Door skin, a method of etching a plate, and an etched plate formed therefrom

1. A method of forming a molded article comprising:

compressing a composite material in a die cavity between a first mold plate and a second mold plate to form a molded article having an exterior surface comprising a simulated wood grain pattern, wherein the first mold plate comprises an etched metal plate having lower portions lying in a plane, spaced ticks extending from the plane of the lower portions, and tonal areas having a plurality of spaced protrusions spaced apart from one another by channels etched in the metal plate.

2. The method of claim 1 , wherein the first plate comprises a member selected from the group consisting of copper, aluminum, cold rolled steel, and stainless steel.

3. The method of claim 1 , wherein the spaced ticks extend from the plane of the lower portions by about 0.005 inches to 0.015 inches.

4. The method of claim 1 , wherein the spaced ticks are variably spaced from each other.

5. The method of claim 1 , wherein the spaced ticks extend parallel to each other.

6. The method of claim 1 , wherein the spaced ticks have variable lengths.

7. The method of claim 1 , wherein the channels have bases that are coplanar with the plane of the lower portions.

8. The method of claim 7 , wherein the protrusions extend from the plane of the bases from between about 0.001 to about 0.003 inches.

9. The method of claim 1 , wherein the molded article comprises a member selected from the group consisting of a door skin, a cabinet door, a furniture door, a wainscot, a panel, a construction component, a decorative molding, and a trim product.

10. A method of forming a molded door skin comprising:

compressing a composite material in a die cavity formed between a first mold plate and a second mold plate to form a molded door skin having an exterior surface comprising a simulated wood grain pattern, wherein the first mold plate comprises an etched metal plate having lower portions lying in a plane, spaced ticks extending from the plane of the lower portions, and tonal areas comprising a plurality of protrusions spaced from one another by channels etched in the metal plate.

11. The method of claim 10 , further comprising applying stain to the molded door skin.

12. The method of claim 10 , wherein the composite material comprises a polymer-based composite.

13. The method of claim 10 , wherein the composite material comprises a member selected from the group consisting of medium density fiberboard, hard board, and fiberboard.

14. The method of claim 10 , wherein the tonal areas have differing densities of the protrusions.

15. The method of claim 10 , wherein the channels have bases that are coplanar with the plane of the lower portions.

16. A method of forming a door comprising:

compressing a composite material in a die cavity formed between a first mold plate and a second mold plate to form a molded door skin having an exterior surface comprising a simulated wood grain pattern, wherein the first mold plate comprises an etched metal plate having lower portions lying in a plane, spaced ticks extending from the plane of the lower portions, and tonal areas comprising a plurality of protrusions spaced from one another by channels etched in the metal plate; and

attaching the molded door skin to a peripheral frame.

17. The method of claim 16 , further comprising applying stain to the molded door skin.

18. The method of claim 16 , wherein the composite material comprises a polymer-based composite.

19. The method of claim 16 , wherein the composite material comprises a member selected from the group consisting of medium density fiberboard, hard board, and fiberboard.

20. The method of claim 16 , wherein the tonal areas have differing densities of the protrusions.