Patent Abstract:
The structures and process for producing the structures of the invention enable extensive and efficient use of veneer and bamboo veneer for slat manufacturing. The techniques employed advantageously accomplish two goals simultaneously, a reduced volume of slat material to reduce the load on the internals of a horizontal blind set, and the provision of a more inexpensive but higher quality long lasting slat outward appearance. One or more core materials made of woven and non-woven and preferably fibrous cloth, as well as combining with metal and other structural layers, are combined with veneers and bamboo veneer to yield a very lightweight slat with good structural characteristics.

Full Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to production methods and products which utilize veneer in a manner that will provide a superior, natural product, especially for window covering components, including slats and methods for construction, to enable the construction of a high quality, consistent louver product which may be trimmed to fit a custom window opening. 
       BACKGROUND OF THE INVENTION 
       [0002]    Slats are utilized in a variety of window coverings, including Venetian blinds, and vertical blinds. Slats have in the past been constructed of thin metal from rolls, curved along the path of their shorter dimension to produce a break through stiffness, holding stiff unless stressed. Other slats use thicker materials, typically flat elongate members. These slats include relatively thicker structures whose stiffness is similar to that of a ruler. Modern materials have enabled the construction of slats having a wide variety of strength and size, and other attributes associated with the materials from which they were constructed. 
         [0003]    Two opposing developing factors are causing new construction methods to be sought. The first factor is the increasing scarcity of materials, both structural and decorative. The second factor is a driving need to have an ever more custom appearance for interior finishings. In terms of materials generally, the price continues to increase. Plain ordinary unfinished wood is increasing in cost and becoming more scarce. High quality wood for producing a high quality wood finish is even more expensive. Synthetic materials which are carbon based continue to rise in price. 
         [0004]    Another aspect of the use of materials in window coverings involves elimination of material volume while allowing the same look as could be achieved in using whole natural materials. Veneers and veneer techniques have long been employed in furniture and furniture making. The veneer technique enables the use of a thin layer of a high quality material which is laminated, glued or affixed to a less expensive structural support to give the impression that the whole member is made solidly of the higher quality material. 
         [0005]    Veneer is good for solid furniture structures as it tends to splinter and crack with nearly any movement of the supporting substrate to which it is attached. The use of veneer with less substantial support substrates can readily result in cracking, splintering and friability. Veneers used to date with window covering materials, particularly horizontal blind slats, have been limited to being used with thick slats which are so thick and rigid that bending will not substantially occur. 
         [0006]    The use of thick slats has a number of its own associated problems. Thicker slats are more expensive because of the sheer volume of material used. For high ceilings or vertically tall windows, thicker slats create significant weight problems. Thicker slats collected at the top of the window opening create a vertically wider block and inhibit the amount of open space which the blind set can created by being vertically raised. 
         [0007]    Heavier components create an even greater and unseen problem. The total weight on the vertical array of horizontal blinds causes greater friction on the lifting components. Greater friction causes failure in each of the components affected. This includes the lift cord, the lift cord wear member where the cord leaves the head rail, a locking mechanism which is used to selectively lock the lift cord, the lift cord contact inside the head rail, and the angular fittings at the point where the lift cords turn down through the head rail. Component parts can wear and fray and thus increase the wear and fray on the lift cords. In some cases this creates an avalanche of wear in which wear on a component causes the lift cord to go from normal condition to rapid wear and failure. 
         [0008]    Weight related wear will in essence destroy the value of the window covering. Worn cord fitting replacement involves the removal of the window covering and a complete re-working of the internal components, as well as a re-threading of the louvers and base slat. Many of the components depend upon the apertures and other support structures which were in existence at the time of manufacture, all of which change from time to time. As a result, a failure in a window covering set will likely render it worthless. The alternative of having someone create parts which are long since obsolete and commercially not available is so expensive that it would be less expensive to simply replace the window covering set. 
         [0009]    Replacement of this type creates additional waste. Even where the window covering is of high quality it will be less expensive to buy a new, integrated window covering set. Where a single matched window covering fails, and becomes beyond repair, all of the window coverings in a room will likely be replaced in order to maintain the aesthetic balance. The result is that the failure rate of a window covering is of the type which creates significant, related waste. 
         [0010]    Therefore, the need to reduce the failure rate in a window covering set is acute and has significant effect. The reduction of slat weight is one of the most critical contributors to increasing the life of window covering sets, particularly horizontal blind sets, over time. Lesser slat weight translates into lesser wear for lift cords and the fittings in a horizontal blind set. 
         [0011]    The variety available for light weight slats have been limited to thin metal having a non-aesthetic look. Further, the use of raw metal slats or painted slats subjects them to being scratched or scored, thus permanently marking them. Raw or painted metal slats lack the resilience and repair ability of wood. Resilience and mark resistance can be had via an outer lacquer coat to reduce friction and the ability to produce scratches, as well as the ability to use wood repair techniques and stains to repair any scratches and the like. 
         [0012]    What is therefore needed is the ability to produce slats having extreme light weight and also a repairable wood finish. The needed slat should be resilient, have the ability to assume a variety of shapes and also be amenable to cutting in order to form custom widths. 
       SUMMARY OF THE INVENTION 
       [0013]    The structures and process for producing the structures of the invention enable extensive and efficient use of veneer and bamboo veneer for slat manufacturing. The techniques employed advantageously accomplish two goals simultaneously, a reduced volume of slat material to reduce the load on the internals of a horizontal blind set, and the provision of a more inexpensive but higher quality long lasting slat outward appearance. One or more core materials made of woven and non-woven and preferably fibrous cloth, as well as combining with metal and other structural layers, are combined with veneers and bamboo veneer to yield a very lightweight slat with good structural characteristics. 
         [0014]    The technique enables scrap, such as block scrap, to be formed into longer effective lengths. Such longer effective lengths can then be cutably formed into slats of various sizes. The joinder of the block scrap is by deeply extending, finite interlock length finger joints which, once the material is cutably formed into slats, remain as relatively shallow (the thickness of the slat) and finite interlock length finger joints. The joints have the added benefit that they statistically “break up” any grain differences which would otherwise create warp, and enable long lengths of slat to be employed from several shorter lengths of scrap. The utilization of multiple sets of finger joints virtually completely eliminates the tendency to warp, and provides additional strength against twist forces. Further, as an added economic benefit above and beyond the benefits already mentioned, the technique not only enables waste normally occurring in slat manufacture to be saved, but actually encourages the manufacture of a superior quality product by encouraging lower cost scrap to be used as the primary resource in the manufacturing process. In other words, longer lengths of higher priced wood can be used elsewhere in products where grain structure and uninterrupted length is necessary, and thus drive down the costs in those industries, while at the same time enabling slat construction almost exclusively from scrap. 
         [0015]    To further utilize scrap wood and to further reduce waste, adjacent narrower widths of wood can be utilized in combination with wider lengths of wood at the finger joint to enable two or more widths of wood material to function as if they were a single width of material. When securely glued, both at the finger joint as well as along the lengths of more narrow material, the resulting slats have as much strength as slats formed from a whole length of wood material. Even where the narrow lengths of wood have a linear, thin, glued interface, superior strength bending and twist resistance is observed. 
         [0016]    A technique for covering the constructed slat with a layer of paper, especially paper bearing a wood grained pattern, followed by use of a gluing material of, for example vinyl acetate resin, followed by providing a clear and appropriately surface finish varnish, preferably of ultraviolet resistant material can produce a slat which has an appearance exactly as if it were formed from a single length of wood material. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    The invention, its configuration, construction, and operation will be best further described in the following detailed description, taken in conjunction with the accompanying drawings in which: 
           [0018]      FIG. 1  illustrates a perspective exploded view of the end of a short length of slat material with exploded lacquer layer with two layers of veneer surrounding a core layer; 
           [0019]      FIG. 2  illustrates a perspective exploded view of the end of a short length of slat material with exploded lacquer layer with two layers of veneer surrounding a pair of inner layers; 
           [0020]      FIG. 3  illustrates a perspective exploded view of the end of a short length of slat material with exploded lacquer layer with a layer of upper veneer and an underlying layer attached to it for support; 
           [0021]      FIG. 4  is illustrates a perspective exploded view of the end of a short length of slat material with exploded lacquer layer with two layers of veneer surrounding a set of three inner layers which may be any type of layer but preferably a center scrap veneer layer surrounded by two cloth or non-woven layers; 
           [0022]      FIG. 5  is a plan view of the end of a bamboo embodiment of the composite slats shown in  FIGS. 1-4 , but emphasizing the generally uniform lateral profile of bamboo assemblies as one possible overall layout as might be seen from the formation of a slat according to the invention utilizing bamboo strips; 
           [0023]      FIG. 6  is an end view of a curved slat having a core layer to illustrate that the technique of the invention can be used for producing curved slats; and 
           [0024]      FIG. 7  is an end view showing a technique in which one or any number of core layers terminate short of the full extent of the width of veneer layers to enable the veneer layers to attach to each other and form a double thickness, shapable, otherwise finely finish able curved edge termination. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0025]    The description and operation of the veneer system and method of the invention will begun to be best described with reference to  FIG. 1  which illustrates an end perspective exploded view of the end of a short length of slat  21  shown in extreme detail. From the outermost perspective, the slat  21  is covered and surrounded with a layer of lacquer, typically an acrylic, typically a UV resistant and UV cured material to seal the components within. As seen in exploded view, the layer of lacquer includes an upper layer  23 , lower layer  25 , left side layer  27  and right side layer  29 . The lacquer is typically sprayed on and thus envelops the entire assembled slat  21 . The lacquer layers  23 ,  25 ,  27 , and  29  completely surround and envelop the slat  21  continuously and may be expected to occur at the ends, such as into the face directed toward the viewer in  FIG. 1 , as is necessary to seal all layers within the slat  21 . 
         [0026]    The lacquer layers  23 ,  25 ,  27 , and  29  will preferably resist ultraviolet radiation degradation, and may include a simple lacquer, a poly resin, polyester or acrylic. The lacquer layers  23 ,  25 ,  27 , and  29  are shown exploded and schematic, but this is a crude representation of the annular surrounding nature and the annular sealing nature which the lacquer layers  23 ,  25 ,  27 , and  29  provide to the more internal layers. Sealing is important as it shuts out moisture and makes the resulting slat  21  (as well as all of the slats shown in subsequent Figures) stronger and more mark resistant. 
         [0027]    This is not to imply necessarily that the lacquer layers  23 ,  25 ,  27 , and  29  make a shiny or even flat finish. Where the finished surfaces  33  and  37  are roughened, the lacquer layers  23 ,  25 ,  27 , and  29  may preferably be thin enough to enable the roughened surface to express itself through the lacquer. As such, the selection of the viscosity of the lacquer layers  23 ,  25 ,  27 , and  29  can effect the outside surface characteristics. A roughened appearance can do more for light dispersal than a simply flat-color appearance, particularly a low light angle incidence. 
         [0028]    Within the slat  21  seen in  FIG. 1  is an upper veneer layer  31  having an upper finished surface  33  and a lower veneer layer  35  having a lower finished surface  37  (indicated but not seen). Since the lacquer layers  23 ,  25 ,  27 , and  29  are typically extremely thin and transparent, the veneer layers  31  and  35 , and their finished surfaces  33  and  37  will form the visual impression of the resulting surface color and texture of the slat  21 . A bonding core layer  39  is provided to which the veneer layers  31  and  35  are attached along their main surfaces opposite their finished surfaces  33  and  37 . A layer of glue or adhesive  41  is also shown for completeness, and only over a rear portion of the slat  21  and will not be shown further, although such layer of flue or adhesive  41  may exist between any of the layers shown for the invention. 
         [0029]    The dimensions for the components shown in  FIG. 1  will be discussed. The purpose of the invention is to provide a wood finish through the use of veneer, to produce an ultra thin slat  21  which is very light, but has a substantial appearance in terms of its color and texture. The upper and lower veneer layers  31  may have a thickness of from about 0.2 mm to about 0.6 mm with the most preferable being veneer thickness nearer the 0.2 side of the thickness scale, limited only by the need to have a minimum thickness which will (1) not become transparent enough to transmit any light from the bonding core layer  39  and (2) will not be so thin where it is desired to show and present a pattern having three dimensional variance, such as deep grain, where the deepest grain might otherwise form an opening to the bonding core layer  39 . 
         [0030]    The bonding core layer  39  may be any of a variety of materials. A few of the materials may include a non-woven material or woven material, cloth, glass, carbon composite, wood, wood veneer, woven wood veneer, cross grain ply-veneer or ply-veneer, or metal. 
         [0031]    The term “woven wood veneer” may refer to a woven pattern of veneer strips having a main length parallel to the grain of the wood. Having such strips woven into a crossing matrix can increase the strength of the woven pattern. There is very little overall difference between woven veneer and a woven cloth except for the size and longitudinal grain of the material. A finely subdivided very thin material approaches a structure similar to cloth. Most woven materials exist as groups of fibers rather than individually cris-crossing to make up the cloth. Many woven materials have significant lateral friction and can have various degrees of cross linking if desired. Cross linking, or cross friction, can be as a result of friction, lateral projecting interfering members, or bonding. 
         [0032]    Ply-veneer is a thin version of ply wood. In Ply wood, alternate layers of wood are bonded or glued together with each succeeding layer having its grain situated at an angle, preferably perpendicular, to the next most adjacent layer, although angularity less than perpendicularity if possible. It will be understood that ply-veneer or woven veneer may have a variety of thicknesses. The number of layers and weaves of such material permitted will depend upon their contribution to the slat into which they will be incorporated. 
         [0033]    Metals which can be used include thin steel, aluminum, titanium, or any other material having the ability to impart a strength to the veneer layers  31  and  35  lying on either side. The ability of the metal or indeed any material of the bonding core layer  39  to bond to the layers of veneer  31  and  35  is important. The bonding of the core layer  39  to the layers of veneer  31  and  35  can be accomplished with any type of glue or adhesive which will give good non-separating results, and may depend upon the materials chosen for the core layer  39  and layers of veneer  31  and  35 . The core layer  39  can have a thickness of from about 0.15 mm to about 0.3 mm. For metals, this number might be a simple, uniform material thickness. For a non-woven, or cloth, or ply veneer or woven veneer, or fiber based core layer  39 , this thickness might be the final thickness after heating and pressing. Heating and pressing and other curing or final bonding steps may help produce an improved tensile strength through forced thickness reduction during processing. 
         [0034]    As a result, the potential thickness of the final slat will depend upon which materials are used, how many layers are used and how the core layer  39  is constructed. At the extreme lower dimensions, where the core layer  39  is made from a paper-thin non-woven material, it may be as low as 0.1 mm, but it is believed that 0.15 mm is necessary to impart some lower acceptable strength. For thicker slats, the core layer  39  (as well as other core-type layers shown in subsequent Figures) may even approach 1.0 mm for a thicker slat. Where the core layer approaches 1.0 mm, the resulting slat may preferably be 3.0 mm or thicker. 
         [0035]    Further, the thickness of the veneer layers  31  and  35  may also depend upon a number of other factors, including the ability to cut and handle the veneer layers  31  and  35 , as well as the needed thickness of the veneer layers  31  and  35  for adequate color appearance. The color appearance of the combination of the core layer  39  and the veneer layers  31  and  35  will combine to affect the thickness of the veneer layers  31  and  35  necessary to produce an acceptable result. As in the Figures following  FIG. 1 , the final thickness of the resulting slat  21  will depend upon the thicknesses of material used with a judicious selection of such materials to make an acceptable appearing slat  21 . 
         [0036]    The thickness of the lacquer layers  23 ,  25 ,  27 , and  29  may be so thin as to be negligible. In some examples, however an effect can be produced by a thicker layer of lacquer, but this should only occur in some types of effects for certain types of window coverings, much like table tops which are over lacquered to produce a three dimensional effect. However, this type of effect is not desired where the goal is to produce the lightest slat  21  possible. 
         [0037]    The finish of the upper finished surface  33  and lower finished surface  37  can be formed either before or after the layers of veneer  31  and  35  are bonded to the core layer  39 . In practice, and especially where the core layer  39  is to have a shape, the layers of veneer  31  and  35  can be added before or after the core layer  39  is shaped or bonded in the same step in which the core material  39  is shaped, such as in a press die or similar. 
         [0038]    The steps for formation, in any order, are to provide layers of veneer  31  and  35 , finish their upper finished surface  33  and lower finished surface  37 , bond the layers of veneer  31  and  35  to the core layer  39 , shape the core layer  39  if necessary, and lastly to apply a surrounding layer of lacquer to form lacquer layers  23 ,  25 ,  27 , and  29  to seal the resulting slat  21 . Pressure, heat, and other environmental aspects may be applied, especially during the bonding step, in order to work with the glues or adhesives present. 
         [0039]    The slat  21  opens the possibility for other combinational processing steps. Sheets of the bonding core layer  39  may be bonded to sheets of veneer, and then finished, before being cut into the slat  21  shape. Shaping of the core layer  39  can occur at any time due to the superior bond formed between the core layer  39  and the upper and lower veneer layers  31  and  35 . Shaping of a core layer  39  can be done by bending, such as over bending to use Young&#39;s modulus for a stable spring back effect, or the shape can be formed based upon heat and pressure in a die or other holding device, which will cause the core layer  39  to achieve a stable shape after such processing. 
         [0040]    The use of a core material with fibrous tensile qualities is important in holding together the upper and lower veneer layers  31  and  35 . This is especially true where wood grain upper and lower veneer layers  31  and  35  have a grain which is longitudinal to the extent of the slat  21  and would tend to exacerbate the splintering effect of each on bending. The core layer  39  provides close attachment, along with isolation of any deleterious synergy from having grain oriented in the same direction. 
         [0041]    Other combinational possibilities are also shown, with general spatial equivalence to previously shown layers being illustrated with the same numbering. Referring to  FIG. 2 , a perspective exploded view of the end of a short length of slat  31  utilizes a pair of core layers, including an upper core layer  53  and a lower core layer  55 . The use of two core layers of either woven or non-woven material gives an opportunity for further strengthening without much expense in terms of adding to the thickness or weight. For example, where upper core layer  53  may have a fibrous structure which is predominantly oriented in one direction, the lower core layer  55  may have a fibrous structure oriented in an orthogonal direction. These directions need not necessarily be oriented along or perpendicular to the length of any resulting slat  31 . In some cases, and depending upon the glue or adhesive  41  used, the bonding of a pair of core layers  53  and  55  can produce a “composite” core which is even stronger. The remainder of the slat  21  is similar to that seen in  FIG. 1 . 
         [0042]    Referring to  FIG. 3 , a perspective exploded view of the end of a short length of slat  61  material with exploded lacquer layer with an upper layer of veneer  31  and an underlying layer  63  having a lower surface  65 . As stated above, it is generally not favored to have two layers of veneer attached to each other, but it is possible. Further, the underlying layer  63  can be any of a number of other materials. Underlying layer  63  can be metal, to support the upper layer of veneer  31 , it can be a simple layer of wood with a lower surface  65  which is painted, it can be a lower sheet of veneer such as lower veneer layer  35 , it can be a wooden layer having grains which are perpendicular to the grains of the upper layer of veneer  31 , and a further variety of materials. In some window coverings and horizontal blinds it is desired to have one side of a slat such as slat  61  to have a finish different than the finish of the upper finished surface  33 . The use of an underlying layer  63  of reflective metal could produce a cooling effect by re-radiating visible light back through the window. Conversely, an underlying layer  63  which is black could help turn incident light into heat by heating of the slat  61 . When it is remembered that the upper veneer layer  31  can range in color from dark wood finish to a bright very light wood finish it can be seen that the upper surface can be light and the lower surface can be dark, and vice versa. 
         [0043]      FIG. 3  illustrates the simplest construction and perhaps therefore the lightest. The use of an underlying layer  63  to give brightness variation can be important and useful. Slat  61  can be particularly useful where the lower surface  65  can be made to be decorative or reflective or have some other useful characteristic. An underlying layer  63  made of polished metal on its lower surface  65 , with a roughened upper surface for bonding to the underside of the upper veneer layer  31  would be one good combination. 
         [0044]    Referring to  FIG. 4 , a slat  71  is shown has having a series of three additional core layers between the upper and lower veneer layers  31  and  35 , namely core layers  73 ,  75 , and  77 . Although the addition of more core layers may add somewhat to the weight, the use of additional core layers can contribute to formation of a stiff, very strong slat  71 . 
         [0045]    Further, it may also be preferable for core layers  73  and  77  to be made from a non-woven or woven cloth or other material, with core layer  75  preferably being a non-decorative or low quality veneer. In this configuration, the core layer  75  as a veneer layer  75  would not need to have high quality as it would not be seen. This opens the possibility of using a scrap wood material having a grain which runs across the shorter dimension of the slat  71  which might be able to give additional strength without sacrificing flexibility. 
         [0046]    Other possibilities for the core layers  73 ,  75  and  77  include the use of a cloth or non-woven for all three. However, it is believed that the best combination is having core layers  73  and  77  made of a fibrous material such as cloth or woven or non-woven material, with core layer  75  being a thin, scrap quality veneer. 
         [0047]    Referring to  FIG. 5 , a plan view of the end of a bamboo embodiment of the composite slats shown in  FIGS. 1-4 , but emphasizing the generally uniform lateral profile of bamboo assemblies. In a related case, U.S. patent Ser. No. 11/529,971; which is incorporated by reference herein, it was shown and described and illustrated in detail how long strips are cut from bamboo culm, boiled in water to cause the bamboo material in the strips to relax, so that they can be pressed flat. The radially arc shaped strips come to have a trapezoidal cross section and are then typically cut into a rectangular square. The exterior of the bamboo is then sanded or planed to produce a bamboo finished surface, either before or after the strips are joined to other strips, to a substrate of different material. The hallmark of bamboo veneer or bamboo boarding is the provision of strips which are close fitting and of uniform width. 
         [0048]      FIG. 5  illustrates an end view of an assembled bamboo slat  81  made in a way in which the bamboo strips have uniform width and generally oppose each other. From the top, the ends of an upper row of bamboo strips  83  are seen. The bamboo strips  83  are attached to each other and to a first core layer  85  of woven or non woven fibrous material. A central core layer  87  can be made of the same materials as were mentioned for bonding core layer  39 , including metal, wood veneer (scrap), composite carbon, and more. 
         [0049]    Under the central core layer  87 , a second core layer  89  of woven or non woven fibrous material is seen. Under the second core layer  89  a lower row of bamboo strips  91  are seen. The result is a slat  81  having a bamboo finish on both sides. Where the central core layer  87  is either bendable or capable of being formed as a non-flat shape, the slat  81  can be shaped accordingly. 
         [0050]    The configuration of  FIG. 5  is just one of many configurations, with some other structural configurations seen in U.S. patent Ser. No. 11/529,971. Where the thickness of the bamboo strips  83  become very thin, the perpendicular quality of their matching adjacent surfaces begins to diminish and the result can be a very thin slat  81 . Where the core layer  87  is made of thin metal, a very thin bamboo slat  81  results. Very thin bamboo can be easily formed and bent, particularly when it is wet or hot. As was described in the above patent, since the bamboo strips  83  and  91  were initially formed from arc pieces of material, it is an easy matter to alter the final formation steps where it is needed to make a thick, shaped slat. The steps of construction of the slats herein can be modified to replace any of the veneer layers with very thin layers of bamboo. 
         [0051]    Further, the manner in which bamboo is made and used, by forming strips, is amenable to the process and layers described by making a slight modification in the order of processing. The bamboo strips  83  can be formed onto first core layer  85  in a separate operation. This can involve a sheet of bamboo strips if varying length and offset from each other which can be kept flat and continue to be processed, sanded, planed, etc. The same is true for the bamboo strips  91  to form the lower layer. Then the upper and lower layer assemblies of the bamboo strips  83  and their core layer  85 , as well as the bamboo strips  91  and their core layer  89  can be then bonded onto central core layer  87 . In some cases, any shaping may be done under any stage of processing and preferably under high pressure to insure that the widths of the bamboo strips  83  and  91  bend adequately across their width and do not produce protrusions at their interfaces. Further sanding or planing might be in order for curved slats. Again, although not shown, the lacquer layers  23 ,  25 ,  27 , and  29  would be applied to the completed bamboo slat  81 . 
         [0052]    Referring to  FIG. 6 , a perspective end view of a curved slat  95  formable with any of the structures and techniques shown herein, is illustrated. Some layering appearance may occur at an end  97 , especially where the end  97  is not painted or where the end  97  is cut, but the remainder of the slat  95  will appear as if it is made of a unitary material. A lift cord aperture  99  is also seen. 
         [0053]    Referring to  FIG. 7  an illustration of the advantage of using veneer is seen. A slat  101  is shown without lacquer layers  23 ,  25 ,  27 , and  29 , and is seen as having an upper veneer layer  103  a core layer  105  and a lower veneer layer  107 . Note that the core layer  105  stops just short of the extent of the lateral extent of the upper veneer layer  103  and the lower veneer layer  107 . Due to the fact that the core layer  105  stops short, and especially where pressure and adhesive is used, the upper veneer layer  103  naturally extends and is attached to the lower veneer layer  107  to form a very slight double veneer termination. Because these layers are bonded together, they present twice the thickness of veneer at the edge and can be easily finished to an edge which is essentially twice the thickness of the upper veneer layer  103  and the lower veneer layer  107 . Since the finishing forces are applied laterally with respect to the view of  FIG. 7 , and because the core layer  105  terminates only very slightly earlier than the upper veneer layer  103  and the lower veneer layer  107 , good structural support is had and separation does not occur under normal finishing. Finishing after formation will most likely involve some blend sanding to remove the upper and lower square corner which might otherwise occur with a square sheet of veneer if such is used for the upper veneer layer  103  and the lower veneer layer  107 . The result is a smooth edge  109  where the dividing line between the upper veneer layer  103  and the lower veneer layer  107  cannot be seen. 
         [0054]    While the present invention has been described in terms of a system and method for forming of various constructions of slats from various layers of wood veneer and thin strips of bamboo, as well as a wide variety of core materials, one skilled in the art will realize that the structure and techniques of the present invention can be applied to many structures, including any structure or technique where joinder with enhanced contact structures for slat formation with veneer and bamboo, both for appearance and for inexpensive structural reinforcement. 
         [0055]    Although the invention has been derived with reference to particular illustrative embodiments thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. Therefore, included within the patent warranted hereon are all such changes and modifications as may reasonably and properly be included within the scope of this contribution to the art.

Technology Classification (CPC): 4