Wood veneer shaping

Abstract

Methods of manufacturing products comprising an area 101 covered with one or more layers of wood veneer 103, wherein the surface of the product conforms with a pre- determined three-dimensional contou

Description

The present invention relates to the production of wood veneer forms. The present invention also relates to methods for producing products of the invention and intermediate products made in the course of those methods. In addition, the invention also considers use of methods, products, and apparatuses of the invention in automobile manufacture and maintenance. In particular, the products of the invention are suitable for use in automotive interiors and such as shelves, facias, instrument panels and armrests of automobiles. In particular, the products of the invention are suitable for producing large parts for use in automobiles. A central function of an automobile is the comfort and convenience it provides the user in being conveyed from place to place. Thus the aesthetic appeal of the cabin of an automobile contributes significantly to the comfort and wellbeing of the occupants. Wood veneer is one particular element that is used for its aesthetic appeal in the interior of cars. Additionally, the advantageous properties of wood veneer have long been recognised in the automotive sector. The thermal and sound insulating properties of wood veneer are extensively employed in the automotive sector and wood veneer can be suitably comprised in multiple components are comprised in a vehicle cabin. Traditional veneer pattern development on concave and complex surfaces is very time consuming. Typically this has been done by hand cutting of the veneer and sanding techniques to develop veneer leaf joining edges. This can require extensive periods of time and concentration by a skilled craftsman. Accordingly, there is a need for methods of producing larger and / or more complex veneer forms without a concomitant increase in the amount of time required for their production. Furthermore, this new method should also produce products, parts and structures that are similarly durable to products produced using previous methods, and are thus suitable for passing the safety inspections required for their inclusion in vehicles. As used herein the term “A” surface is the surface that faces the user / customer and the term “B” surface refers to the surface that faces the inside of the car away from the user. Necessarily the B surface does not need to be as aesthetically pleasing as the A surface. It is therefore an object of the invention to provide a method of producing wood veneered surfaces of larger surface area. An additional object of the invention is to provide a method of producing wood veneered surfaces of greater or deeper curvature have been provided hitherto. Accordingly, it is an object of the invention to provide products of the methods of the invention. The invention provides a method of manufacturing a product comprising an area covered with one or more layers of wood veneer, wherein the surface of the product conforms with a pre-determined three-dimensional contoured surface comprising the steps of: a) making a carrier wherein the “A” surface of the carrier is shaped to substantially match the three-dimensional contoured surface; b) dividing the three-dimensional contoured surface into a multiplicity of separate three-dimensional sections, projecting the area of two or more three-dimensional sections onto one or more substantially flat pieces of wood veneer to define the boundary of one or more 2D projected sections, and cutting the veneer along the boundaries of the 2D projected sections; and c) assembling and shaping the 2D veneer sections together on the carrier to conform with part of the three-dimensional contoured surface such that all or part of their boundaries abut substantially without voids or spaces remaining. The method may additionally comprise the steps of: a) making a tool wherein all or part of the outer surface of the tool is shaped to substantially match the three-dimensional contoured surface; b) installing the outer surface of the tool on or in the three-dimensional contoured surface formed by the veneer sections; and c) pushing the facing surfaces of the carrier and tool together to apply pressure to the veneer sections. The pre-determined three-dimensional contoured surface may be concave or convex. All or a portion of the pre-determined three-dimensional contoured surface may be concave. A cooperating tool or mould to follow the shape of the carrier for the veneer surface may be used and the cooperating tool has a substantially convex surface. The assembled veneer sections and the adhesives are thus sandwiched between the convex mould and the concave carrier while the adhesives cure. In addition, a layer of neoprene material may be sandwiched between the tool and the veneer layer during the curing process. This has the advantage of compensating for variations in the veneer as the sections are bonded to the carrier as the adhesive cures. Accordingly, the “A” surface of the veneer part (i.e. that surface that is visible to the occupants of the automobile vehicle cabin) faces the mould and is thus invisible during the curing process. This is unusual because in the past, typically, it is the “B” surface that has been in contact with the veneer carrier and the mould beneath the carrier. Accordingly, hitherto typically the “A” surface has been visible during the step of forming the veneer and compressing the layers together in a vacuum bag. This is a counterintuitive step as the Craftsman would normally wish to see the product as it is being formed rather than it being invisible in such a manner that flaws can only be found after the mould has been opened. The method may additionally comprise the step of fixing the veneer sections in place with an adhesive. The veneer sections may comprise a self-adhesive layer on the “B” surface thereof. This has the advantage of convenient placement and fixing of the veneer sections. Alternatively or in addition, sections of adhesive may be cut to match the area of the veneer sections so that, advantageously, the whole area of the “B” surface of the veneer can be fixed or secured to the carrier structure. The applied pressure may be 1 atmosphere. The pressure may be applied by placing the assembly of components in a vacuum bag and evacuating the air from therein. The method may comprise the additional step of installing a padding layer between the tool and the veneer surface, preferably a rubber material, most preferably neoprene. This has the advantage of compensating for variations in the veneer as the sections are bonded to the carrier as the adhesive cures. The method may comprise the additional step of installing a porous layer of material between the rear of the carrier and the interior of the vacuum bag. For large products or ones without any apertures therethrough it is possible that areas within the vacuum bag will not be efficiently or sufficiently evacuated when the air is removed. It is also possible that evacuation from a bag on such a scale will not be conducted evenly and thus yield differential pressure points on the product during production, with the potential that flaws in the product may be caused. In order to ameliorate this problem a layer of “fleece” or porous material, typically of wool is installed on the rear of the carrier so that this layer of porous material contacts the vacuum bag during the evacuation and curing stage. Use of this porous layer of material means that evacuation is even across the area that atmospheric pressure is being applied to and means that flaws or errors due to differences in pressure while establishing or maintaining evacuation is less likely. The product may comprise one layer of wood veneer. This is advantageous in terms of the balance between the aesthetic effect of the wood veneer, where only a single layer is visible, the weight of multiple layers of veneer, and the time investment required to install multiple veneer layers. The carrier may be made of aluminium. This has the advantage of being a convenient and standard material for producing carrier sections. Furthermore, it has a good degree of geometric stability and so wood veneer can be reliably and stably attached to this material. The method may comprise the additional step of laser cutting the sections of veneer from the substantially flat pieces of wood veneer. The sections of veneer may be substantially 25-30 mm in width. This sizing has the advantage of balancing the need for larger sections to cover the area with less cutting of sections with the need for smaller sections to accommodate changes in geometry of the 3D contour. The area covered with wood veneer may be approximately 1.6 metres (meters) in width. The area covered with wood veneer may have a width or other dimension in a range selected from 0.5-1 metres, 0.75-1.25 metres, 1-1.5 metres, 1.25-1.75 metres, 1.5-2 metres, 1.75-2.25 metres, 2-2.5 metres, 2.25-2.75 metres, or 2.5-3 metres. The area covered with wood veneer may comprise a mixture of convex and concave portions. The area covered with wood veneer may be substantially concave. As noted elsewhere herein, the present invention allows larger and more complex surfaces to be adorned or covered with a layer of wood veneer. The width : depth ratio of a concave area of wood veneer may be selected from 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:12, 1:14, 1:16, 1:18, 1:20, 1:25, 1:30, 1:40, or 1:50. The width : depth ratio of a convex area of wood veneer may be selected from 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:12, 1:14, 1:16, 1:18, 1:20, 1:25, 1:30, 1:40, or 1:50. The invention also provides one or more products obtainable according to the methods described herein. The invention also provides a product comprising an area of wood veneer of 1 metre or greater in width, wherein all or a part of the area covered with wood veneer is substantially concave. Preferably, the area of wood veneer is substantially concave. The product may comprise a multiplicity of wood veneer sections. Preferably one or more of the multiplicity of wood veneer sections abut at their edges. Most preferably, each of the multiplicity of wood veneer sections abut at their edges. Preferably, the area of wood veneer does not have holes or portals therethrough. Thus the present invention advantageously employs Computer Aided Design (CAD) software to section the veneer 3D surface data and the project sections onto a 2D plan. The sections so defined may then be laser cut from veneer leaves. The sections can then be mounted directly to the veneer carrier. Advantageously, using this method the complicated veneer joining profiles perfectly align without the need for further manual cutting. Accordingly, the CAD model is used to model a veneer surface and to section the veneer 3D surface data. Section in this context means cut the modelled contoured veneer layer in the CAD model into a multiplicity of separate pieces. These three-dimensional (3D) sections of the surface are then projected (transformed) onto a 2D plan. Accordingly, two-dimensional sections that can be deformed or warped to match the three-dimensional structure of the sections of the three-dimensional product are then laser cut from veneer leaves. The cut sections can then be mounted directly to the veneer carrier. The complicated veneer joining profiles align to comply with a very high degree of tolerance and without the need for further manual cutting. This has the particular advantage of cutting the production time. More than cutting the production time being able to apply the adhesives and the large number of veneer sections to form a complete product before the adhesives cure means that the product can be produced in a single concerted process without pauses in production. In this way, ideally, the veneer can be applied to the carrier in a single day. This has an additional further advantage in that wood is a natural product and its form is affected by ambient humidity. Veneer is significantly less affected by ambient humidity once it is fixed in place. Accordingly, it is a significant advantage to be able to apply all of the veneer sections in a single session. Applying veneer in multiple sessions runs the risk of the humidity changing and thus the size of the veneer sections being significantly altered and thus significantly complicating the process of assembly. This enables veneer surfaces following or conforming with complex shapes or geometry to be produced more easily. Previously, the size or shaping of such surfaces would have been considered technically incredibly challenging to the point of effective impossibility. Using known techniques to develop the veneer pattern would require hundreds of hours of hand development to approach the quality of the products produced according to the present invention. That is the present invention yields higher quality (“cleaner”) results in a much reduced time. The product of the invention may comprise a layer of glue or adhesive between the carrier and the layer of veneer. This yields greater structural stability to the finished product. An adhesive material in the context of the present invention may be a resin, glue or other adhesive. An adhesive is typically a liquid, semiliquid or paste / pliable material that cures to form a structurally stable solid material. Accordingly, a broad range of synthetic or natural materials may be considered bonding materials in the context of the present invention. The outermost layer of veneer is termed the “face veneer.” Typically the face veneer is 0.55 mm thick. However, the thickness of the face veneer can vary due to manufacturing tolerances. Thus the face veneer may be 0.4 mm, 0.45 mm, 0.5 mm, 0.55 mm, 0.6 mm, 0.65 mm, or 0.7 mm thick. Substantially any form of wood veneer can be used in the context of the present invention. A non-exhaustive of veneer is set out below in the following list: Tudor Oak, Macassar Ebony, Oak Cluster, Paldao, Smoked Chestnut, Tuscan Ash Burr, Waterfall Bubinga, Oak Burr, Brushed Black Metal Fascia, Roman Oak, Rosewood, Royal Teak, Palisander Crown, Palisander Straight Grain, Silver Birch, Teak, Teak (Embellished), Smoked Eucalyptus, Rosewood, Ash Burr, Black Stained Ash, Mahogany Flare, Royal Walnut (Circassian Walnut), Royal Walnut, Walnut Burr, Black Stained Ash, Blackwood, Mimosa Negra, Silver Birch, Caleidolegno. Additional veneer types are set out in the table below: Veneer (Wood Name) Scientific Name (Genus / Species) Blackwood Acer Pseudoplatanus Macassar Ebony (Calamander) Diospyros Celebica Mimosa Negra Cordia elaeagnoides Paldao Dracontomelum dao Royal Walnut (Circassian) Juglans nigra Santos Palisander Crown Machaerium Scleroxylon Smoked Eucalyptus Eucalyptus Globulus Teak Tectona grandis Silver Birch Betula spp. Ash Burr Fraxinus excelsior ssp. Mahogany Flare Khaya Ivorensis Oak Cluster Quercus Robur Smoked Chestnut Castanea sativa Walnut Burr Juglans Hindsii Tudor Oak rift Quercus Robur Obsidian Ayous Triplochiton scleroxylon White Oak Quercus alba ssp. Brown Oak Quercus Robur Australian Walnut Endiandra palmerstonii Sapele Entandrophragma cylindricum Light Elm Ulmus Rubra Tulip Tulipfera liriodendron Copper (Dark Amber) Tulipfera liriodendron Preferably the veneer used is selected from Blackwood, Macassar Ebony (Calamander), Mimosa Negra, Paldao, Royal Walnut (Circassian), Santos Palisander Crown, Smoked Eucalyptus, or Teak. The product comprising wood veneer may comprise fixing means attached to the carrier or other part of the product for location and attachment of the product to a further structure. The further structure may be a subassembly of a vehicle. Preferably the subassembly is a carrier structure. The subassembly may be a carrier for inclusion as a component or subassembly in a vehicle interior. The component may be a shelf, ledge, “horseshoe,” dashboard, or fascia. The subassembly may be a carrier for inclusion as a component or subassembly in a vehicle door. Preferably the carrier may be produced by 3D printing. The advantage of using 3D printing is that bespoke parts can be produced and thus the significant cost of tooling can be avoided, which is only economic when products are produced in significantly greater numbers. The 3D printing method may be fused deposition modelling (FDM). The carrier may be 3D printed using Nylon 12 CF material. Nylon 12 CF material comprises flaked carbon fibre material that is thus is included in the 3D printed product. Use of 12CF in 3D printing yields a product with greater strength in line with the planes of the 3D printed product. Thus, the product that is made is stronger than the standard plastics material typically used for 3D printing. Preferably, the method comprises the additional step of allowing the resin or glue to cure. The curing process may be under conditions of elevated pressure and / or temperature. Preferably the pressure is 1 atmosphere. Preferably the temperature is in the range 50-70 degrees Celsius. Most preferably, the temperature is in the range 60-70 degrees Celsius. The curing process can take place at room temperature; however, the process is speeded by heating the glue to 60-70° C in order that it cures faster. The method may additionally comprise a step of applying pressure to the surface of the assembled components by inserting the assembly in a flexible, airtight bag or shroud and evacuating the volume therein such that part of the bag or shroud abuts the exterior of the assembly. This has the advantage of being simple to achieve and requiring less tooling in the form of cooperating male - female moulding tools than are required in other techniques that are typically used. Thus, objects made with wood veneer have most advantageous properties, making them particularly suitable for inclusion in vehicles and automobiles, be they powered such as automobiles (cars), aeroplanes and boats, or unpowered, such as pedal cycles (e.g. bicycles), sailing vessels and skateboards. Such parts include many sections of the interior trim of automobiles, including the fascia, i.e. the section of bulkhead in a car located in front of the passenger but also extending to the areas of the dashboard surrounding the instrument mounting section, dashboard, instrument panels and armrest sections. The component may be a shelf, ledge, “horseshoe” (as shown in the Examples and Figures), dashboard or fascia. Preferably the component is a “horseshoe” (as shown in the Examples and Figures). Thus, products of the invention may be for use in a vehicle, furniture, or part of a building. Preferably the product is for use in a vehicle, most preferably wherein the vehicle is an automobile or car. Advantageously, products of the invention and products produced according to methods of the invention have characteristics of sufficient strength and structural stability to comply with the engineering requirements for installation in vehicles, including automobiles. Thus, products of the invention may be for use in the interior or cabin of a vehicle. Preferably products of the invention are comprised in a vehicle headliner, ceiling panel, door, seat, armrest, wall, wall panel, flooring, floor panel, dashboard, instrument panel, or parcel shelf. Advantageously, products of the invention and products produced according to methods of the invention can comprise a variety efface veneers or other surface decoration in order to match and accommodate other elements within a vehicle cabin or interior. Accordingly, the invention also provides a vehicle comprising a product of the invention. The vehicle may be an automobile, aeroplane, or boat. Preferably the vehicle is an automobile. Examples and Drawings The invention will now be described with reference to the following drawings and examples in which: Fig. 1 shows a perspective view of a 3D contoured surface 101 for installation in an automobile in the “horseshoe” area behind the left-hand front seat of an automobile. The different sections of veneer 103 are shown assembled into the horseshoe 101 and, in exploded view, areas of backing material are also shown. Fig 2 shows a side view of a 3D contoured surface 101 (as shown in Fig. 1) for installation in an automobile in the “horseshoe” area behind the left-hand front seat of an automobile. The different sections of veneer 103 are shown assembled into the horseshoe 101 and, in exploded view, areas of backing material are also shown. Fig. 3 is a photograph of an assembled multi-part wood veneer section for installation in the “horseshoe” area to the rear of the driver and passenger seat of an automobile. Fig. 4, Fig. 4a, 4b, and 4c are photographs of different views of an assembled multipart wood veneer section for installation in the “horseshoe” area to the rear of the driver and passenger seat of an automobile. Example Wood Veneer Furniture for an Automobile A contoured surface of an automobile part, in this case the “Horseshoe” section of an automobile interior is designed in CAD (Computer Aided Design) software. From this CAD design a veneer carrier is produced. While the carrier can be made by conventional means, i.e. by injection moulding or similar, for low volume applications it can advantageously be made by 3D printing. The veneer carrier may be concave or convex. However, in the present example the veneer carrier is concave and is used to produce a substantially concave veneer part. Accordingly, the CAD model is used to model a veneer surface and to section the veneer 3D surface data. Section in this context means cut the modelled contoured veneer layer in the CAD model into a multiplicity of separate pieces. These three-dimensional sections are then projected (transformed) onto a 2D plan. Accordingly, two-dimensional sections that can be deformed or warped to match the three-dimensional structure of the sections of the three-dimensional product are then laser cut from veneer leaves. The cut sections can then be mounted directly to the veneer carrier. The complicated veneer joining profiles align to comply with a very high degree of tolerance and without the need for further manual cutting. This has the particular advantage of cutting the production time. More than cutting the production time being able to apply the adhesives and the large number of veneer sections to form a complete product before the adhesives cure means that the product can be produced in a single concerted process without pauses in production. In this way, ideally, the veneer can be applied to the carrier in a single day. This has an additional further advantage in that wood is a natural product and its form is affected by ambient humidity. Veneer is significantly less affected by ambient humidity once it is fixed in place. Accordingly, it is a significant advantage to be able to apply all of the veneer sections in a single session. Applying veneer in multiple sessions runs the risk of the humidity changing and thus the size of the veneer sections being significantly altered and thus significantly complicating the process of assembly. In the past veneer parts have been attached to the veneer carrier and then secured in position using a vacuum-based technique wherein the part is assembled and placed within a vacuum bag so that evacuation of the bag causes atmospheric pressure to be applied substantially equally over the surface of the veneer while the adhesives cure. Thus, previously it has been advantageous for the near parts to be substantially convex. However, in the present example the veneer part is substantially concave. Necessarily, placing concave parts in a vacuum bag may leave a void in the hollow of the concave area and so force cannot be guaranteed to be evenly distributed. Thus, in the present example a cooperating tool or mould for the carrier for the veneer surface is used and the cooperating tool has a substantially convex surface. The assembled veneer sections and the adhesives are thus sandwiched between the convex mould and the concave carrier while the adhesives cure. In addition, a layer of neoprene material is sandwiched between the tool and the veneer layer during the curing process. This has the advantage of compensating for variations in the veneer as the sections are bonded to the carrier as the adhesive cures. Accordingly, the “A” surface of the veneer part (i.e. that surface that is visible to the occupants of the automobile vehicle cabin) faces the mould and thus invisible during the curing process. This is unusual because in the past, typically, it is the “B” surface that has been in contact with the veneer carrier and the mould beneath the carrier. Accordingly, hitherto typically the “A” surface has been visible during the step of forming the veneer and compressing the layers together in a vacuum bag. This is a counterintuitive step as the Craftsman would normally wish to see the product as it is being formed rather than it being invisible in such a manner that flaws can only be found after the mould has been opened. In this example the wood veneer product has no holds or aperture is therethrough. The product is also 1.6 m in width. Accordingly, such a scale means that it is possible that areas within the vacuum bag will not be efficiently or sufficiently evacuated when the air is removed. It is also possible that evacuation from a bag on such a scale will not be conducted evenly and thus yield differential pressure points on the product during production, with the potential that flaws in the product may be caused. In order to ameliorate this problem a layer of “fleece” or porous material, typically of wool is installed on the rear of the carrier so that this layer of porous material contacts the vacuum bag during the evacuation and curing stage. Use of this porous layer of material means that evacuation is even across the area that atmospheric pressure is being applied to and means that flaws or errors due to differences in pressure while establishing or maintaining evacuation is less likely. The resulting assembly is then placed inside a vacuum bag, sealed, and a vacuum applied in order that 1 atmosphere of pressure is brought to bear on the veneered surface while the adhesive cures. The curing process can take place at room temperature; however, the process may be speeded by heating the glue to 60-70°C in order that it cures faster. Typically the veneer is 0.4 mm thick, however, other thicknesses are possible with veneers that are available. Furthermore, this process can be carried out with any available veneer. A non-exhaustive of veneer is set out below in the following list: Tudor Oak, Macassar Ebony, Oak Cluster, Paldao, Smoked Chestnut, Tuscan Ash Burr, Waterfall Bubinga, Oak Burr, Brushed Black Metal Fascia, Roman Oak, Rosewood, Royal Teak, Palisander Crown, Palisander Straight Grain, Silver Birch, Teak, Teak (Embellished), Smoked Eucalyptus, Rosewood, Ash Burr, Black Stained Ash, Mahogany Flare, Royal Walnut (Circassian Walnut), Royal Walnut, Walnut Burr, Black Stained Ash, Blackwood, Mimosa Negra, Silver Birch, Caleidolegno. Additional veneer types are set out in the table below: Veneer (Wood Name) Scientific Name (Genus / Species) Origin Blackwood Acer Pseudoplatanus France Macassar Ebony (Calamander) Diospyros Celebica Indonesia Mimosa Negra Cordia elaeagnoides Mexico Paldao Dracontomelum dao South-East Asia -Papua new guinea / lndonesia / Malaysia / Philippines Royal Walnut (Circassian) Juglans nigra USA Santos Palisander Crown Machaerium Scleroxylon Brazil / Bolivia Smoked Eucalyptus Eucalyptus Globulus Spain Teak Tectona grandis Brazil Silver Birch Betula spp. Estonia Ash Burr Fraxinus excelsior ssp. France Mahogany Flare Khaya Ivorensis Cameroon Oak Cluster Quercus Robur Germany Smoked Chestnut Castanea sativa Italy / France Walnut Burr Juglans Hindsii USA Tudor Oak rift Quercus Robur Czech Republic Obsidian Ayous Triplochiton scleroxylon Cameroon White Oak Quercus alba ssp. USA Brown Oak Quercus Robur Germany Australian Walnut Endiandra palmerstonii Australia - North-Eastern Queensland Sapele Entandrophragma cylindricum Cameroon / Gabon / Congo Light Elm Ulm us Rubra USA Tulip Tulipfera liriodendron USA Copper (Dark Amber) Tulipfera liriodendron USA Once the veneer layer is applied, the A surface is typically further prepared by sanding. The exterior of the product may then be lacquered using known processes. One 5 example is the varnish and lacquering system manufactured by Votteler (Votteler Lackfabrik GmbH &Co. KG.) The product may then be polished using known processes. Thus the invention provides producing large wood veneer products and components 10 for inclusion in automobiles that meet specific engineering, design, and aesthetic parameters. In particular the invention yields improved methods of producing concave wood veneer products and the intermediate products required in their production.

Claims

1. A method of manufacturing a product comprising an area covered with one or more layers of wood veneer, wherein the surface of the product conforms with a predetermined three-dimensional contoured surface comprising the steps of:a) making a carrier wherein the “A” surface of the carrier is shaped to substantially match the three-dimensional contoured surface;b) dividing the three-dimensional contoured surface into a multiplicity of separate three-dimensional sections, projecting the area of two or more three-dimensional sections onto one or more substantially flat pieces of wood veneer to define the boundary of one or more 2D projected sections, and cutting the veneer along the boundaries of the 2D projected sections; andc) assembling and shaping the 2D veneer sections together on the carrier to conform with part of the three-dimensional contoured surface such that all or part of their boundaries abut substantially without voids or spaces remaining.

2. A method according to claim 1, comprising the additional steps of:a) making a tool wherein all or part of the outer surface of the tool is shaped to substantially match the three-dimensional contoured surface;b) installing the outer surface of the tool on or in the three-dimensional contoured surface formed by the veneer sections; andc) pushing the facing surfaces of the carrier and tool together to apply pressure to the veneer sections.

3. A method according to claim 1 of claim 2, comprising the additional step of fixing the veneer sections in place with an adhesive.

4. A method according to claim 3, wherein the veneer sections comprise a self-adhesive layer on the “B” surface thereof.

5. A method according to any of claims 2 to 4, wherein the applied pressure is 1 atmosphere.

6. A method according to any of claims 2 to 5, wherein the pressure is applied by placing the assembly of components in a vacuum bag and evacuating the air from therein.

7. A method according to any of claims 2 to 6, comprising the additional step of installing a padding layer between the tool and the veneer surface, preferably a rubber material, most preferably neoprene.

8. A method according to any of claims 2 to 7, comprising the additional step of installing a porous layer of material between the rear of the carrier and the interior of the vacuum bag.

9. A method according to any previous claim, wherein the product comprises one layer of wood veneer.

10. A method according to any previous claim, wherein the carrier is aluminium.

11. A method according to any previous claim, wherein the sections of veneer are laser cut from the substantially flat pieces of wood veneer.

12. A method according to any previous claim, wherein the sections of veneer are substantially 25-30 mm in width.

13. A method according to any previous claim, wherein area covered with wood veneer is approximately 1.6 metres (meters) in width.

14. A method according to any previous claim, wherein all or a part of the area covered with wood veneer is substantially concave.

15. A product obtainable according to the method of any of claims 1 to 14.

16. A product comprising an area of wood veneer of 1 metre or greater in width, wherein all or a part of the area covered with wood veneer is substantially concave.

17. A product according to claim 16, wherein the area of wood veneer is substantially concave.

18. A product according to claim 16 or claim 17, wherein the product comprises a multiplicity of wood veneer sections.

19. A product according to claim 18, wherein the multiplicity of wood veneer sections abut at their edges.

20. A product according to any of claims 16 to 19, wherein the area of wood veneer does not have holes or portals therethrough.

21. A product according to any of claims 16 to 19, wherein the multiplicity of wood veneer sections are secured to an underlying carrier structure with adhesive.

22. A product according to any of claims 16 to 21 or produced according to any of claims 1 to 15, for use in a vehicle, furniture, or part of a building.

23. A product according to claim 22 for use in the interior or cabin of a vehicle.

24. A vehicle comprising a product according to any of claims 16 to 21 or produced according to any of claims 1 to 15.

25. A vehicle according to claim 24, wherein the vehicle is an automobile, aeroplane, or boat, preferably the vehicle is an automobile.

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