Method of manufacturing a decorative substrate and decorative substrate produced thereby

Abstract

A method of forming a composite article is disclosed that involves providing a press having first and second platens, a cellulosic fiber substrate having a first thickness, and a layer of material such as a wood veneer, foil, or non-creped paper, where the layer of material has a thickness less than the thickness of the cellulosic fiber substrate. A layer of bonding material is placed onto the cellulosic fiber substrate or the layer of material, and the layer of material is placed onto the cellulosic fiber substrate so that the bonding material is between the layer of material and the cellulosic fiber substrate. The cellulosic fiber substrate and layer of material are placed between the first and second platens, and at least one of the first and second platens is moved toward the other of the first and second platens to deform the cellulosic fiber substrate and layer of material into a predetermined configuration while bonding the layer of material to the cellulosic fiber substrate without cracking or wrinkling the layer of material.

1 . A method of forming a wood composite article comprising the steps of:
 providing a press having first and second platens;   providing a first wood fiber substrate having a first thickness;   providing a layer of material selected from the group consisting of wood veneers, foils, and non-creped papers;   interposing a bonding material between the wood fiber substrate and the layer of material;   placing the layer of material onto the wood fiber substrate;   placing the wood fiber substrate and layer of material between the first and second platens; and   moving at least one of the first and second platens toward the other of the first and second platens to deform the wood fiber substrate and layer of material into a predetermined configuration while bonding the layer of material to the wood fiber substrate without cracking or wrinkling the layer of material.   
     
     
         2 . (canceled) 
     
     
         3 . A composite article comprising a layer of MDF having a first surface and a layer of wood veneer bonded to the first surface, the first surface having been deformed under the application of heat and pressure while in contact with the layer of wood veneer to form a sharp edge in said layer of wood veneer. 
     
     
         4 . A method of forming a molded door panel, comprising the steps of:
 providing a press;   providing an MDF substrate having first and second sides;   overlaying a flat sheet of wood veneer on the first side;   placing the MDF substrate and wood veneer overlay into the press;   closing the press to simultaneously deform the MDF substrate and wood veneer and bond the wood veneer to the MDF substrate to create a molded door panel.   
     
     
         5 . The method of  claim 4  including the additional steps of removing the molded door panel from the press and moistening the wood veneer. 
     
     
         6 . The method of  claim 5  wherein said step of moistening the wood veneer comprises the step of applying water to the wood veneer. 
     
     
         7 . The method of  claim 4  wherein said step of deforming the MDF substrate comprises the step of forming at least one linear depression in the MDF substrate. 
     
     
         8 . The method of  claim 7  wherein the step of laying a flat sheet of wood veneer in the press over the first side comprises the steps of providing a flat sheet of wood veneer having a grain direction and laying the flat sheet of wood veneer in the press over the first side with the grain direction parallel to the at least one linear depression. 
     
     
         9 . The method of  claim 4  including the additional step of applying a layer of adhesive to one of the MDF substrate and the flat sheet of veneer. 
     
     
         10 . The method of  claim 4  wherein the step of providing a flat sheet of wood veneer comprises the step of providing a flat sheet of wood veneer having a backing. 
     
     
         11 . The method of  claim 4  wherein the step of providing a flat sheet of wood veneer comprises the step of providing a flat sheet of wood veneer having a meltable adhesive layer. 
     
     
         12 . (canceled) 
     
     
         13 . The method of  claim 4  wherein the step of providing a flat sheet of wood veneer comprises the step of providing a flat sheet of wood veneer comprising a plurality of narrow strips. 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . (canceled) 
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . (canceled)