Door skin, a method of etching a plate for forming a wood grain pattern in the door skin, and an etched plate formed therefrom
A door skin featuring a facing having an exterior surface and an interior surface can be provided. A wood grain pattern portion can be formed in the exterior surface of the facing. The wood grain pattern portion can feature a plurality of grooves formed in the exterior surface of the facing, the grooves are recessed from a first plane of the exterior surface, and tonal portions formed in the exterior surface of the facing. The tonal portions can include at least a first protrusion, a second protrusion, and a third protrusion. Spacing between the first protrusion and the second protrusion can be different from spacing between the second protrusion and the third protrusion.
1. An embossing plate for forming a wood grain pattern into a door skin, the embossing plate comprising:
a) a plate having a first surface;
b) a plurality of ridges formed on the first surface; and
c) tonal portions formed in the first surface of said plate, the tonal portions comprising a plurality of depressions, wherein spacing between at least some of the depressions have different widths and at least some of the depressions have different depths.
2. The embossing plate of claim 1 , wherein the tonal portions comprise at least a first depression, a second depression, and a third depression, wherein spacing between the first depression and the second depression is different than spacing between the second depression and the third depression.
3. The embossing plate of claim 1 , wherein the ridges are raised from the first surface by about 0.001 inches to about 0.003 inches.
4. The embossing plate of claim 1 , wherein the depressions are arranged randomly in the exterior surface.
5. The embossing plate of claim 1 , wherein the depressions are separated from each other by protrusions.
6. The embossing plate of claim 5 , wherein the depressions have depths of about 0.0005 inches to about 0.001 inches.
7. The embossing plate of claim 1 , wherein some of said tonal portions are disposed between adjacent ridges.
8. The embossing plate of claim 1 , wherein the depressions are randomly distributed.
9. The embossing plate of claim 1 , wherein the depressions have flat bottom surfaces that are rectangular, triangular, oval, or circular shape.
10. The embossing plate of claim 1 , wherein the depressions have different bottom surface areas.
11. The embossing plate of claim 10 , wherein the bottom surface areas of the depressions range from about 0.0064 mm 2 to about 0.0625 mm 2 .
12. The embossing plate of claim 1 , wherein the depressions have convex or concave bottom surfaces.
13. The embossing plate of claim 1 , wherein the depressions in areas of higher depression density have greater depth than the depressions in areas of lower depression density.
14. The embossing plate of claim 1 , wherein the depression density of the depressions is about 10,000 to about 160,000 per square inch.
15. The embossing plate of claim 1 , wherein the depressions are separated from one another by interconnected protrusions.
16. The embossing plate of claim 15 , wherein the interconnected protrusions are non-uniformly arranged.
17. The embossing plate of claim 1 , wherein the embossing plate is made of metal.
18. The embossing plate of claim 1 , wherein the depressions are box shaped.
19. The embossing plate of claim 1 , wherein the plurality of ridges formed on the first surface are arranged in an inverse configuration to a plurality of grooves simulating an appearance of wood ticks.
20. The embossing plate of claim 19 , wherein the depressions formed in the first surface of said plate are arranged in an inverse configuration to a plurality of protrusions simulating an appearance of wood background tone.