least onebracket 506 has an “L” shaped geometry. In one example, fasteners such asscrews 408 or the like are driven into thecomposite panels 100 to couple the at least onebracket 506 to thepanels 100. In another example, theglass pane 404 engages the at least onebracket 506 when disposed within the glass cavity. Theglass pane 404 engages the at least onebracket 506 and theinner surface 403 of thecomposite panel 100, in still another example. Optionally, thefiberboard substrate 204 of thecomposite panel 100 is more deformable than the at least onebracket 506. In another option, thefiberboard substrate 204 absorbs pressure between thecomposite panel 100 and theglass pane 404 when theglass pane 404 is engaged against theinner surface 403 of thepanel 100. Theglass pane 404 is secured within thecomposite panels 100 andinsulation core 302, in one example, withbeads 407. Thebeads 407 are coupled to thecomposite panels 100 with nails, screws or the like. -
FIG. 6 is a block diagram showing amethod 600 for making a composite panel. At 602, a fiberboard substrate including wood fiber and a waterproof resin is compressed. In one option, themethod 600 includes milling the at least one face of the fiberboard substrate to provide at least one profiled face. At 604, a waterproof adhesive is applied to at least one surface of a first veneer. At 606, the at least one surface of the first veneer is coupled to at least one face of the fiberboard substrate. Optionally, at least the first veneer is pliable and assumes a profile substantially corresponding to the at least one profiled face of the fiberboard substrate when the veneer is pressed against the at least one profiled face. In another example, the waterproof adhesive is applied to at least one surface of a second veneer. 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, 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.
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FIG. 7 is a front view of adoor assembly 700.Door assembly 700 includescomposite panels 702A, B, C, D, E. In one option, corresponding panels are included on the opposite side of thedoor assembly 700. Optionally, thepanels 702A, B, C, D, E and corresponding panels are included in panel assemblies including an insulation core, described above. Thepanels 702A, B, C, D, E include similar materials, in another option. The geometry ofpanels 702A, B, C, D, E are varied, in yet another option, to provide different sizes and shapes of panels. In one example,panels 702A, B, C, D, E have differing profiles to provide different decorative appearances for the panels. - The
door assembly 700 includes adoor 701 havingstiles 704A, B, C, D and rails 706A, B, C, D. In one example, thedoor assembly 700, includingstiles 704A, B, C, D and rails 706A, B, C, D is constructed from wood. Thestiles 704A, B, C, D and rails 706A, B, C, D include aluminum, steel, or the like, in another example. In yet another example, thestiles 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, thedoor 701 includes ahandle 708, for example a door knob. Thedoor assembly 700 includes a frame for installation of thedoor assembly 700 within a surface (e.g. a wall), in another option. -
FIG. 8 is a front view ofdoor assembly 800. In one example,door assembly 800 includes at least oneglass pane 802 disposed within adoor 801. Thedoor assembly 800 includesmultiple glass panes 802, in another example. In yet another example, theglass pane 802 is coupled to apanel 804 including a fiberboard substrate, waterproof adhesive and at least one veneer. Optionally, theglass pane 802 is coupled to thepanel 804 and a corresponding panel on the opposite side of thedoor 801. A panel assembly, similar to panel assembly 400 (FIG. 4 ), includes theglass pane 802 disposed within thepanels 804 and an insulation core, in another option. -
FIG. 9 is a cross-sectional view of adoor assembly 900 includingpanel assembly 300. In one example,panel assembly 300 is retained within a panel cavity of thedoor assembly 900 dimensioned and configured to house thepanel assembly 300. As shown inFIG. 9 , thepanel assembly 300 is retained betweenstiles 901. In another option, thepanel assembly 300 is retained betweenstiles 901 and/or rails of a door. Thepanel assembly 300 is retained within thedoor assembly 900 withglazing caps 902, in another example. In one option, theglazing cap 902 includes adeformable seat 904. In another option, thedeformable seat 904 includes vinyl, rubber or the like. Thedeformable seat 904 includes atongue 906 dimensioned and configured to interference fit within akerf 908 of thestile 901, in yet another option. Thetongue 906 includes at least oneridge 910. The at least oneridge 910 is dimensioned and configured to engage a surface of thekerf 908. Optionally, engagement of the at least oneridge 910 applies a torsional force to thedeformable seat 904, forcing a retaininglip 912 to engage against thepanel assembly 300. In one option, the retaininglip 912 engages thefirst veneer 200. The retaining lip includes adeformable bead 913, in another option, to engage against thefirst veneer 200. In yet another option, the retaininglip 912 and an opposingsurface 914 of thestile 901 retain thepanel assembly 300 within thedoor assembly 900. A sealant 915 (e.g. silicone) is applied to retaininglip 912, in still another option. Thesealant 915 creates a seal between theglazing cap 902 and thepanel assembly 300 to substantially prevent moisture penetration between thepanel assembly 300 and thestiles 901 and/or rails of thedoor assembly 900. In another example, theglazing cap 902 includes adecorative trim 916 coupled to thedeformable seat 902. In one option, thedeformable seat 902 includes avinyl barb 918 dimensioned and configured to interference fit within akerf 920 of thedeformable seat 902. The decorative trim includes but is not limited to wood, wood composite, or the like. In another example,panel assembly 300 is retained within thedoor assembly 900 with glazing beads. Glazing beads are engaged to thepanel assembly 300, in one option, and nails or the like are driven through the glazing beads to retain thepanel assembly 300 and glazing bead within thedoor assembly 900. - In yet another example, a panel assembly including an
insulation core 302 and onepanel 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. Theinsulation core 302 is disposed within the clad door so it engages the integral second panel. Thepanel 100 is then inserted into the clad door against theinsulation core 302 and aglazing cap 902 or the like is used to retain the panel assembly within the door. -
FIG. 10 is a block diagram illustrating amethod 1000 for making a door assembly. At 1002, a door is provided including at least one panel cavity dimensioned and configured to house at least one panel assembly. At 1004, an insulation core is disposed within the at least one panel cavity. At 1006, a first panel is disposed within the at least one panel cavity. The first panel includes a fiberboard substrate of wood fiber and a waterproof resin and a veneer coupled to the substrate with a waterproof adhesive. In one option, the first face of the insulation core is engaged against the first panel. At 1008, the first panel and the insulation core are retained within the at least one panel cavity. In one option, a second panel is disposed within the at least one panel cavity. The second panel includes a fiberboard substrate of wood fiber and the waterproof resin, in one example, and a veneer coupled to the substrate with the waterproof resin. Optionally, themethod 1000 includes disposing at least one glass pane within at least one glass cavity in the first panel, the insulation core and the second panel. A bracket is coupled to the first panel and the second panel, in another option, along surfaces defining the at least one glass cavity of the first panel and the second panel. - 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.
Claims (32)
1. A panel comprising:
a fiberboard substrate including wood fiber and a waterproof resin;
at least one veneer disposed over a first face of the fiberboard substrate; and
a waterproof adhesive disposed between the at least one veneer and the fiberboard substrate.
2. The panel of claim 1 , wherein the first face of the fiberboard substrate has a profiled surface.
3. The panel of claim 2 , wherein 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.
4. The panel of claim 1 , further comprising a second veneer disposed over a second face of the fiberboard substrate.
5. The panel of claim 1 , wherein the waterproof resin includes phenol formaldehyde.
6. The panel of claim 1 , wherein the waterproof resin includes methyl di-isocyanate.
7. The panel of claim 1 , wherein the waterproof adhesive includes cyanuramide.
8. The panel of claim 1 , wherein the waterproof adhesive includes polyurethane.
9. The panel of claim 1 , wherein the waterproof adhesive includes urethane.
10. A door assembly comprising:
a door including at least one panel cavity;
an insulation core disposed within the at least one panel cavity; and
at least one panel disposed within the at least one panel cavity and coupled to the door, including
a fiberboard substrate including wood fiber and a waterproof resin and having at least one profiled face,
a first veneer coupled to the at least one profiled face with a waterproof adhesive, wherein the first veneer has a profile corresponding to the at least one profiled face of the fiberboard substrate, and
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.
11. The door assembly of claim 10 , further comprising a glazing cap coupled to the door and engaged against the at least one panel.
12. The door assembly of claim 11 , wherein a sealant is disposed between the at least one panel and the glazing cap.
13. The door assembly of claim 10 , wherein 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.
14. The door assembly of claim 10 , further comprising:
a second panel including 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.
15. The door assembly of claim 14 , further comprising at least one bracket coupled to the at least one panel and to the second panel.
16. The door assembly of claim 10 , further comprising at least one glass pane disposed within the insulation core and the at least one panel.
17. The door assembly of claim 10 , wherein the first veneer is pliable and assumes the profile corresponding to the profiled face of the fiberboard substrate when disposed over the fiberboard substrate.
18. A method of making a panel comprising:
compressing a fiberboard substrate including wood fiber and a waterproof resin, wherein the fiberboard substrate includes at least one face;
applying a waterproof adhesive to at least one surface of a first veneer; and
coupling the at least one surface of the first veneer to the at least one face of the fiberboard substrate.
19. The method of claim 18 , wherein applying the waterproof adhesive to the at least one surface of the first veneer includes applying an adhesive including cyanuramide.
20. The method of claim 18 , wherein applying the waterproof adhesive to the at least one surface of the first veneer includes applying an adhesive including urethane.
21. The method of claim 18 , further comprising:
applying the waterproof adhesive to at least one surface of a second veneer; and
coupling the at least one surface of the second veneer to another face of the fiberboard substrate.
22. The method of claim 18 , further comprising milling the at least one face of the fiberboard substrate to provide at least one profiled face.
23. The method of claim 18 , wherein coupling the at least one surface of the first veneer to the at least one face of the fiberboard substrate includes pressing the first veneer against at least one profiled face of the fiberboard substrate, wherein the first veneer is pliable and assumes a profile substantially corresponding to the at least one profiled face.
24. The method of claim 18 , wherein compressing a fiberboard substrate includes heating the fiberboard substrate.
25. The method of claim 18 , wherein coupling the at least one surface of the first veneer to the at least one face of the fiberboard substrate includes heating the waterproof adhesive.
26. A method of making a door assembly comprising:
providing a door, wherein the door includes at least one panel cavity;
disposing an insulation core within the at least one panel cavity;
disposing a first panel within the at least one panel cavity, wherein the first panel includes a fiberboard substrate of wood fiber and a waterproof resin and a veneer coupled to the fiberboard substrate with a waterproof adhesive, wherein a first face of the insulation core is engaged against the first panel; and
retaining the first panel and the insulation core within the at least one panel cavity.
27. The method of claim 26 , wherein retaining the first panel and the insulation core within the at least one panel cavity includes coupling a glazing cap to the door and engaging the glazing cap against the veneer of the first panel.
28. The method of claim 27 , wherein retaining the first panel and the insulation core within the at least one panel cavity includes interposing a sealant between the glazing cap and the veneer of the first panel.
29. The method of claim 26 , wherein retaining the first panel and the insulation core within the at least one panel cavity includes coupling a glazing bead to the door and engaging the glazing bead against the veneer of the first panel.
30. The method of claim 26 , further comprising disposing a second panel within the at least one panel cavity, wherein the second panel includes a fiberboard substrate of wood fiber and the waterproof resin and a veneer coupled to the fiberboard substrate with the waterproof adhesive.
31. The method of claim 30 , further comprising disposing at least one glass pane within at least one glass cavity in the first panel, the insulation core and the second panel.
32. The method of claim 31 , further comprising coupling a bracket to the first panel and the second panel along surfaces defining the glass cavities of the first panel and the second panel.
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US10/809,047 US20050210829A1 (en) | 2004-03-25 | 2004-03-25 | Wood composite panel |
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US10/809,047 US20050210829A1 (en) | 2004-03-25 | 2004-03-25 | Wood composite panel |
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US20050210829A1 true US20050210829A1 (en) | 2005-09-29 |
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US10/809,047 Abandoned US20050210829A1 (en) | 2004-03-25 | 2004-03-25 | Wood composite panel |
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Publication number | Priority date | Publication date | Assignee | Title |
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US20030084633A1 (en) * | 1995-06-30 | 2003-05-08 | Francois Zuber | Method, assembly and additional coat for the construction of interior works |
US20170355177A1 (en) * | 2014-11-17 | 2017-12-14 | Fahiem Amod Bux | Method for forming a panel, particularly skin for a hollow core door, and a method of manufacturing a hollow core door |
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US20030084633A1 (en) * | 1995-06-30 | 2003-05-08 | Francois Zuber | Method, assembly and additional coat for the construction of interior works |
US7208225B2 (en) * | 1995-06-30 | 2007-04-24 | Lafarge Platres | Prefabricated plaster board |
US20170355177A1 (en) * | 2014-11-17 | 2017-12-14 | Fahiem Amod Bux | Method for forming a panel, particularly skin for a hollow core door, and a method of manufacturing a hollow core door |
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