Wood composite panel

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.

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.