AU2005237136A1 - Applying Timber Veneer - Google Patents

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant: Actual Inventor: Address for Service: Invention Title: Details of Associated Provisional Applications: JOHN SUNG IL WOO JOHN SUNG IL WOO HODGKINSON McINNES PAPPAS Patent Trade Mark Attorneys Level 3, 20 Alfred Street MILSONS POINT NSW 2061 "APPLYING TIMBER VENEER" 2004906696 2005902833 filed 24 November 2004 filed 1 June 2005 The following statement is a full description of this invention, including the best method of performing it known to me: P20323AU02 -2- APPLYING TIMBER VENEER

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BACKGROUND OF THE INVENTION 0 Z The present invention relates to a method of applying a timber veneer to objects, 1 and in particular, to objects that have complex shapes, or to old objects that have a worn or shabby surface finish, which can be covered and rejuvenated with a new timber veneer finish.

It is often desirable to cover both new and old objects with timber veneer so as to trn take advantage of the beauty and advantages of the timber finish, and to disguise the Oactual material that comprises the objects. Another reason for applying a timber veneer to old objects is to replace the existing shabby finish on worn furniture or other household items, like chipped paintwork, with a fresh veneer finish. It would also be advantageous to apply a timber veneer finish to the surface of complex shapes, which have in the past been difficult to cover with a timber veneer, or where the timber veneer is easily damaged because it imperfectly covers or is attached to the complicated surface shapes.

Previously it has been difficult to cover surfaces that have a complex shape or an existing poor finish with a timber veneer. Generally, it is relatively easy to apply a timber veneer to a flat surface, or to a freshly prepared or smooth and undamaged surface. However, problems arise when trying to apply a veneer to a complex shape; sometimes the veneer broke away from corners or curved surface areas, the veneer does not adhere well, and while initially it may appear that the object has been properly covered, over time, the surface of the veneer is easily degraded or damaged. Similar problems occur when applying a veneer to existing objects that have a worn surface.

When both these factors apply, with existing objects that also have a complicated surface shape, then the problems are compounded.

It would therefore be useful to find a new way of applying a timber veneer finish to objects that avoids or reduces these problems, or by being a fresh approach, provides a useful alternative to existing methods of applying timber veneer to objects.

SUMMARY OF THE INVENTION The present invention in its various forms and embodiments generally concerns a Z method of applying a timber veneer to an object, which comprises the steps of: (a) taking a sheet of the veneer and moistening the veneer with water; allowing it to dry until the surface is dry to the touch; applying glue to at least one of, one surface of \ID the veneer, or the object; applying the veneer to the object with the glue between, ¢€3 Sand applying pressure on the veneer at least by hand to bond the veneer to the object; (e) removing excess glue from the outside surface of the veneer; sandpapering the outside surface of the veneer;(g) optionally then applying further pressure by ironing the veneer at least by hand, to further bond the veneer to the object; and(h) allowing the object and bonded veneer to dry and cure.

Preferably, the veneer is from 0.05 to 0.5 mm thick, and more preferably the veneer is from 0.1 to 0.3 mm thick, and most preferably the veneer is about 0.2 mm thick. Also it is preferred that in step the ironing is occurring. Ideally, heat may be applied together with the ironing. It is preferred that in the ironing, the iron is heated to between about 40 to 200 degrees Celsius, or more preferably the iron is heated to between about 80 to 100 degrees Celcius, or most preferably, it is heated up to, or just below, the maximum heat to be applied that will not mark or burn the veneer.

As another preferred feature, in step the pressure is applied with the aid of sandpaper, and the sandpaper may be fine grade sandpaper of less than 220 grade. In step preferably, the excess glue may be removed with the aid of a blade, or it may be removed using a damp cloth. Preferably, the glue may be a PVA glue or a silicone based PVA glue. Preferably the object may have a surface that is substantially smooth.

Also it is preferred, that the object may be made of any one or more substantially of the materials: metal, wood, or stone, or the materials covered with a plastic veneer, or paint, or a wood veneer.

The invention also concerns an object to which a timber veneer has been applied according to the method described above. Ideally, in this case, the veneer may be from 0.05 to 0.5 mm thick, or from 0.1 to 0.3 mm thick, or the veneer may be about 0.2 mm thick. Ideally, the object may have a substantially smooth surface, or the object may be -4- O made substantially of any one or more of the materials: metal, wood, or stone, or the Smaterials may be covered with a plastic veneer, or paint, or a wood veneer.

0 Z BRIEF DESCRIPTION OF DRAWINGS The invention is now discussed with reference to drawings, where: Figure 1 shows a timber article prepared and ready for covering with timber veneer according to the invention; Figure 2 shows a metal door having glue spread across the surface, ready to be covered with the timber veneer; SFigure 3 shows the metal door of Figure 2 which has the timber veneer being applied; Figure 4 shows a metal door of a refrigerator of Figure 3; and Figure 5 shows a metal door of another refrigerator with a different timber veneer applied in accordance with the invention; Figure 6 shows a car which has been covered with a variety of timber veneers according to the invention.

DESCRIPTION OF PREFERRED EMBODIMENTS As shown in the Figures the invention concerns a better method of applying a timber veneer to the surface of objects.

The veneer may be applied to a variety of objects. Most any object may be utilised, but to get the best results, the object should ideally have a surface that is smooth. It is preferred to apply the veneer to the surface objects made from materials such as: metal, wood, or stone, or such materials covered with a plastic veneer, or paint, or a wood veneer, for example. For instance, the veneer may be bonded to furniture, household white-goods, light fittings, walls and doors, kitchen cabinets or wardrobes, or on most hard surfaces. The veneer may be applied to such items as: refrigerators, dishwashers or washing machines and/or some or all of their panels and doors; metal doors; pieces of furniture; lamp shades; stone, "gyprocked", or wooden panels, either painted, wall-papered or plain; electrical switch plates or other interior fittings, glass or plastics, or even to motor cars.

It is preferred to use the method of the present invention to apply the veneer to surfaces that have complex surfaces, such as those with curves or corners. It is also r preferred to use the method of applying the veneer to existing objects, so as to refurbish their surface finish. The method may also be used to apply a veneer to existing objects 0 that would not be constructed from wood, to give them a surprising appearance, such as with lamp shades or motor cars.

Any type of wood veneer may be used with the invention. The veneer may be IND natural wood or reconstituted wood. The veneer of any type of wood may be used, Sincluding hard and soft woods, including for example woods such as pine, wenge, CS american oak, padouk, american walnut, silky beech, ash and reconstituted timber veneers. Often it is preferred to use a timber that has an attractive colour or grain pattern. Otherwise, a timber grain and colour can be selected to complement the decor of the surroundings where it will be located.

The veneer is preferably a thin veneer having a thickness of from 0.05 to 0.5 mm.

Commercial veneers typically have a thickness of about 0.5mm, but it has been found that using a thinner veneer can give superior results. It is preferred to use a veneer with a thickness of between 0.1 to 0.3 mm, and most preferred is a veneer with a thickness of about 0.2 mm.

In the method of the invention, the first step is to prepare the veneer. It may be cut to a suitable shape for application to the article, or a sheet of veneer may be applied and then trimmed to the right size later, during or after application. Or a combination of these options may be used. Most preferably, the veneer is trimmed to the correct shape for the surface it will cover prior to the application steps.

The veneer is then moistened with water. This may be done by dipping the sheet or portion of veneer into water, or by spraying or wiping the sheet with water, or by using a wet cloth or sponge. Then the veneer is allowed to dry until its surface is dry to the touch. For example, with a 0.2mm thick veneer, at normal room temperature, this may take around 10 minutes.

Glue is then coated either on one side of the veneer, or on to the object to be covered, or on to both of these surfaces. The glue may be applied by any suitable means, such as spraying, or by using a brush or other applicator. A glue is selected that is suitable for bonding wood to the material of the object. Commonly, a metal-bonding glue will be used for cementing the veneer to metal objects, and a plastics- or wood- -6bonding type of glue will be used for other materials. The selection of the appropriate N glue for cementing wood to other materials is known in the industry, and may involve 0 some simple trials and experimentation. One part or multi-part glues or cements may be used according to the circumstances. For example, a two part adhesive can be used such N, 5 as a contact adhesive where each surface to be joined is coated with the cement, and then pressed together to form a bond. Or a single layer adhesive may be used, such as PVA glue.

A preferred glue for timber objects is PVA glue. A preferred glue for metal objects is silicone based PVA glue. Various other glues may be suitable, but it is useful to test a sample first to observe the results, and then adjust the quantities or assess its suitability.

The veneer is then applied to the surface of the object, with the glue located in between. Then any excess glue is then removed from the surface of the veneer. This may be done with a scraper, using a damp cloth or sponge, or using something similar, or preferably by using a well squeezed wet cotton towel.

The veneer layer is positioned on to the surface of the object using hand pressure, so that the grain or decoration of the wood is matched or contrasted with adjacent areas, according to the person's aesthetic judgement.

The veneer can be applied to take advantage of the grain in the timber, and the different colours and patterns in the timber. For example, sheets or panels of veneer may be applied in matching or in contrasting patterns, such as book matching, random matching, herringbone matching and diamond and reverse matching.

In situations where panels or sheets of the veneer are joined on the surface, then they can be slightly overlapped, and then a sharp knife is used to cut the top and bottom overlapped veneer at the same time. This provides a closely matched and invisible join.

The pressure and positioning in this step may be assisted by using sandpaper.

Preferably a fine grade of sandpaper is used, ideally with a grade of less than about 220.

The veneer may be rubbed by the sandpaper, preferably gently, to conform to the surface it is covering, and to remove or ease out bubbles or air pockets. The thin layer of veneer is continuing to dry during this step, and the sandpaper will preferentially be -7o applied to the drier areas of the veneer covering, or to those areas that are becoming dry N as the application step proceeds. The pressure by hand or with the aid of sandpaper is 0 used to ease the layer of veneer across curved areas or around comers. The thinness of the veneer allows it to be bend around comers and into depressions in the surface of the object.

IDAfter the veneer is bonded to the surface, it may be allowed to fully dry and cure.

However, as an optional, and often preferred additional step, the bonded veneered Ssurface may be further treated by applying an iron or similar hard surface and/or heat source. The ironing step may be carried out using a hot iron, which preferably is heated to a temperature of between 40 to 200 degrees Celsius, and most preferably in the range of from around 80 to 100 Celsius.

The ideal temperature when this step is carried out is preferably determined by experience and simple experimentation. Most preferably, this step is conducted at as high a temperature as possible that does not mark or burn the veneer. It is generally easy to determine this temperature, by trying the ironing on a sample of the veneer, and adjusting the temperature of the iron up or down, until it is at the maximum temperature, or slightly below, where the sample is unscathed. With experience of using the same veneers it becomes relatively straightforward to choose the correct temperature for the iron.

By ironing the surface, the drying and curing is rate increased, and any air or glue pockets or bubbles between the layers are removed.

After the drying and curing of the applied veneer, it is usual to treat the surface with commonly applied wood treatments. This may involve further sanding and polishing of the wood surface. This may also involve applying staining, lacquers.

coatings, and protective treatments. For instance, the veneer surface can be stained, or french polished to alter its colouring or to bring out the pattern of the grain.

Polyurethane or acrylic timber coatings can also be applied to further protect the finish.

Suitable such coating include "Polyurethan 2" packs or "Acrilic 2" packs. The coatings can be applied by any suitable means, such as by rags, brush, spraying and the like.

SEXAMPLE 1 An item of timber furniture had a veneer coating applied, as shown in Figure 1, 0 Z which originally had paint covering it. The surface of the furniture was prepared, by briefly fine sand-papering the painted surface and cleaning of any dust. Then PVA glue was applied to the surface. The timber veneer, having a thickness of 0.2 mm, was INO prepared by first wetting it with water, and allowing it to dry to the touch. A layer of veneer was applied to the surface of the furniture, in sections. The veneer was pressed to Sthe surface, and any excess glue removed using a damp cotton cloth. Then the surface was lightly sandpapered using very fine sandpaper. Finally, a hot iron was used to press any bubbles or voids out from under the veneer layer, and to bond the two layers together. Care was taken not to burn or discolour the timber while doing so. The furniture covered by veneer was then allowed to cure and fully dry. The surface was then sprayed with a polyurethane coating.

EXAMPLE 2 In a similar manner, a metal door had a wood veneer coating applied to it, as shown in Figures 2 and 3. A similar method to that described in Example 1 was followed. Because the door was steel, a silicone based PVA glue was used.

EXAMPLE3 In a similar manner to that described in Example 2, metal refrigerator doors had a wood veneer coating applied to it, as shown in Figures 4 and 5. In this example the veneer covered curved metal surfaces. The results were very successful.

EXAMPLE 4 An acrylic transparent plastic lamp shade, in the general shape of a cylinder, had a layer of the timber veneer applied to its interior surface, following the process described in the earlier examples. The light from the lamp penetrated the thin veneer to provide a attractive appearance.

-9u EXAMPLE An old Volkswagen "VW" car had a layer of timber veneer applied to its surface Z as shown in Figure 6, following the process described above. A variety of different "j timbers was used for the veneers, providing a contrast of colours and grains. The veneer covered the metal surface of the car. A weather protective coating was applied as a final INO finish.

It will be apparent that obvious variations or modifications may be made in n accordance with the spirit of the invention that are intended to be part of the invention, O and any such obvious variations or modification are therefore within the scope of the 0

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10 invention.

Claims (17)

1. A method of applying a timber veneer to an object, which comprises the steps of: 0 Z taking a sheet of the veneer and moistening said veneer with water; S(b) allowing said veneer to dry until the surface of said veneer is dry to the touch; applying glue to at least one of, one surface of said veneer, or one surface of IND said object; applying said veneer to said object with said glue between, and applying Cc pressure on said veneer at least by hand to bond said veneer to said object; t removing excess glue from the outside surface of said veneer; S(f) sandpapering the outside surface of said veneer; optionally, then applying further pressure by ironing said veneer at least by hand, to further bond said veneer to said object; and allowing said object and bonded veneer to dry and cure.

2. The method of applying a timber veneer to an object according to claim 1, wherein said veneer is from 0.05 to 0.5 mm thick.

3. The method of applying a timber veneer to an object according to claim 2, wherein said veneer is from 0.1 to 0.3 mm thick.

4. The method of applying a timber veneer to an object according to claim 3, wherein said veneer is about 0.2 mm thick. The method of applying a timber veneer to an object according to any one of claims 1 to 4, wherein step occurs.

6. The method of applying a timber veneer to an object according to claim wherein heat is applied with said ironing.

7. The method of applying a timber veneer to an object according to claim 6, wherein in said ironing, the iron is heated to between about 40 to 200 degrees Celsius.

8. The method of applying a timber veneer to an object according to claim 7, wherein said iron is heated to between about 80 to 100 degrees Celcius. -11

9. The method of applying a timber veneer to an object according to claim 5, where up to, orjust below, the maximum heat is applied that will not mark or bum said 0 veneer. z The method of applying a timber veneer to an object according to any one of claims 1 to 9, wherein in step said pressure is applied with the aid of pressing INO or rubbing sandpaper on said veneer. t 11. The method of applying a timber veneer to an object according to claim wherein said sandpaper is fine grade sandpaper of less than 220 grade.

12. The method of applying a timber veneer to an object according to any one of claims 1 to 13, wherein said glue is a PVA glue or a silicone based PVA glue.

13. A method of applying a timber veneer to an object according to of any one of claims 1 to 12, where said object has a surface that is substantially smooth.

14. The method of applying a timber veneer to an object according to any one of claims 1 to 11, wherein in step said excess glue is removed with the aid of a blade. The method of applying a timber veneer to an object according to any one of claims 1 to 13, wherein in step said excess glue is removed using a damp cloth.

16. The method of applying a timber veneer to an object according to any one of claims 1 to 15, where said object is made substantially of any one or more of the materials: metal, wood, or stone, or wherein said materials are covered with a plastic veneer, or paint, or a wood veneer.

17. An object to which a timber veneer has been applied according to the method of any one of claims 1 to 16.

18. An object which has a timber veneer applied to its surface, wherein said veneer is from 0.05 to 0.5 mm thick.

19. The object according to claim 18, wherein said veneer is from 0.1 to 0.3 mm thick. -12- O 20. The object of claim 19 wherein said veneer is about 0.2 mm thick.

21. The object according to any one of claims 17 to 20, wherein said object has a 0 Z substantially smooth surface. N22. The object according to any one of claims 17 to 21, wherein said object is made substantially of any one or more of the materials: metal, wood, or stone, or Cc wherein said materials are covered with a plastic veneer, or paint, or a wood veneer.

23. A method of applying a timber veneer to an object substantially as herein described and with reference to the drawings, and/or the Examples. Dated this 24 th day of November 2005 JOHN SUNG IL WOO HODGKINSON McINNES PAPPAS Patent Attorneys for the Applicant