Corrugated wood sheets and articles having a multi-ply panel wall structure comprising same

Abstract

Receptacles having a multi-ply panel wall structure. The multi-ply panel comprises primarily natural and/or bio-degradable fibrous or cellulose materials, such as wood. The wood multi-ply panel is processed and formed by pressing multiple layers of thin wood sheets that retain their natural grain structure. The sheets are heat pressed molded to shape into the desired receptacle configuration, which may be done in a single step. The wood layer may have a corrugated sheet structure.

1 . A wood panel, comprising at least a first ply of wood having an initial corrugated structure prior to forming the wood panel.  
   
   
       2 . The wood panel as in  claim 1 , wherein the first ply of wood in the corrugated structure retains at least one of its wood grains, fiber structure, or cellulose structure after forming the wood panel.  
   
   
       3 . The wood panel as in  claim 1 , wherein the first ply of wood has wood grains generally in a direction parallel, orthogonal or diagonal to a longitudinal direction of the corrugated structure.  
   
   
       4 . The wood panel as in  claim 1 , wherein the corrugated structure has a sectional profile comprising alternating symmetrical or asymmetrical sections.  
   
   
       5 . The wood panel as in  claim 4 , wherein each of the section resembles at least one of the following:V-shape, U-shape, arcuate, semi-circular, rectangular, sinusoidal, hyperbolic, parabolic, or elliptical.  
   
   
       6 . The wood panel as in  claim 1 , comprises at least a second ply of material having a generally flat structure, wherein the second ply of material is coupled to the first ply.  
   
   
       7 . The wood panel as in  claim 6 , wherein the second ply comprises at least one of a synthetic or non-synthetic material.  
   
   
       8 . The wood panel as in  claim 7 , wherein the synthetic or non-synthetic material comprises at least one of: knitted fabric, non-knitted fabric, felt sheet, metal sheet, wood sheet, paper sheet, plastic sheet, glue sheet, mesh sheet, perforated sheet or gauze sheet.  
   
   
       9 . The wood panel as in  claim 6 , wherein the second ply comprises a wood sheet, wherein the first ply and the second ply have grain directions that are generally in same direction, orthogonal or diagonal to each other.  
   
   
       10 . The wood panel as in  claim 6 , wherein the second ply initially has an initial corrugated structure prior to forming the wood panel.  
   
   
       11 . The wood panel as in  claim 6 , wherein the second ply does not extend to cover the entire first ply, wherein the second ply is located at one or more sections with respect to the first ply to provide reinforcement of the wood panel at said one or more sections.  
   
   
       12 . The wood panel as in  claim 6 , wherein the second ply and the first play define a space between the corrugated structure of the first ply and the second ply.  
   
   
       13 . An article of manufacture, comprising a body including the wood panel as in  claim 1 .  
   
   
       14 . The article of manufacture as in  claim 13 , wherein the body comprises a receptacle having a laminated wall structure of which the wood panel is a part.  
   
   
       15 . A receptacle for packing or serving food, comprising a body section for holding food, having a laminated wall structure that comprises primarily wood.  
   
   
       16 . The receptacle as in  claim 15 , wherein the laminated wall structure comprises at least one layer of wood having an initial corrugated structure prior to forming the laminated wall structure.  
   
   
       17 . A process for forming a wood panel structure, comprising: 
 providing a first ply of wood having a corrugated structure;    providing a second ply of material; and    coupling the first ply to the second ply.    
   
   
       18 . The process of  claim 17 , wherein the step of coupling comprises at least one of gluing or pressing the first ply to the second ply, without or without an intermediate layer.  
   
   
       19 . The process of  claim 18 , further comprises pressing the first and second ply to form an article have a wall section of which the wood panel structure is a part.  
   
   
       20 . An article of manufacture, made in accordance with the process of  claim 17.