Reverse molded panel
View Patent ↗A reverse molded fiberboard panel; a wainscot kit comprising a plurality of differently sized reverse molded panels, and a planar finishing or spacer panel, adapted to completely cover any size wall between a wall base board and a wall chair rail; and a method of reverse molding a loose cellulosic mat, in a single pressing step, to provide one or more relatively high density, raised panels without requiring preliminary pressing, or other pre-shaping step, such as scalping. The reverse-molded panels are molded in a conventional, multi-opening fiberboard press, in a single pressing step process, while achieving excellent transfer of mold detail (embossing fidelity) without visually noticeable fiber fracture.
1. A reverse-molded, wood composite article having an interior surface and an opposite exterior surface, said article comprising:
a planar portion having a first thickness and an interior surface which is configured to adhere to a support;
a panel portion; and
a reverse-molded, contoured wall portion extending outwardly from the planar portion and integrally interconnecting the planar portion and the panel portion, the contoured wall portion having a second thickness less than the first thickness.
2. The reverse-molded, wood composite article of claim 1 , wherein the reverse-molded, wood composite article includes less than 5% by weight resin binder.
3. The reverse-molded, wood composite article of claim 1 , wherein reverse-molded, wood composite article has a specific gravity of about 0.96 to about 1.08.
4. The reverse-molded, wood composite article of claim 1 , wherein the planar portion has a specific gravity in a range of about 0.98 to 1.00.
5. The reverse-molded, wood composite article of claim 1 , wherein the reverse-molded, contoured wall comprises a portion extending at an angle of about 25° to about 35°.
6. The reverse-molded, wood composite article of claim 1 , wherein the reverse-molded, wood composite article is a door skin.
7. The reverse-molded, wood composite article of claim 1 , wherein the reverse-molded, wood composite article is a wainscot panel.
8. A reverse-molded, wood composite article having an interior surface and an opposite exterior surface, said article comprising:
an interior surface comprising a planar region for adhering to surface;
an exterior surface opposite the interior surface;
a planar surface portion;
a panel portion; and
a reverse-molded, contoured wall interconnecting and integral with the planar surface portion and the panel, the reverse-molded, contoured wall comprising an apex having a specific gravity in a range of about 1.02 and about 1.08.
9. The reverse-molded, wood composite article of claim 8 , wherein reverse-molded, wood composite article has a specific gravity in a range of about 0.96 to about 1.08.
10. The reverse-molded, wood composite article of claim 8 , wherein the reverse-molded, wood composite article comprises less than 5% by weight resin binder.
11. The reverse-molded, wood composite article of claim 8 , wherein the reverse-molded, contoured wall portion extends outwardly from the exterior surface of the planar surface portion a distance of 5-10 mm.
12. The reverse-molded, wood composite article of claim 8 , wherein the reverse-molded, contoured wall portion comprises a portion extending at an angle of about 25° to about 35°.
13. The reverse-molded, wood composite article of claim 8 , wherein the reverse-molded, wood composite article comprises cellulosic fibers.
14. The reverse-molded, wood composite article of claim 13 , wherein the cellulosic fibers comprise at least 40% by weight softwood fibers.
15. A reverse-molded, wood composite article and substrate combination comprising:
a substrate having an attachment surface;
a reverse-molded, wood composite article having an interior surface and an opposite exterior surface, the interior surface attached to the attachment surface of the substrate, the reverse-molded, wood composite article further comprising a planar portion, a panel portion, and a reverse-molded, contoured wall portion extending outwardly from the planar portion away from the substrate, the reverse-molded, contoured wall interconnecting the planar surface portion and the panel portion.
16. The reverse-molded, wood composite article, substrate combination of claim 15 , wherein the planar portion has a first thickness and the reverse-molded, contoured wall has a second thickness, the second thickness being less than the first thickness.
17. The reverse-molded, wood composite article, substrate combination of claim 15 , wherein reverse-molded, wood composite article has a specific gravity in a range of about 0.96 to about 1.08.
18. The reverse-molded, wood composite article, substrate combination of claim 15 , wherein the reverse-molded, wood composite article comprises a door skin and the substrate comprises a frame.
19. The reverse-molded, wood composite article, substrate combination of claim 15 , wherein the reverse-molded, wood composite article comprises a wainscot panel and substrate comprises a wall.
20. The reverse-molded, wood composite article, substrate combination of claim 15 , wherein the reverse-molded, contoured wall portion comprises a convex region and a concave region.