Semi-finished wood simulating product and method

Abstract

A semi-finished wood simulating product and method is disclosed. The product is manufactured by providing a substrate having at least one surface to be finished. A liquid basecoat is applied on the substrate and dried. A wood grain pattern is deposited, in liquid form, on the basecoat. Some of the pattern is transferred from the originally deposited position on the basecoat to a subsequent position. The pattern is then cured. A polymerizable protective coating is applied onto the substrate overlying the basecoat and the pattern. The protective coating seals the substrate and is adapted for accepting a colorant to be applied by an end user. The protective coating is then polymerized. Additionally, if a porous substrate is provided, a sealer is applied prior to the liquid basecoat and is then cured.

Description

[0001] The present invention relates generally to semi-finished wood simulating products and methods, and more particularly to semi-finished products capable of accepting wood stain, paint or varnish as applied by an end user at an installation site and methods of manufacturing semi-finished wood simulating products.[0002] There is a need to substitute wood simulating products for solid or real wood products to reduce material costs. This need to substitute simulated wood products for real wood is particularly acute for hardwood products. These hardwoods include woods such as lauan mahogany, and other woods of that same family, the bulk of which come from the Philippines and other pacific and forest locations. Over the last ten years, the availability of such woods has greatly diminished, and the remaining supply has diminished markedly in quality. There are also substantial environmental issues and concerns affecting both the quality and quantity of the real wood supply, in part, b...

AI Technical Summary

Benefits of technology

The solution provides a durable, customizable, and aesthetically pleasing wood simulating product that can be lightly sanded and finished on-site, addressing the limitations of traditional methods by allowing color and wood type changes, while maintaining the visual and tactile qualities of real wood.

Problems solved by technology

Over the last ten years, the availability of such woods has greatly diminished, and the remaining supply has diminished markedly in quality.

There are also substantial environmental issues and concerns affecting both the quality and quantity of the real wood supply, in part, because these woods come from "rain forest" areas which have been "harvested" over the years as part of a general land clearing program which did not include replanting, etc.

There are numerous problems inherent in the traditional methods.

These problems include the risk of the paper or vinyl overlay product peeling from the substrate.

Another problem is that bubbles and blisters sometimes occur in the overlay process.

Other problems are that the protective coating is not cleanable with a solvent or capable of being sanded to eliminate surface imperfections and scratches which occur during shipping and handling.

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