Patent ID: 9352486
Filing Date: 2016-05-31
CPC Classification: B27N,B32B,Y10T

Claim Text:
1. A composite non-planar door skin comprising: a medium density fiberboard defining a continuous layer having an exterior major surface comprising a planar central portion extending along a first plane, a first planar side portion and a second planar side portion positioned at opposite first and second sides of the planar central portion and extending in a second plane, a planar top portion and a planar lower portion positioned at opposite third and fourth sides of the planar central portion and extending in said second plane, where the second plane is spaced apart from the first plane, a first angled wall connecting the first side of the planar central portion to the first planar side portion, a second angled wall connecting the second side of the planar central portion to the second planar side portion, a third angled wall connecting the planar top portion with the third side of the planar central portion, and a fourth angled wall connecting the planar lower portion with the fourth side of the planar central portion, wherein the third angled wall and the fourth angled wall have a slope that is less than a slope of the first and second angled walls; a wood veneer layer covering the exterior major surface of the medium density fiberboard, the wood veneer layer comprising a planar central portion, planar side portions, and angled walls corresponding to and overlaying the planar central portion, the first and second planar side portions, the planar top portion, the planar lower portion, and the first, second, third, and fourth angled walls of the medium density fiberboard, wherein the medium density fiberboard and the wood veneer layer are bonded to one another and simultaneously deformed into the composite non-planar door skin without cracking or wrinkling of the wood veneer layer by heating and moisturizing the medium density fiberboard but not the wood veneer layer, placing the medium density fiberboard and the wood veneer layer in contact with one another in a press, deforming and bonding the medium density fiberboard and the wood veneer layer together under application of heat and pressure to form the composite non-planar door skin, removing the composite non-planar door skin from the press, and wetting the composite non-planar door skin to raise the moisture content of the wood veneer layer.