Grooved Panel Product and Method
A grooved panel furniture component having plies spaced apart and parallel to one another, giving the appearance of scored wood. The plies are laminated to a substrate that has a solid color that contrasts with the plies. The panel may be cut to any desired size through a die cut process. In one embodiment of the present invention, the panel may be comprised of paperboard that has a decorative paper poly extruded on its visible surfaces. A sheet of the paperboard with the poly extruded decorative paper is cut into plies.
1 . A panel component, comprising:
a substrate comprising a top surface, a bottom surface, and a color; and
a plurality of plies, each ply comprising
a top surface comprising a color that contrast with the color of the substrate, and
a bottom surface,
wherein each bottom surface of each of the plurality of plies is attached to the top surface of the substrate and wherein the plurality of plies are spaced apart substantially parallel to one another so that a portion of the top surface of the substrate is visible.
2 . The panel component of claim 1 , wherein the plurality of plies is formed from a paperboard material.
3 . The panel component of claim 1 , wherein at least one of the plurality of plies has a wood-grain pattern on the top surface and is attached to the substrate with the top surface visible.
4 . The panel component of claim 1 , wherein the color of the substrate is selected from a group consisting of brown, black, or tan.
5 . The panel component of claim 1 , wherein the bottom surface of the substrate has a wood-grain pattern.
6 . The panel component of claim 1 , wherein a score is formed along a portion of the top surface of the substrate.
7 . A panel component, comprising:
(a) a paperboard substrate comprising a color selected from a group consisting of brown, black, or tan; and
(b) a plurality of paperboard plies each ply comprising
(i) a top surface having a wood-grain pattern; and
(ii) a bottom surface attached to the substrate,
wherein the plurality of paperboard plies are spaced apart substantially parallel to one another and are attached to the substrate such that both of the top surface of the plurality of plies and at least a portion of the substrate is visible to form a plurality of grooves.
8 . The component panel of claim 7 , wherein the plurality of plies are spaced apart between 3/32″ and ¾″ of an inch.
9 . The component panel of claim 7 , wherein a bottom surface of the substrate has a wood-grained pattern.
10 . The method for forming a grooved panel component, comprising:
providing a sheet of paperboard;
poly extruding a decorative paper to the paperboard to form a combination sheet;
creating a plurality of plies from the combination sheet;
spacing the plurality of plies apart; and
adhering the plurality of plies to a substrate.
11 . The method of claim 10 , wherein adhering the plurality of plies to a substrate further comprises adhering the plurality of plies by laminating the plurality of plies to the substrate.
12 . The method of claim 10 , wherein creating a plurality of plies further comprises creating a plurality of plies by running the combination sheet through a splitting machine.
13 . The method of claim 12 , wherein spacing the plurality of plies apart further comprises spacing the plurality of plies apart by running the plurality of plies through a route plate.
14 . The method of 10 , further comprising providing a substrate made of paperboard material after spacing the plurality of plies apart and before adhering the plurality of plies to the substrate.
15 . The method of 14 , wherein providing a substrate made of paperboard material further comprises providing a substrate made of paperboard material, wherein a bottom surface of the substrate has a wood-grain pattern.
16 . The method of 14 , wherein providing a substrate made of paperboard material further comprises providing a substrate made of paperboard material, the substrate being of a solid brown, black, or tan color.
17 . A ready to assemble furniture unit having a panel component, the panel component comprising:
(a) a substrate formed from a paperboard material comprising
(i) a color selected from a group consisting of brown, black or tan and
(ii) a bottom surface having a wood-grain pattern; and
(b) a plurality of plies attached to the substrate, the plurality of plies comprising
(i) a paperboard material and
(ii) a wood-grain pattern on a top surface of at least one of the plurality of plies that contrasts with the solid color of the substrate,
wherein the plurality of plies are spaced apart in a substantially parallel manner and adhered to a top surface of the substrate so that the color of the substrate is visible.