US20200254809A1 - Door skin, a method of etching a plate for forming a wood grain pattern in the door skin, and an etched plate formed therefrom - Google Patents
Door skin, a method of etching a plate for forming a wood grain pattern in the door skin, and an etched plate formed therefrom Download PDFInfo
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- US20200254809A1 US20200254809A1 US16/793,423 US202016793423A US2020254809A1 US 20200254809 A1 US20200254809 A1 US 20200254809A1 US 202016793423 A US202016793423 A US 202016793423A US 2020254809 A1 US2020254809 A1 US 2020254809A1
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- Prior art keywords
- wood grain
- grain pattern
- image
- door skin
- protrusions
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
- B44C5/0453—Ornamental plaques, e.g. decorative panels, decorative veneers produced by processes involving moulding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
- B29C59/022—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44B—MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING
- B44B5/00—Machines or apparatus for embossing decorations or marks, e.g. embossing coins
- B44B5/02—Dies; Accessories
- B44B5/026—Dies
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44F—SPECIAL DESIGNS OR PICTURES
- B44F9/00—Designs imitating natural patterns
- B44F9/02—Designs imitating natural patterns wood grain effects
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- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
- E06B3/70—Door leaves
- E06B3/7001—Coverings therefor; Door leaves imitating traditional raised panel doors, e.g. engraved or embossed surfaces, with trim strips applied to the surfaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2905/00—Use of metals, their alloys or their compounds, as mould material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
- Y10T428/24066—Wood grain
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24438—Artificial wood or leather grain surface
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24595—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness and varying density
Definitions
- FIG. 4 is an enlarged cross-sectional view of the circled portion 22 of FIG. 1 ;
- FIG. 6 is an enlarged alternative perspective view of the circled portion 2 - 2 of FIG. 1 ;
- depressions 34 , 36 , 38 , 40 can have a uniform depth.
- depressions 34 , 36 , 38 , 40 can have varying depths.
- the depth of depressions 34 , 36 , 38 , 40 is associated with the density of the protrusions 24 , 26 , 28 , 30 , 32 .
- a tonal portion 16 comprising a low number of protrusions per square inch (low protrusion density) is associated with a low contrast background area of the natural wood pattern.
- a low protrusion density is about 2% to about 10%, preferably about 4 to about 7%.
- the tonal portions not covered by protrusions are covered by depressions.
- the protrusion density and the depression density of a tonal portion preferably add up to 100%.
- the number of protrusions/depressions can vary in different tonal portions 16 throughout the wood grain pattern.
- portions of the wood grain pattern can omit tonal portions 16 .
- some portions of the area between adjacent ticks 14 can omit protrusions 24 , 26 , 28 , 30 , 32 such that a bi-color or glossy appearance results after stain is applied to facing 10 .
- tonal portions 16 need not be situated between adjacent ticks 14 .
- Stain can be applied to facing 10 using various techniques.
- stain can be applied by brushing or wiping stain on the external surface of facing 10 such that stain is applied to door skin D in a manner similar to the application of stain to a piece of natural wood.
- Any number of coats of stain can be applied to facing 10 and any type of stain can be used.
- a heavily pigmented stain can be used such that a single coat can cling and congeal within ticks 14 and depressions 34 , 36 , 38 , 40 .
- the stain is retained in the depressions and produces a darker appearance in areas where the depression density is high (low protrusion density). In the areas where the depression density is low (high protrusion density), a lighter appearance is produced.
Abstract
A door skin featuring a facing having an exterior surface and an interior surface can be provided. A wood grain pattern portion can be formed in the exterior surface of the facing. The wood grain pattern portion can feature a plurality of grooves formed in the exterior surface of the facing, the grooves are recessed from a first plane of the exterior surface, and tonal portions formed in the exterior surface of the facing. The tonal portions can include at least a first protrusion, a second protrusion, and a third protrusion. Spacing between the first protrusion and the second protrusion can be different from spacing between the second protrusion and the third protrusion.
Description
- This application is a continuation of application Ser. No. 15/688,399, filed Aug. 28, 2017, now U.S. Pat. No. 10,562,339, which is a divisional of application Ser. No. 14/709,012, filed May 11, 2015, now U.S. Pat. No. 9,744,801, which claims benefit to U.S. Provisional Patent Application No. 61/990,853, filed May 9, 2014, all of the disclosures of which are incorporated herein by reference and to which priorities are claimed.
- The present invention is directed to an interior or exterior passage door, door skin (sometimes called door facing) or other molded article, such as wainscot, furniture door, cabinet door, decorative molding, trim product, paneling, millwork, or the like, having a naturally appearing wood grain pattern formed in an exterior surface. The wood grain pattern has a plurality of grooves formed in the exterior surface. The grooves are recessed from the exterior surface. Tonal portions are also formed in the exterior surface. The tonal portions include at least a first protrusion, a second protrusion, and a third protrusion, wherein spacing between the first protrusion and the second protrusion is different than spacing between the second protrusion and the third protrusion. The invention is also directed to a method of etching a plate, for use as an embossing plate or with a molded die set, for forming a wood grain pattern in the exterior surface of the door skin or molded article and the resulting etched plate.
- A wood grain pattern is created by cells that make up a piece of natural wood. As the piece of wood is processed, the cells are split open exposing pores in the wood. The pores create a pattern of valleys and rifts that result in the wood grain pattern. Valleys are large pores that are long and narrow and have a texture and depth such that they are easily discernable within a grain pattern. Rifts are smaller pores that are less distinct. The rifts can have various sizes and be randomly spaced at variable concentrations throughout the grain pattern based on the cell formation of the wood. Because rifts create less contrast, the rifts contribute to a subtle tonal background pattern within the wood grain pattern.
- Recreating a natural wood grain pattern in a molded article such as a door skin is difficult. Traditionally, an image of a natural wood grain pattern has been used to recreate the wood grain pattern in the molded article. For example, a line pattern image based on the image of the natural wood grain can be printed onto an exterior surface of the door skin. However, the printed pattern created on the door skin is two dimensional and lacks the depth or texture found in the natural wood grain pattern. Moreover, depositing print ink directly onto the door skin creates a wood grain pattern that may lack crisp definition of wood grain lines and adequate contrast of varying tones found in the background of the natural wood grain pattern.
- In an attempt to add depth and texture to create a more realistic wood grain pattern, a door skin can be pressed with an embossing plate etched with a wood grain pattern. The wood grain pattern of the embossing plate can be created from an image of the natural wood grain pattern where the image includes ticks that correspond to the valleys within the image of the wood grain pattern and background tonal portions that correspond with the rifts. The embossing plates can be etched by patterning a resist on the metal and subjecting the surface to acid to remove portions of the metal plate creating a textured surface including the tick and tonal patterns. The etched plate is thus a negative of the pattern to be formed in the door skin.
- Due to limitations arising during the process of etching the embossing plate, the size, shape, and configuration of the wood grain pattern associated with the tick and tonal portions can create inaccurate formations. For instance, when walls of the plate between adjacent ticks and/or tonal portions are too narrow, the acid used to etch the embossing plate can eat into the sides of the tick and/or tonal portions, destroying delineation between adjacent ticks and/or tonal portions. In order to prevent the acid from etching between adjacent ticks and/or tonal portions, the image of the natural wood grain pattern can be modified such that the ticks and/or tonal portions are spaced apart a predetermined distance. For example, tonal portions can be arranged in a geometric pattern where all projections within a tonal portion are uniformly spaced from one another. However, the resulting wood grain pattern embossed into the door skin may not accurately resemble a natural wood pattern and can create a configuration and/or appearance that upon close appearance may not appear realistic.
- Therefore, there is a need for an embossing plate for molding a door skin or other molded article with a wood grain pattern that more accurately captures the subtle contrasts necessary to create realistically appearing wood ticks and background tonal portions as found in a natural wood grain pattern. Yet a further need in the art is to form an embossing plate useful to create a door skin having wood grain pattern with features and surface characteristics acceptable to consumers both aesthetically and from a price point. Additionally, there is a need for a door skin and a door formed from two door skins that have naturally appearing wood grain images.
- An aspect of the invention provides a door skin or door facing having an exterior surface and an interior surface. The door skin can further include a wood grain pattern portion formed in the exterior surface. The wood grain pattern portion features a plurality of grooves formed in the exterior surface. The grooves are recessed from the exterior surface. Tonal portions are formed in the exterior surface. The tonal portions can comprise at least a first protrusion, a second protrusion, and a third protrusion. Spacing between the first protrusion and the second protrusion is different than spacing between the second protrusion and the third protrusion.
- Another aspect of the invention provides an embossing plate for forming a wood grain pattern into a door skin, the plate being formed of metal and having a first surface. The metal plate further includes spaced ridges formed in the first surface of the plate and extending therefrom into the plate. Tonal portions are formed in the first surface of the plate. The tonal portions include at least a first depression, a second depression, and a third depression. The spacing between the first depression and the second depression is different from spacing between the second depression and the third depression.
- A third aspect of the invention provides a method of etching a wood grain pattern into an embossing plate. An image of a piece of wood having a wood grain pattern, including ticks and background tones, is captured. The wood grain pattern includes ticks and background tones. A line art image associated with the ticks of the wood grain pattern is created from the image of the piece of wood. A background art image associated with the background tones of the wood grain pattern is created from the image of the piece of wood. The background art image includes at least a first pixel, a second pixel, and a third pixel. Spacing between the first pixel and the second pixel can be different than spacing between the second pixel and the third pixel. A master image can be rendered from the line art image and the background art image. A pattern transfer can be created from the master image. The embossing plate can be etched according to the pattern transfer.
- Other aspects of the invention, including apparatus, articles, methods, systems, assemblies, and the like which constitute part of the invention, will become more apparent upon reading the following detailed description of the exemplary embodiments.
- The accompanying drawings are incorporated in and constitute a part of the specification. The drawings, together with the general description given above and the detailed description, serve to explain the principles of the invention. In such drawings:
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FIG. 1 is a front elevation of an exemplary door skin according to an exemplary embodiment of the present disclosure; -
FIG. 2 is an enlarged fragmentary plan view of an exemplary wood grain pattern portion according to an exemplary embodiment of the present disclosure; -
FIG. 3 is an enlarged perspective view of the circledportion 22 ofFIG. 1 ; -
FIG. 4 is an enlarged cross-sectional view of the circledportion 22 ofFIG. 1 ; -
FIG. 5 is an enlarged perspective view of an alternative view of circled portion 2-2 ofFIG. 1 ; -
FIG. 6 is an enlarged alternative perspective view of the circled portion 2-2 ofFIG. 1 ; -
FIG. 7 is a fragmentary perspective view of an exemplary etched metal plate according to an exemplary embodiment of the present disclosure; -
FIG. 8 is a fragmentary screen art image of an exemplary wood grain pattern portion according to an exemplary embodiment of the present disclosure; -
FIG. 9 is a fragmentary screen art image of a background art image used to create the screen art image of an exemplary wood grain pattern portion according to an exemplary embodiment of the present disclosure; -
FIG. 10A is a grayscale scan image of a wood pattern; -
FIG. 10B is a bitmap image of the wood pattern; -
FIG. 10C is an enlarged image of the bitmap image ofFIG. 10B ; -
FIG. 10D is an enlarged the bitmap image (enlargement ofFIG. 10E ) with ticks added; and -
FIG. 10E shows the final bitmap image with ticks added that is used to make the metal plates. - Reference will now be made in detail to exemplary embodiments and methods of the invention. It should be noted, however, that the invention in its broader aspects is not necessarily limited to the specific details, representative materials and methods, and illustrative examples shown and described in connection with the exemplary embodiments and methods.
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FIG. 1 illustrates a door D having a naturally appearingwood grain pattern 12 formed in an exterior surface 9 of a door facing 10, also known as a door skin. Facing 10 can be formed using various materials. For example, facing 10 can comprise wood composite or fiberglass reinforced polymer, such as a sheet molding compound (SMC), block molding compound (BMC), or the like. -
FIG. 2 illustrates an enlarged plan view ofwood grain pattern 12. Awood grain pattern 12 is provided within an exterior surface 9 of facing 10. Thewood grain pattern 12 includes ticks (or grooves) 14 andtonal portions 16 that are arranged to create an aesthetic and texturally pleasing and realistically appearing wood grain pattern. Particularly,tonal portions 16 include randomly spaced dot patterns that reflect a more natural wood grain pattern. The randomly spaced dot patterns include portions having various dot densities. For example, darker areas 18 of thewood grain pattern 12 have a higher density of dots because of a relatively high number of dots within a predetermined area where the dots are spaced relatively close together. Thelighter areas 20 of thewood pattern 12 have a lower density because a lesser number of dots are within the predetermined area and the dots are spaced relatively further apart than the dot patterns in the darker areas 18. - The wood grain pattern formed in an exterior surface 9 of facing 10 is further illustrated in
FIGS. 3 and 4 . For example,FIG. 3 illustrates an enlarged perspective view of the circledportion 22 ofFIG. 1 andFIG. 4 illustrates an enlarged cross-sectional view of the same circled portion. Exterior surface 9 of facing 10 of door D comprises a plurality of spaced ticks 14. Each of theticks 14 is defined by opposingwalls 13 and a base 15 interconnecting thewalls 13. Opposingwalls 13 can have any configuration such as sloped, curved, etc. - A plurality of
outer portions 11 lie substantially on the most exteriorly disposed surfaces of facing 10.Outer portions 11 separateadjacent ticks 14. Preferably, ticks 14 are recessed from the surface 9, defined byouter portions 11, from between about 0.001 inches to about 0.003 inches, and may have variable widths. As such,outer portions 11 may also have variable widths, as best shown inFIG. 3 . The depth ofticks 14 may vary from the preferred range depending on the substrate used to mold door skin D, as well as the wood species being simulated. In addition,adjacent ticks 14 may be spaced from each other by variable distances, and extend longitudinally relative to each other by variable distances, and extend longitudinally relative to each other by variable lengths. - One of ordinary skill recognizes that the configuration of the
ticks 14 simulates a natural wood grain pattern. As such, eachtick 14 can have substantially any length and/or width. For example, as best illustrated inFIG. 1 , someticks 14 extend the entire length of door skin D whileother ticks 14 extend a predetermined distance to simulate an appearance of soft, flowing wood ticks. The wood ticks 14 contribute to the arched or cathedral appearance present in many wood species. One observing a natural wood grain pattern will see, depending upon the wood species, a series of ticks presenting a “cathedral” image, with tonal portions arranged between the ticks. The tonal portions have greater or lesser spacing and appearance, thus contributing to the overall appearance of the pattern. In oak, for example, the cathedrals are relatively large and the tonal portions also relatively large and well defined. In cherry, on the other hand, one does not normally see large cathedral formations and the tonal portions tend to be relatively small and closely arranged together. - Facing 10 further comprises background or
tonal portions 16. For clarity and ease of illustration, onetonal portion 16 is illustrated inFIG. 3 . However, one of ordinary skill in the art will recognize that any number oftonal portions 16 can be included in the wood grain pattern portion of facing 10.Tonal portions 16 each comprise a plurality of spacedprotrusions depressions depressions Protrusions 24 can be randomly spaced such thatdepressions first protrusion 24 and asecond protrusion 26 can be different than spacing B between thesecond protrusion 26 and athird protrusion 28. In addition spacing C between thethird protrusion 28 and afourth protrusion 30 can be different than spacing A and/or B and a spacing D between theforth protrusion 30 and afifth protrusion 32 can be different from spacing A, B, and/or C. In an exemplary embodiment, spacing A has a width less than spacing B, spacing B has a width less than spacing C, and spacing C has a width less than spacing D. It is noted that thetonal portions 16 can include a pattern of protrusions and depressions that is reversed from that illustrated inFIG. 3 . Specifically,protrusions depressions protrusions protrusions - Preferably protrusions 24, 26, 28, 30, 32 and
depressions protrusions depressions Depressions outer portions 11 to a depth of between about 0.0005 inches and 0.001 inches. - As best illustrated in
FIG. 4 ,depressions FIG. 5 ,depressions depressions protrusions protrusions depressions adjacent protrusions depression 34 can have a depth of E,depression 36 can have a depth of F,depression 38 can have a depth of G, anddepression 40 can have a depth of H where depth E is greater than depth F which is greater than depth G which is greater than depth H. - In another exemplary embodiment, the depth of
depressions - While
protrusions FIG. 3 as having a box-like shape configuration with flat tops,protrusions example protrusions protrusions Protrusions outer portions 11. Additionally, the protrusions need not all have the same shape. For example,protrusions FIG. 3 , while theother protrusions protrusions other protrusions protrusions FIGS. 3 and 4 show separate regions fortonal portions 16 and ticks 14, in certain embodiments, theprotrusions ticks 14 may be intertwined such that theprotrusions outer portions 11 separatingadjacent ticks 14. -
Tonal portion 16 can include any number ofprotrusions protrusions protrusions protrusions tonal portion 16 comprising a high number of protrusions per square inch (high protrusion density) is associated with a high contrast background area of the natural wood grain pattern. A high protrusion density is about 35 to about 50% (i.e. that protrusions occupy 40-50% or the total areas), preferably about 40 to about 45%. Atonal portion 16 comprising a low number of protrusions per square inch (low protrusion density) is associated with a low contrast background area of the natural wood pattern. A low protrusion density is about 2% to about 10%, preferably about 4 to about 7%. The tonal portions not covered by protrusions are covered by depressions. Thus, the protrusion density and the depression density of a tonal portion preferably add up to 100%. One of ordinary skill in the art will appreciate that the number of protrusions/depressions can vary in differenttonal portions 16 throughout the wood grain pattern. In addition, while not illustrated, one of ordinary skill in the art will appreciate that portions of the wood grain pattern can omittonal portions 16. For example, some portions of the area betweenadjacent ticks 14 can omitprotrusions tonal portions 16 need not be situated betweenadjacent ticks 14. - In an exemplary embodiment, ticks 14,
protrusions depressions ticks 14 anddepressions outer surfaces 11 andprotrusions wider ticks 42 hold more stain as compared to shallower,narrow ticks 44, as best shown inFIG. 5 . In this way, the deeper,wider ticks 42 have a darker, more prominent appearance and the narrow,shallow ticks 44 simulate lighter, more delicate wood ticks. Likewise,depressions protrusions protrusions - Stain can be applied to facing 10 using various techniques. For example, stain can be applied by brushing or wiping stain on the external surface of facing 10 such that stain is applied to door skin D in a manner similar to the application of stain to a piece of natural wood. Any number of coats of stain can be applied to facing 10 and any type of stain can be used. For example, a heavily pigmented stain can be used such that a single coat can cling and congeal within
ticks 14 anddepressions -
FIG. 6 illustrates an enlarged perspective view of an alternative view of circledportion 22 ofFIG. 1 according to exemplary embodiment of the present disclosure. Specifically,FIG. 6 illustrates a portion of a wood grain pattern provided in facing 10 comprisingticks 14 andprotrusions FIG. 6 are more randomly sized and spaced than those ofFIG. 3 . For example, spacing I betweenprotrusions protrusions protrusions protrusions protrusions protrusions - Although the tonal area is described herein as containing individual protrusions with interconnected depressions, the reverse is also encompassed by the present invention, where the tonal area contains individual depressions with interconnected protrusions. In the tonal areas of
FIGS. 3 and 6 , the depressions and protrusions could be reversed, as long as they are able to produce the desired wood grain pattern up on staining by producing dark appearances in areas with high depression densities and light appearances is areas with low depression densities. -
Wood grain pattern 12 can be formed within facing 10 using various methods such as employing an etched plate, such as in an embossing plate or molded die set, or other process known in the art. -
FIG. 7 illustrates a fragmentary perspective view of an exemplary etched metal plate P according to an exemplary embodiment of the present disclosure. Metal plate P can be manufactured using various techniques. For example, metal plate P can be etched to create an embossing plate or a mold die used to form a wood grain pattern in an exterior surface of a molded article, such as door skin D. Various etching techniques can be implemented including chemical etching, laser etching, etc. - Metal plate P is a negative-image of the
wood grain pattern 12 formed into door facing 10 and is processed to includeridges 52 anddepressions Ridges 52 correspond to theticks 14 formed in facing 10 anddepressions tonal portions 16, includingprotrusions Depressions depressions depressions depressions depressions protrusions depressions ridges 52 can be depressions and depressions can be ridges. -
Tonal portions 51 correspond totonal portions 16 ofwood grain pattern 12. For example,tonal portion 51, as best shown inFIG. 7 , includes anarea 53 with a plurality ofdepressions area 53. Becausetonal portion 51 of plate P is an inverse configuration of thetonal portion 16 of an embossed article,depressions area 53. The depth of each depression varies depending on the desired height ofprotrusions depressions tonal portion 51 is etched into plate P to correspond to the desired tonal variations in an embossed article, such as door skin D. Similarly, the configuration ofrecesses 52 is configured to correspond to the desired size, shape, and depth of a desired wood tick pattern to be formed in the door skin D. AlthoughFIG. 7 shows a plate with individual depressions and connected protrusions, the present invention also contemplates the reverse, where the plate contains individual protrusions with interconnected depressions. -
FIG. 8 illustrates an exemplary wood grain pattern portion according to an exemplary embodiment of the present disclosure. For example,FIG. 8 illustrates a resultingwood grain pattern 12 transferred to facing 10 of door skin D using various techniques. Thewood grain pattern 12 is based on a combination image comprising awood grain pattern 12 havingwood tick portions 14 and backgroundtonal portions 16. In an exemplary embodiment, an image of a natural piece of wood is photographed to derive textures, tones, and patterns to be simulated inwood grain pattern 12. For example, each natural wood board is prepared for photography by burning and wire brushing the board surface in order to accentuate fine ticks, background color, and tone of the board. The image of the prepared board is captured using conventional photography methods. Alternatively, the image is derived using digital imaging techniques, as known in the art. A plurality of boards can be photographed, each representing a stile, a rail, and a panel of the ultimately to be produced door skin. In an exemplary embodiment, the boards may be of different wood species, so that the stiles and rails may be one species and the panels another species. - The photographs may then be assembled into the appearance of a door, with the wood gain pattern of each board oriented as desired. Thus, a naturally appearing door can be achieved, with the wood grain of the stiles oriented perpendicular to that of the rails, and the wood grain of the panel(s) oriented as desired.
- The image of the naturally occurring wood grain may be altered using various photographic arts or computer imaging techniques. For example, the image may be enhanced by increasing the resolution and/or applying filters to the resulting image. In an exemplary embodiment, one or more filters such as a half tone filter, a mezzotint-like filter, a dithers filter and/or a posterizations filter, can be applied to the enhanced resolution image. The image is separated by camera or computer imaging to produce a first image associated with the ticks from the initial image and a second image associated with the wood tones from the initial image. For example, the image may be processed using a color separator, whereby the initial image is separated by camera or computer imaging to produce a first image showing the wood ticks of the initial image, and a second imaging showing the wood tones of the initial image.
- The first image associated with the ticks may be enhanced using various photographic or computer imaging techniques. For example, the resolution of the first image may be increased to create an image of flowing ticks. Specifically, the size of the image can be increased to, for example, 300% to increase the resolution of the image to preferably from about 600 dpi to about 2400 dpi. In this way, the thickness of the
ticks 14 is easily adjusted and spaced apart from each other to avoid etching lines in plate P that are too close together. Preferably, this adjustment involves scaling allticks 14 shown in the image based upon the thickest tick as the baseline or reference against which all other ticks are dimensioned. - The second image can also be enhanced by photographic or computer modeling techniques to achieve the desired contrast and density of the wood tones. In an exemplary embodiment, the image associated with the wood tones is converted from a color image to a black and white image such that the tones are represented in gray scale pixels. At least one filter can be applied to the gray scale image to create the random dot pattern associated with the tonal portions of the wood grain pattern. For example, one or more of a half tone filter, a mezzotint-like filter, a dithers filter and/or a posterizations filter can be applied to create non-uniform tonal areas. After one or more of the filters is applied, a random dot pattern is created that includes various dot densities that better captures the subtle background tones that naturally occur in the
wood grain pattern 12. For instance, the second image includes pixels that are non-uniformly spaced from each other such that pixels associated with the lighter tones of the initial image are spaced further apart from pixels associated with darker tones. An enlarged portion of the second image can include tonal portions, as illustrated inFIG. 9 , where the tonal portions include pixels within area A having a denser pixel concentration than pixels within areas B and C. In an exemplary embodiment, each pixel of the second image has the same area. Alternatively, the pixels associated with the darker tones can have a larger area than the pixels associated with the lighter tones. - The first image and second image are combined to render a master image of the
wood grain pattern 12, including both the wood tick portions and the background tonal portions. A pattern transfer can be created from the master image where the pattern transfer is used to assist in forming the desired wood grain pattern on the metal plate P. Metal plate P can be etched using the pattern transfer such that recesses 53 anddepressions wood grain pattern 12 onto facing 10. - In an exemplary embodiment, an image is rendered by first scanning the wood grain in grayscale (
FIG. 10A ). Alternatively, if scanned in color, the color scan may be converted to grayscale using software available in the art. The grayscale image is then converted to a bitmap image (FIG. 10B ) which is made up of pixels.FIG. 10C is an enlarged portion of the bitmap image ofFIG. 10B , which shows that the bitmap image is made up of a plurality of pixels (dots) 110. Areas where the pixels are very close together are ticks and areas where the dots are further apart are tonal areas in the original wood. The bit map image is then enhanced to addticks 112 to portions where the dots are very close together (FIG. 10D ). The ticks are enhanced asdark lines 112 instead of individual dots that are very close together. The final enhanced image is shown inFIG. 10E , which is then used to make plates, e.g. by acid etching. In the plates, theindividual pixels 110 in the image are rendered as protrusions, and thedark lines 112 are rendered as raised ridges. - The foregoing detailed description of the certain exemplary embodiments has been provided for the purpose of explaining the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use contemplated. This description is not necessarily intended to be exhaustive or to limit the invention to the precise embodiments disclosed. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way.
Claims (20)
1. A door skin, comprising:
a door facing comprising a polymeric material and having an exterior surface and an interior surface, the exterior surface containing a wood grain pattern formed therein, the wood grain pattern comprising:
a) a plurality of grooves formed in the exterior surface facing for simulating the appearance of wood ticks, the grooves being recessed from the exterior surface; and
b) tonal portions formed in the exterior surface for simulating the appearance of wood background tone, the tonal portions comprising a plurality of spaced depressions, wherein spacing between the depressions have different widths and depths.
2. The door skin of claim 1 , wherein the tonal portions comprise at least a first depression, a second depression, and a third depression, wherein spacing between the first depression and the second depression is different than spacing between the second depression and the third depression.
3. The door skin of claim 1 , wherein the tonal portions are arrayed in portions of varying density.
4. The door skin of claim 3 , wherein the tonal portions have a higher depression density in darker appearing portions and have reduced depression density in lighter appearing portions.
5. The door skin of claim 1 , wherein the depressions are arranged randomly in the exterior surface.
6. The door skin of claim 1 , wherein the depressions are separated from each other by protrusions.
7. The door skin of claim 1 , wherein the polymeric material is one of a sheet molding compound and a block molding reinforced by fiberglass.
8. The door skin of claim 1 , wherein at least some of said tonal portions are disposed between adjacent grooves.
9. An embossing plate for forming a wood grain pattern into a door skin, the embossing plate comprising:
a) a metal plate having a first surface;
b) a plurality of ridges etched on the first surface; and
c) tonal portions etched in the first surface of said plate, the tonal portions comprising a plurality of protrusions, wherein spacing between at least some of the protrusions have different widths and heights.
10. The embossing plate of claim 9 , wherein the tonal portions comprise at least a first protrusion, a second protrusion, and a third protrusion, wherein spacing between the first protrusion and the second protrusion is different than spacing between the second protrusion and the third protrusion.
11. The embossing plate of claim 9 , wherein the ridges are raised from the exterior surface by about 0.001 inches to about 0.003 inches.
12. The embossing plate of claim 9 , wherein the protrusions are arranged randomly in the exterior surface.
13. The embossing plate of claim 9 , wherein the protrusions are separated from each other by depressions.
14. The embossing plate of claim 13 , wherein the depression have depths of about 0.0005 inches to about 0.001 inches.
15. The embossing plate of claim 9 , wherein some of said tonal portions are disposed between adjacent ridges.
16. A method of etching a wood grain pattern into a metal embossing plate, comprising the steps of:
a) capturing an image of a piece of wood comprising a wood grain pattern, wherein the wood grain pattern comprises ticks and background tones;
b) creating from the image a line art image associated with the ticks of the wood grain pattern;
c) creating from the image a background art image associated with the background tones of the wood grain pattern, said background art image comprising a plurality of pixels, wherein spacing between at least some of the pixels are different from each other;
d) rendering a master image from the line art image and the background art image;
e) creating a pattern transfer from the master image; and
f) etching the metal embossing plate according to said pattern transfer.
17. The method of claim 16 , wherein step f) produces depressions in areas of a surface of the embossing plate corresponding to the background tones and ridges in areas of the surface of the embossing plate corresponding to ticks.
18. The method of claim 16 , wherein the master image includes tick portions and background tone portions.
19. (canceled)
20. The method of claim 16 , wherein steps b) to d) are accomplished by photographic or computer modeling techniques.
Priority Applications (1)
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US16/793,423 US20200254809A1 (en) | 2014-05-09 | 2020-02-18 | Door skin, a method of etching a plate for forming a wood grain pattern in the door skin, and an etched plate formed therefrom |
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US201461990853P | 2014-05-09 | 2014-05-09 | |
US14/709,012 US9744801B2 (en) | 2014-05-09 | 2015-05-11 | Door skin, a method of etching a plate for forming a wood grain pattern in the door skin, and an etched plate formed therefrom |
US15/688,399 US10562339B2 (en) | 2014-05-09 | 2017-08-28 | Door skin, a method of etching a plate for forming a wood grain pattern in the door skin, and an etched plate formed therefrom |
US16/793,423 US20200254809A1 (en) | 2014-05-09 | 2020-02-18 | Door skin, a method of etching a plate for forming a wood grain pattern in the door skin, and an etched plate formed therefrom |
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US15/688,399 Continuation US10562339B2 (en) | 2014-05-09 | 2017-08-28 | Door skin, a method of etching a plate for forming a wood grain pattern in the door skin, and an etched plate formed therefrom |
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US15/688,399 Active 2035-10-29 US10562339B2 (en) | 2014-05-09 | 2017-08-28 | Door skin, a method of etching a plate for forming a wood grain pattern in the door skin, and an etched plate formed therefrom |
US16/793,423 Abandoned US20200254809A1 (en) | 2014-05-09 | 2020-02-18 | Door skin, a method of etching a plate for forming a wood grain pattern in the door skin, and an etched plate formed therefrom |
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US15/688,399 Active 2035-10-29 US10562339B2 (en) | 2014-05-09 | 2017-08-28 | Door skin, a method of etching a plate for forming a wood grain pattern in the door skin, and an etched plate formed therefrom |
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USD918424S1 (en) * | 2013-09-20 | 2021-05-04 | Jeld-Wen, Inc. | Door |
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USD797312S1 (en) * | 2015-12-31 | 2017-09-12 | Jeld-Wen, Inc. | Door |
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- 2015-05-11 PL PL15724158T patent/PL3140128T3/en unknown
- 2015-05-11 EP EP15724158.9A patent/EP3140128B1/en active Active
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USD918424S1 (en) * | 2013-09-20 | 2021-05-04 | Jeld-Wen, Inc. | Door |
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US10562339B2 (en) | 2020-02-18 |
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PL3140128T3 (en) | 2020-12-28 |
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