US2634534A - Ornamented wood and method of manufacture - Google Patents

Description

A R-1111M, 1953 Filed April 27, 1948 2 SHEETSSHEET l Figs 3;

INVENTOR.

Aprifl a4, 1953 0. BROWN 2,634,534

ORNAMENTED WOOD AND METHOD OF MANUFACTURE Filed April 27, 1948 2 SHEETSSHEET 2 a; C TE] 39 {0 g 2? o 0 W 0ma 4wMi "y Al-5W M y 6; 1?; I 16.15%, 6, J4. I (010a JNVENTOR.

i afentecl Apr. 14, l93

OFFICE ORNAMENTED WOOD AND METHOD OF MANUFACTURE Owen Brown, Los Angeles, Calif.

Application April 27, 1948, Serial No. 23,650

7 Claims.

The invention, as above entitled, relates to wood; to the conservation thereof by improving the quality and utility of certain articles made therefrom; to the methods employed; and, coincidentally, to mechanical devices of special kinds utilized in the manufacture of such articles.

The essence of my invention is primarily resident in the product thereof. Certain apparatus and certain methods therewith, howeveras foretoldhave been found essential in accomplishing my sundry objectives, and are therefore to be regarded as interrelated components of the invention, contributing mutually to many of the principal ends attained.

As every lumberman, every lumber yard operative, and every employee in a woodworking plant knows, the number one source of grief in the domain of wood utilization is the ubiquitous knot. As an economic factor, the knot problem inthe lumber industry is comparable to the prob-- lem of the boll-Weevil in the cotton belt, or to all of the combination of parasitic pests which harass the horticulturist.

* But since knots are an inherent by-product of board footagethere being as yet no way to grow trees without limbs and branches-the general attitude toward this subject has, necessarily, been one of complete resignation. When a tree is felled, the lumberman is reconciled by the thought that a substantial percentage of it will produce good No. 1 lumber; and the fact that another substantial percentage will inevitably be milled as No. 2 and No. 3 common, and perhaps other grades-on a normal market-scarcely Worthy of classification or the cost of ripping and. surfacing, has ever been accepted as beyond any hope of alleviation.

Hence an annual loss-of a great many millions of dollars is sustained by reason of the drastic mark-down which must be made in otherwise structurally sound board lumber, and all on account of knots.

'Other factors, however, contribute to the aggregation of difficulties whereby otherwise sound boards must be classed with the lower grades; and some kinds of woods are especially subject to such evils. For example, Douglas fir, along with sundry other soft woods, is particularly subject to checking and splitting; while among such conifers, in various sections of the lumber country, north, south, east and west, resin streaks,; wood-sawyer borings and the like all contribute a pro-rata of the troubles and tribulations which beset the business of cutting, manufacturing and merchandising board lumber.

According to the invention, however, most of these difficulties can be overcome and countless millions of feet of low grade lumber, which ordinarily would be suitable only for certain exterior sheathing, crating, scaffolding and the like, converted into high-priced wall panels, show-case frames and window backdrops, furniture, bar room fixtures, and interior trim for a wide variety of homes, apartment houses and places of business.

A primary object, therefore, is to utilize low grade lumber at the mill by converting the same, at that point, into products of manufacture which will greatly enhance its utility and eye appeal, while multiplying the wholesale and retail prices which it will bring in the open market.

Another important object is to eliminate the usual planing operations at the lumber mill where-after rippingeven the low-grade cuts have heretofore had to be run through the surfacer to produce 8-1-5, 8-2-8 or 8-4-3 stock,-

a-ccording to what the specification might happen to call for.

Another object is to produce a laminated wood product having one, at least, face-ply which may be thus further utilized without having had to be subjected immediately to an expensive sanding operationusually essential, however, wherein rotary-cut face-plies of Douglas fir, and other woods, subject to considerable minor surface deformations in the log peeling or unwinding operation, are employed.

Another object is to produce a laminated wood product which will combine the desirable bulk of dimensional mill stock with the additional tensile strength incorporated by the employment of plywood structural principles.

Another object is to produce a laminated wood product wherein unsightly knots, splits, worm holes, sap streaks and the like are entirely hidden from the eye; and wherein these deformities are replaced, at the Wood surface, by low-cost veneers of soft woods which are subject to simple, inexpensive treatments rendering them more optically appealing, for most ornamental applications,-

than comparable surfaces obtained from among the highest priced hardwoods.

Another object is to retain the full dimensioning of rough-cut mill stock, for use in producing such laminated articles, without involving the immense wastage of usable surface wood now being merely converted into shavings and sawdust by planers, stickers, sanders and the like.

Another object is to approximately double the square footage of low-grade mill stock, suitable for many of the ends of the invention, by ripping the logs into fully dimensioned -inch lumber instead of the standard so-called l-inch stock, which latter actually is reduced to approximately three-quarters stock after S-Z-S or 8-4-5 treatments; it being apparent that while original half-inch boards, after upper and lower surfacings, would usually be unsuitable for most dimensional uses as general yard stock, such full measure half-inch boards, when edge-glued in the manner hereafter explained and laminated on both sides, will, in actuality, result in a combination product of from to inch in thicknessdepending on the thickness of the faceplies used. 4

To besure, full measure cuts of even one-quarter inch stock could be used, the upper and lower plies resulting an increased thickness of from minimum to /2 inch or more.

Another object is to provide a simple but highly effective method of filling the holes created in board lumber where loose knots have fallen out, as well as a means by which exceedingly large splits may be quickly closed before the laminating procedures.

Another object is to produce a laminated wood product according to the invention which may, if desired, have the same widths as standard plywood panels-wider if requiredand which may also be as long as the longest standard panels or longer.

And since the general character of a logwhether suitable for high grade or mostly low grade cuts-is usually known before milling, it is another object to be able to produce core-wood, suitable as the inner stock of the laminated products, in boards of much wider sizes, whereby fewer smaller boards-according to the usual mill cuts up to 12-inch stoc-k-wou1d be required for edge-bonding.

Another object is to produce a laminated wood product which, following the required subsequent treatments on both sides thereof as hereafter explained, will be entirely suitable for many interior walls and/or partitions, without benefit of studding, where quarter-inch plywood, for example, would in itself be structurally insufficient.

And a subsidiary object is to provide such walls and/or partitions which, upon installation, will require no further finish or ornamentation with attendant additional manual labor and material costs.

Yet another object is to produce a decorated wood surface wherein, without utilizing plywood of standard existing types, sundry combed or striated configurations may be incorporated therein according to the currently popular demands of the market from time to time.

line with the previous objective, it is an object to produce a combination wood product having any desirable pattern of striations, preferably running longitudinally with the grain trend, and including intermediary spacings, the

former completely closed with casting plaster or the like and the resultant surface so uniformly smoothed as to present a highly novel and ornamental effect; thus combining pattern variations and any elected variegations of the respective wood and plaster components-the former also ornamentally toned, by preference, in order to bring out and enhance the figured effects of the natural wood grain.

Another object is to produce a laminated wood product as aforesaid, but modified in that the natural and pleasingly intricate shallow checks or cavities, lacy veinings and other anomalous dents and configurations in the unsanded, surfaces of rotary-cut plies-particularly veneers of raw firwood and the like, and no two alikeare retained and the said plaster component deposited within such cavities and veinings instead of between the ridge portions of the before mentioned combed or striated surfaces.

Another object is to utilize the natural unsanded surfaces of my laminated wood product, according to the last foregoing objective, but wherein the plasterizing step may be omitted anda new type of finish provided in its stead: said finish bearing a certain resemblance to certain Sugied wood, but having superior elements of optical appeal which are largely lost in wood treated by the standard Japanese or Americanized Sugi method.

Another object is to provide production line machinery which may be utilized in the low-cost manufacture of finished wood and woodecom'ebination products, according to the means and modes hereafter related.

Another object is to be able to impose any desired figure pattern of ornamentation in a wood surfaceexemplified by floral effects, basket-weaving, and countless other decorative motifs-as by embossing platens, roller-dies or comparable other mechanical means for stamping such patterns thereon, and thereafter loading the recessed areas with casting plaster or equivalent means whereby, upon resurfacing, a new and novel ornamental effect may be had on Wood.

Still another object is to obtain novel plaid effects and the like in a Wood surface, more especially a surface having a face-ply-according to the invention-of rough, unsanded rotarycut veneering, in which said surface is marked both laterally and longitudinally by a prede-,

termined pattern of shallow kerfing lines (the longitudinal lines criss-crossing the lateral lines) and the whole of said surface so loaded by said plaster and the like and thence resurfaced as to simulate a wide-meshed fabric appearance against the wood background.

And a subsidiary object is to produce an imitative effect of the last aforesaid loaded kcrfing lines by merely imprinting a similar pattern thereof on the previously treated surface-as by screen-printing.

Other objectives will be apparent from an examination of the further descriptive data hereinafter, inclusive of the claims and the drawings, in which latter- Fig. 1, broken open to reveal the main components, represents one typical composite product according to my invention; that is, including edge-bonded dimensional stock covered on at least one side thereof with a face-ply of preferably rotary-cut wood and the latter further ornamented according to the sundry available options. Holes leftby loose knots are graphically shown before being normally plugged up and smoothly scraped.

Fig. 2 illustrates how the composite panel board of Fig. 1 could be utilized as a partition-or even a complete wall memberbetween the rooms of a building, having both surfaces thereof ornamented as in said Fig. 1. The view is a vertical section, which could be taken at any elected vertical area through the Fig. 1 panel; an optional double-strength panel being also indicated at upper right.

i 3 is a somewhat enlarged fragmental view of the panel board of Fig. 1, or similar composite, which could be taken along the line I-l and is therefore an end-grain view.

Fig. 4 is the partially diagrammatic layout of a so-called plasterizer; that is, apparatus by the operation of which the plaster coat or its equivalent may be applied in volume production, whereby to produce certain of the finished products of Fig. l, for example. The view is a side elevation.

Fig. 5, looking down from above, is the partially diagrammatic layout of the major components given in Fig. 4.

Fig. 6 is the fragmental view of an alternative type of panel board, as thus broken open; especially illustrating the unique tapestried effect which may be obtained in the natural wood grain of the rotary-cut face-ply, without the usual sanding operation whereby to smooth out surface irregularities-the latter being fully retained in this species.

Fig. 7 is another view, comparable to Fig. 6, wherein the natural but highly distinctive irregularities of the rotary-cut surface ply, before sanding, is retained; and whereby, in lieu of any necessary sanding whatever, further treatments are applied thereto.

Fig. 8 is the schematized representation of a composite wood panel, viewed edgewise, receiving an application of water-thin liquid required according to either of the two distinct options there illustrated.

Fig. 9 shows the wood panel of Fig. 8, having been duly impregnated according to the Fig. 8 view and suitably dried, undergoing thermatographic treatment in the manner to be hereafter explained.

, Fig. 10 shows the panel of Figs. 8 and 9 upon its arrival at the plasterizer, so-called; said panel being here shown while moving automatically under the doctor-blade schematically indicated.

Fig. 11 represents a battery of infra-red lamps-or equivalent drying means-through which the panel of Figs. 8, 9, 10 may be moved to thoroughly dry out the plasterizing coat.

Fig. 12 is the brief representation of a pneumatic sanding drum, which may be used for very quickly, inexpensively removing the thin film of plaster which was not entirely scraped away from the ridges by the doctor-blade of Fig. 10. Shown also is a brushing element for automatically removing portions of the abraded plaster, wh1ch otherwise would quickly clog up the sanding surface.

Fig. 13 is the schematic view of one of plaster dust.

And Fig. 14 is the schematic arrangement of type of roller-coater, which can be employed to apply a components especially recommended for the volume production coating and finishing of panels according to the variant product which was mentioned in connection with Fig. 7.

Numerals and other lead-line characters are duplicated only where the same relate descrip tively to like full components, and to parts thereof requiring separate indicia.

General distinguishments No invention is claimed in merely utilizing individual wood boards as a base means, upon which an upper and/or a lower face-ply of veneerwood has been bonded to produce a laminated product. Such an article per se, in the broad art, is old and the method thereof has been used for generations in the manufacture of fine cabinet-work and furniture, for example.

The fact that such laminated products, as presently and long previously employed, are generally made up from good sound dimensional stock, to which high-grade hardwood veneers are laminated, more especially whereby to obtain greatly enhanced burlwood and crotch effects which are usually lacking in fiat-cut boards, is not held to alter the basic structure thereof. In brief, invention is not herealleged in merely substituting ordinary soft-wood veneers, assuch, for hardwood fiitches; but new and unobvious results begin whereinaccording to my stepwise procedures and the resultant products thereof important, unexpected benefits are bad by the employment of particular kinds of face-plies over edge-bonded stock, for example, and by means of which distinct commercial advantages are thence obtained which have not, heretofore, occurred to the skilled operatives of the art.

Thus, while no obvious seeming advantage would accrue in bonding low-cost Douglas fir face-plies, for instance, to other soft wood dimensional stock in lieu of standard plywood panels, I have discovered that rough, unsanded, rotary-cut veneers of this particular wood-- when so utilizedaiford a ground upon which it is possible, at very low cost, to obtain unique and visually superior effects. These are arrived at without even subjecting the face-plies to the usual expensive re-surfacings which-in this industryhave been deemed necessary to produce; a desirable article ready for the applicationof stains, for instance; or, to cite another case in point, for use as a base for wall paper treatments,

following the bonding thereto of blank-stock,

deadening felt, or the like to kill the normally unhappy pattern of wood grain which, upon its prior contact with water-soluble adhesives, would swell and protrude visibly through ordinary wall paper.

Moreover, by utilizing such rotary-cut plies, and by the application of special low-cost treatments thereto in combination with board stock which, on a normal market, represents little more than junk lumber, I obtain finished products which even in the unfinished state are difiicult to distinguish from fully built up laminations of higher-priced multi-ply veneerboards. manner set out herein, a most visually superior product is the result; one which, bulk for bulk, has all the required tensile strength at a sub stantially lower production cost than said built up articles of manufacture but worth a great deal more at the retail level. I

This is made possible, in part, by the use of said low-grade board stock wherein, at exceedj And when further processed, in the ingly smallraw material and labor costs, gaping knot-holes are quickly plugged with a fast-drying, non-shrinking material which, for the purposes of the invention, restores the boards to their prior strength and soundness. However, such restoration would not, quite obviously, serve to hide the but further emphasized unsightliness of the doctored up board without applying said overlay of the at least one face-ply as a stepwise further preliminary procedure; and which, is by preference, antecedent to said surface ornamentation according to the methods herein and to the resultant finished products to be described.

Furthermore, as another desirable preliminary procedure, wherein particularly wide panel boards are desired, the thus doctored and restored dimensional cuts are also edge-bonded be-. fore receiving at least one face-ply thereon. Such bonding, in itself, is also old in the art and is often done as a means of uniting mill cuts made from western sugar pine, alder, tupelo gum and other woods-to mention a few-which can be then band-sawed, chucked, and turned to good advantage on a head-stock where the inveneerwood, for instance, preliminary to the fur- I ther striking improvements which are shortly to be explained.

In this connection, the value of the present invention is enhanced, in no small degree, by the recent important advance in the art of edgebonding per se; said advance being due to the advent of new high-speed automatic machinery therefor, as more fully described hereinafter.

Emphasis is herein placed upon rotary-cut firwood largely for the reason that such plies or veneers, due to the rotary-cutting method itself and to the nature of this wood, results in the peculiarly anomalous grain effects which were pointed out earlier; but comparably variant effects may be had from other desirable woodssuch as west coast hemlock, to mention but one rather similar variety; and it is to be understood that'the invention is by no means solely limited to the use of Douglas fir. In certain of the fully augmented processes, a very substantial 'number and variety of woods may be employed, whether the veneers are rotary cut or flat-cut.

Thus in particular areas of the domestic lumber country, selected cypress and other relatively low-cost woods could be utilized over dimensional base-stock of Southern long-leaf and loblolly yellow pine; and in view of the relatively light weight of the individual face-plies of Douglas fir, it would be economically practicable to ship the. latter components, if necessary, from the Pacific Northwest for further processing in combination with low grade boards turned out by saw mills remote from the main centers of the plywood industry proper.

Incidentally, while the present invention deals with ornamented Wood products ,of the express class defined, the fact that certain of the steps which are essential in arriving at the end results herein may also be applied to standard plywood sheets, for instance, in no Way minimizes its utility as primarily conceived or vice versa.

8. That is, the invention, in any of its components, may have other uses even though the same might be obvious by-products of the over-all methods which are given herewithin. Therefore, the hereafter appended claims should be construed as broadly as the status of the present art or arts will allow.

Specific examples In order to clearly disclose and explain themvention, certain graphic forms thereof have been selected, as exemplified by Figs. 1 to 3 and Figs. 6 and 7, wherein a plurality of species is depicted.

Fig. 1, for instance, typifies a combination panel l0 comprised of only three edge-bonded dimensional boards ll, l2 and I3, having-in this limited viewthe upper face-ply l4 laminated thereto; and element l4 per se is ornately processed whereby the resultant ridges l5 are interspaced by lesser pin-stripes I6. Stripes I6 as well as ridges 15 are, in this version, interspersed with the blank areas ll; these latter being the gouged out areas-to be clarified shortly--wherein longitudinal strips of white or tinted plaster or the like have been interposed in a manner suggesting marquetry.

Otherwise viewed, the areas ll constitute a ground against which the said ridges and pinstripes themselves present an appearance simulating expensive inlay work.

Although not visible in the fully processed panel H), the face-ply It may also have the shallower pin-stripes I8, with the more minute complementary grooving thereinbetween, which stripes do not project sufficiently high to be visible at the surface level of the loaded panel but are adapted to serve as additional means for more securely keying the plasterizing component to the wood stock.

This function of the lesser pin-stripes I8 is particularly evident when viewed sectionally in the fragmental detail of Fig. 3, where other features of Fig. 1 are also readily identifiable. Fig. 3, moreover, shows a thin film or top-coat M of desirably clear cellulose lacquer or its equivalent; and in a production article, where handrubbed semi-gloss effects are not required and would not be preferred by the majority of prospective users, element I9 can be a low-cost lacquer sanding sealer or any suitable other transparent or translucent top coat. For another example, it could be wall-paper lacquer.

Indeed, but less desirably, the coating l9 could be omitted since plaster, when once set up, is no longer water soluble and the surface could be kept quite clean with a damp rag or sponge. Moreover, it could be waxed or treated with a clear drying oil.

The ornamentation of Figs. 1 and 3 may, to be sure, be varied according to individual preferences. For example, instead of ridges l5 and pin-stripes it, including the plasterizing treatment, the panel I0 could be sand-blasted and further processed conformable with either of the methods set forth in my prior co-pending application entitled Process for Ornamenting Various Objects, Including Means Therefor and Methods Relating Thereto, Serial No. 630,890, now abandoned. or a treatment selected from among the various options given in the prior co-pending entry "Thermatography: The Art of Synthetic Colorization, as Applied to Certain Thermochemically sensitized Surfaces, Including Apparatus Therefor and the Resultant Products Thereof, Serial No. 630,889, affords another alternative.

According to yet another option, the face-ply could be given a grooved effect somewhat similar, but not exactly identical, to the combed or striated design set forth in Patent No. 2,286,068 to Donald Deskey, since the latter is directed to structure and deals primarily with the problem of edge-separation of abutted plywood panels of orthodox fabrication and is not directed to pattern grooving per se. If suitably seasoned board stock II, I2 and I3 is employed, there will ordinarily be no problem of edge separation wherein panels I may be used, in abutted relations, as wall panels; as see also later reference to crisscrossing the sandwiches.

In the species here featured, it is preferable to leave at least certain of the elongate bandsexemplified by ridges Isufficiently wide to emphasize the thus interrupted natural grain pattern of the wood; and, if preferred, ridges I5 may be much wider than here shown and the plasterized areas I'I considerably smaller, for instance. Indeed, the whole pattern may be so changed that some or all of the plasterized areas would be but mere pin-stripes; and they may be either closely or widely spaced, as elected.

Ridges I5 and stripes I6 are preferably given a color treatment in some shade or shades to pleasingly contrast with areas II. And while sundry dies, stains and the like may be so employed, the preferred treatment is to utilize one of the so-called myrreltine formulas of said second named co-pending application? more particularly, a formula wherein the hard grain areas are especially emphasized; as see said case for all required details. See also the co-entered application called Articles of Pre-fabricated, Prekerfed and Pre-finished Plywood, Including Methods and Apparatus Accessory Thereto, Serial No. 23,649.

Some structural advantages As to the detailed construction of panel Ill, it would be superfluous to relate the specific procedures whereby the edges of the boards II, I2 and I3 are glue bonded to one another, or the equally old and well known method of laying up and laminating plywood plies, whereby element I4 is quite similarly secured to the dimensional. wood backing. (See, however, the subsequent references to high-speed edge-bonding.) In brief, since no invention is claimed as to these features per se, the standard techniques of the related art or arts may be utilized.

As shown in Fig. 2, it is preferable to provide both the face-ply I4 and the outer ply I 4' on the opposite side whereby to produce a sounder, stronger panel less subject to possible warpage under severe climate extremes, and one which will not disclose any unsightly knots or other disfigurements on either side.

Another object in providing a duality of faceplies, on obverse and reverse sides of panel III, resides in the fact that the same may then more advantageously utilize only inch board stock as mentioned earlier in the objects. Thus, by providing face-plies of only inch thickness, the fully laminated panel III would be of an inch thick; and if %-inch face-plies are employed the panel would be of an inch thick before other processing. If such panels are to be used as walls or partitions within or between the rooms of a building, the necessity for prefinishing both sides thereof is obvious. The lower moldings 20, 20 and glue-lines 2i, 2! are self-explanatory.

In this connection, it may often happen, in some structures, that a panel of considerably increased tensile strength would be desirable. For this special demand, any required plurality of panels It, It and the like may be laminated to one another, in the manner of conventional plywood, according to the suggestion given in Fig. 2. Intermediary rotary-cut plies I4 would be desirable in such composites, though not entirely essential.

It should also be emphasized, at this point, that elements I I, I2 and I3 need not be sandwiched co-longitudinally with the face-plies but may be laid up with their grain crosswise thereto for greater stability, increased tensile strength and insurance against warpage-as see hypothetical transverse placement of the board stock at areas divided by the cross-lines II' and I2. As explained hereafter, automatic edge-gluers can readily be built to accommodate any predetermined width or length of the boards to be bonded; and it is a'simple matter to thereafter cross-cut the resultant slabs as required for corewood. A1- ternatively, the face-plies could be cut to lay transversely with respect to the grain trend of the corewood and to their own. lengthwise dimension.

See also the yet more graphic arrangement of elements II,' I2 and M in Fig. 6, to be detailed hereinafter.

In the matter of the preliminary reclamation or .doctoring of the boards II, I2 and I3, certain options are presented. In the case of knots which are merely loose but have not fallen out, the latter may be left without treatment of any kind, ex-

cept optionally, since it is evident that upon the bonding of both the face-plies I4 and I4 thereto such knots will be loose no longer. Sapstreaks may be ignored but relatively wide splits 22 can be quickly filled and, to be sure, such a treatment of knot-holes 23 would be normal in any event; Partially broken out knots, as in panel I I, Fig. 1, can be so dealt with if the broken away area justifies.

Sundry substances may be employed for filling holes 23 and splits 22, including various glue and sawdust mixtures; but I have found ordinary grades of casting plaster most satisfactory in every way-especially the rapid setting types. A portion of fine sawdust may be added; but if too much sawdust is used, or if small shavings or drillcuttings are employed, it will be difficult or impossible to obtain a cleanly scraped surface. The plaster is mixed with water according to standard proportions-more plaster relatively, for quicker sets; and, by preference, with the fully edgebonded boards resting flatly on smooth table-tops, the plaster may be merely troweled into the holes or cracks with an ordinary thin casing knife or small masons trowel and the same device used for quickly scraping the surfaces clean of any excess plaster.

Some quick-setting plasters, when mixed to a doughy consistency, will set up in a very few minutes, and the further bonding operations with regard to face-plies I4, I4 can be carried out at any time thereafter.

One great advantage of casting plaster is that it will adhere tightly to the walls of the knotholes and, unlike so-called plastic wood, wood dough and similar products, it does not thereafter shrink during a long hardening and drying process. Nor is it, therefore, necessary to apply an excessive amount thereof in order to allow for subsequent shrinkage as well as for a tedious sanding job to re-smooth the surface to be patched. On the contrary, it hardens in a few minutes and most of the standard domestic lgrades have a very slight expansion coeificiehtapproximately 1.75 percent-but the latter is relatively neglible and will not be sufiicient to interfere with a close adhesion of the face-plies.

Standard casting plasters may also be used forloading the grooving I! of the panels l; and for this latter purpose it is usually desirable to "slightly prolong the setting time, in order 'thatthere need be no great hurry in mixing and applying the plasterizing coat, and no difficulty in maintaining the doctor blades quite clean at "alltimes in accord with the method to be explained relative to Figs. 4 and 5. So-called Red Top 20-minute set or Red-Top 30-minute set has produced satisfactory results.

The recommended proportions are about 100 parts of the plaster by weight to 60 to 64 parts of water by weight, It is usually good practice. but not entirely essential, to initially pre-wet the surface of the face-plies before application of the plaster, which should be neither too thick nor too thin as to its consistency at the time of application. If dry colors are to be mixed therewith, for obtaining pastel shades in the areas [1, such colors are preferably added to the waternot to the plaster-and then well dissolved before completing the mix. The usual method of sifting the plaster into the Water, while continuing a stirring operation, is normally preferred, and sundry apparatus fOr accomplishing such operations in production can be provided. The United States Gypsum Co., for example, maintains a service staff which can usually make specific recommendations covering any like technical feature.

The plasterz'zer With reference, now, to the plasterizing apparatus of Figs. 4 and 5, elements 24 in the latter view are preferably individual chain-belts which engage over complementary sprocket wheels 25 and 25' at respective ends of the so-called plasterizer machines of the drawings. Belts 24 are driven by motor 26 through wheels 25, the latter being carried on suitable shafting 21 from standards 28. At least a duality of endless belts 24, preferably, are provided with occasional links having the upstanding pusher dogs 29, which may be had as standard equipment; it being the function of dogs 29 to maintain each of the panels [0 in their correct positions while moving through the plasterizer (ill-as see both Figs. 4 and 5.

However, it is quite essential that the panels shall move over an unyielding bed means, and, in addition to the belts 24 (which may have supporting intermediary idlers which are not specifically shown) there are provided a requisite plurality of preferably metal table leafs 3|; which leafs are herein shown as being mounted with their fiat sides facing laterally and their narrowest edges at bottom and top, over which the panels Ill are slidably moved by dogs 29. This type of mounting, as well supported by the various spaced uprights 32, Fig. 4, provides a par ticularly rigid structure with adequate spaces between the leafs 3|, as well as between each of the belts 24, through which all excess plaster may drop through from the localized area of the doctor-blade 33 onto the flexible conveyor belt 34. Element 26' of Figs. 4 and 5 is the schematic representation of a speed-regulator, sinceit is highly important that panels I0 shall move at a pretimed rate of travel, for reasons which will be duly further clarified.

Belt34, driven by motor 26, is preferably of the type which travels over driver and idler-rollers, the latter formed to produce a centrally disposed sag therein; which belt comprises a moving, through-like receptacle for said excess plaster material. Details, including the troughing mechanisms, concerning this auxiliary device are not here given, since the same may be in accord with such standard equipment items as the Link-Belt Company's No. self-aligning troughing idler and belt assembly, for example; as see their Standard Equipment Catalog No. 850, pages 148 to 152.

To those skilled in such matters, it will be unnecessary to dwell at length on the structure of doctor-blade 33; but in the diagrammatic drawing of Fig. 5 blade 33 is conveniently linked to .a pitman rod 35 and the latter pivoted to the crank-arm 36 operated'by motor 31. In practice, however, blade 33 could be operated by a rackand-pinion device, by hydraulic mechanism, or as otherwise elected.

Obviously, the blade 33 would itself be guidably mounted for lateral movements to and from the respective schematic pressure- sprays 33, 38; it being the function of these latter components to maintain the doctor blade '33 clear of any incrustations of the plaster 39, emanating from schematic hopper feed 40, into which the suitably mixed plaster material may be continuously introduced in any professionally determined satisfactory manner. Equipment of the class described can be readily supplied to order by such specialists as the Binks Mfg. Co., Chicago 12, Ill. See also the Non-clogging Spray-Nozzles, for specialty pressure spray installations, illustrated and described on page 147 of said catalog No. 850 of the Link-Belt 00., Chicago, Ill.

Operation of the means for moving the doctor blade to and from the right and left pressure sprays may be made intermittent, at whatever intervals are deemed advisable to avoid any possibility of the plaster adhering thereto; and this could be a relatively rapid operation following the movement of each of panels In through the blade member. The obvious function of the latter is to afford a straight-edge from one side of the panels to the other; so that as rapidly as the plaster 39 is fed through hopper 40, and is thus spread out over the work from side to side, blade 33 will automatically scrape smoothly across the ridges l5 and elements It, Fig. 3, during the travel of belt members 24 according to arrows 4 i.

In order to avoid unnecessary waste, the flow of plaster through hopper 40 will be carefully metered and, as aforesaid, all excess thereof will drop immediately from the area of the doctor blade onto conveyor 34 for automatic removal. As required, the hopper 40 may have any preferred mixing and/or force-feeding device 4ll' see Fig. 10operable to maintain a predetermined fiow of the fluid material therefrom to panels I0. And the blade 33 could, but less desirably, be moved along with hopper 40, relative to the panels instead of in the preferred manner explained.

There are various other ways of utilizing the relatively small percentage of surplus plaster, without having to waste the same.

If it is desired to have a duality of doctorblades, one for use during a brief interval when the other is being spray-cleaned, and the two op.- erable in tandem positions, such a minor adaptation will lie within the province of ordinary engineering skills after the benefit to be derived from the information herein given.

In the Fig. 4 view elements 35 and 3B are abstracted, so that the doctor-blade 33 may be clearly seen in this vertical position. In said Fig. 4, element 42 represents a battery of infra-red drying lamps; or a hot-air blast, for example, may be employed for a like purposenamely, the force drying of the plaster impregnations in the surface recesses of panels 56. Standard 28, belt 24' and sprocket wheel 25 indicate any suitable means for carrying off the panels H! from the plasterizer.

Operative procedures In the over-all treatment-of the face-plies according to Figs. 1 to 5 inclusive, the panels I0, following the standard laminating operation, will be then run through a wide planer or the like having a serrated blading component adequately ground for this express purpose; as see, for instance, the specific reference to such apparatus in said Patent No. 2,286,068 to Deskey.

After the foregoing step, the panels could be e y stained according to the optional (upper and lower) devices of Fig. 8; the hydrant, in combination with a hopper 43 having an elongate wick 44, being one means for applying a selected chemical stain or water-soluble dye, for example; the capillary action of the wick causing an adequate amount, only, of the dye fluid to be applied to the upper surfaces of the panels. Alternatively, the fluid could be applied to the inverted undersides of the panels according to the specialty roller-coater having applicator-roller 45; as see said prior co-pending case bearing Serial No. 630,889 for details thereon, and including a so-called turncradle disclosed therein for rapidly reversing the panels following this operation.

The preferred method of coloring ridges l5 and areas I6, however, as aforesaid, is by thermatographic treatments; in which case the devices of Fig. 8 could be employed in the application of so-called chemical activators and/or other colorizers as may be required. After that, the panels iwhich are conveniently distinguished herein by the species term marvex-may be fed to an automatic thermatograph, as schematically indicated by the manifold-and-burne-r-point combination 46 of Fig. 9. And from element 46 the panels may be transferred immediately to the plasterizer, having hopper 40 and doctor blade 33; the lamp 4?, Fig. 11, being self-explanatory in view of element d2 of Fig. 4. These marvex type panels should thence be laid in a flat position to allow the plaster to set firmly, but artificial heat may be applied thereto as expertly determined. Intense overheating could cause the plaster to curl out of the grooves I! and breakoff.

When the panels I B are thoroughly dry, it will be found that although their surfaces were desirably scraped quite clean by the doctor blade 33, and, while the plaster was wet, the wood pattern in areas l5 and I6 showed quite distinctly, a thin semi-opaque film later formed thereover while the plaster was being dried. A preferred method of removing this filmy overcast is to run the panels once lightly under a pneumatic sanding drum 48, Fig. 12; and then, following a preferred interim application of a blower-device (not shown), operating by suction to normally carry off all plaster dust created by the sanding operation, the panels I!) are preferably given a single top-coat [9 of clear air-drying nitro-cel- 14 lulose lacquer or its equivalent, as generally indicated by the roller-coater 49 of Fig. 13.

Incidentally, while the plasterized panels of said marvex type will sand quite readily, the drum 48 would quickly become clogged up with portions of the removed plaster dust except for the elongate brush device 48', which is adapted to bear against the drum substantially as indicated. The bristles of brush 48' should be only suificiently stiif to keep the drum continuously cleaned without removing the abradant surfacmg.

Although, according to the data at hand, casting plaster is believed to be preferred for the plasterizing component of the invention, it will be evident to craftsmen in sundry allied fields that other substances could readily, though less desirably, be substituted. For one or two exam ples: it would be possible to utilize Danish or domestic bolted whiting in a glue mixturein the proportions of about *7 parts by weight of whiting to 1 of clear gelatin glue, for example according to formulas usually followed in the spray-coating of picture frames as a preliminary to burnishing jobs or the application of gold or metal leaf. Such coatings can be sanded, but a relatively long drying time is required and the volume of the material shrinks considerably while drying. Another option would be the use of one of sundry white cements; but all in all, it is believed that casting plaster-which is also variously called gypsum, plaster of Paris, gesso, etc.--is definitely preferable.

The treatment suggested in relation to Figs. 1

and 3 is to be regarded as typical, rather than necessarily preferred of its class; it being immediately obvious to skilled ractitioners that sundry other effects could be used, in lieu of the longitudinal grooving for high-low reliefing the surface of face-ply I4 before plasterizing the sameas by sand-blasting, by charring and,

wire-brushing, by roller-die embossing, et cetera, which are all old and well known as methods per se. In fact, the method of sand-blasting the surface ply M in lieu of the specific high-low pattern of Figs. 1 and 3 is to be especially recommended. For such treatments, however, faceplies having relatively closely spaced and narrow hard-grain areas-for greater delicacy-are most suitable. If the grain figure is also attractively looped and intricately curled, or presents a closely barred and wavy appearance, the effect will be much 'improvedsomewhat suggesting cloisonne.

For this treatment, face-plies having broad areas of hard grain are to be avoided unless for the deliberate purpose of producing spectacular effects. Such a technique is not to be confused with the fully augmented Sugi method of the Japanese, as also practiced on such domestic woods as southern cypress, for instance, wherein the charred and brushed surfaces are thence treated to orthodox coating and wipe-off operation according to well known procedures for ap-, plying and partially removing scrummage coats.

The best results are had by a preliminary deep blasting of the untoned face-plies, using fine grain grit, such as Carborundum, on the order of to mesh, and relatively low tank pressure, say 45 lbs. or thereabout; after which the surface is preferably given a myrreltine treatment according to said last named co-pending application (Serial No. 630,889) before plasterizing. The thermochemic treatment should, by preference, be one wherein the hard grain is '15 quickly colorized; as see said application. with respect. to formulas featuring nitric and hydrochloric acid, the former for reddish tones and the latter for shades ranging from amber to black.

Some other species.

The panel lfl of Fig. 6 presents another of the various optional decorative finishes which may be employed. In this view, which features what is conveniently called the 'moquette" finish, faceply I4 has been laminated to one side of the edge-bonded board stock, including boards II" and I2", as was similarly explained relative to panel In of Figs; 1 to 3. The'main distinguishinent between panels l and I 0* resides in the fact that instead of utilizing the longitudinal groovingas explained, or some other mechanically imposed high-low surface effect, unless optionally, face-ply I l has, in the version which will be initially explained, been left quite plain. According to one preferred process specific thereto, it is necessary that ply HI shall remain unsanded.

The rough rotary-cut face-ply will be variously surface pitted or otherwise shallowly indented over substantial areas thereof, generally irregularly following the grain pattern; and after a suitable preliminary treatment it is desirable to load each and all, such indentations and the like with casting plaster, whereby to present sundry, multifarious effects; as, for one example, according to the blotches 50 and the like of Fig. 6. The remaining areas intermediary of blotches 50 will also usually receive, here and there, more minute streaks and/or dapplings, against the contrasty ground tone of a so-called myrreltine preliminary finish, preferably, following in general the method mentioned with regard to panel 10 and Figs. 8 and9.

As one of the sides of rotary-cut firwood veneers is usually considerably rougher than the other, and since a rough, irregularly checked surface is usually preferred for the effect shown in Fig. 6, it is important that the face-ply to be ornamented shall be laid up with this end in view, before consignment to the hot press.

After the impregnation of the face-ply Hi with a suitable activator and/or stable colorizer, and, after a drying operation, the panel having been thence given the thermatographic treatment of Fig. 9, it will be immediately ready for the plasterizing step. The latter may be followed through in approximately the same manner as was earlier explained relative to Figs. 4, 5, 10, l1, l2 and 13, and including the top coat of clear in accord with said Fig. 13 exhibit.

Face-plies treated in the so-called moquette manner will resent a most pleasingly dappled, variegated appearance, often suggesting exceedingly delicate mosaic work or even tapestry in some of the more intricately indented wood patterns. Only the light sanding operation, as mentioned previously in connection with Fig. 12, is necessary to remove excess plaster, and the cost of processing is even less than in the case of panel I!) including the mechanical serrating operation or its equivalent of the latter named species. Obviously much less plaster will be required to fill the relatively shallow recesses 50.

The last foregoing method may be simplified by first merely staining the panel [0 any suitable color, using chemical stains or aniline dyes for example, prior to plasterizing; and the plaster material itself may, of course, be of any preferred color. Or the plaster coat can be applied over the uncolored wood. The moquette finish automatically imparts a pastel effect, and when this appearance is to be retained it is important to seal the surface with a clear water-white wall paper lacquer or the like. Some effects, however, may be further enhanced by using lacquers or the like having more build, followed by me.- chanical rubbing.

Surfaces treated in the foregoing manner can often be further improved. Thus if a still lighter, more pastel effect is desired, the previously plasterized and smoothly sanded surface may thence receive an extra scrummage coat-followed by the usual subsequent wipe-off, as by means of squeegee and rubbing rollers elsewhere ex? plained whereby to deposit additional inert, light colored or white pigment in the not previously fully filled Wood grain. While such a treatment will additionally cloud the grain pattern, the resultant effect is not objectionable, but, on the contrary, imparts a desirable extra component of ornamentation when maximum pas telization is desired. And to retain such an effect the top coat should be, by preference, the aforesaid wall-paper lacquer or its substantial equivalent.

In this connection the moquette finish may be varied somewhat whereby, for illustration, to incorporate certain features of panel [0. Thus, if desired, the striping generally indicated by dotted line areas I! may be imposed as striae, but in view of the great beauty of the unstriated wood per se such grooving should be utilized sparingly, and for best effects elements I! are quite narrow pin-stripes of any expertly determined width and spacing.

Optional other effects may be obtained by additionally imposing the cross-grain shallow striae I'I one or more thereof at each blocked off area shown; and it is obvious that each such striation will receive its pro-rata of the plasterizer. Clearly, too, such striations, whether longitudinal or transverse the face-ply or both, is optional with respect to either of the species disclosed. Wherein exceptionally narrow transverse striae are desired, rotary slitter knives are preferred to toothed cutting edges.

If the grainwise striae or kerfing lines are to be initially imposed by planer blades, the latter should be very deeply ground, so that the areas between each of the grooves Ii will remain unsurfaced. For this particular treatment, however, the preferred apparatus is either the aforesaid slitter knives or a multiple rotary table saw set-up, each blade making one of the cuts but all of them preferably carried on a single shaft. Comparable saw or slitter set-ups are commonly employed in various divisions of the woodworking art and need not be graphically shown or otherwise detailed. The blades may be set to make relatively shallow, clean-cut striations and the remainder of the face-ply remains as before. Needless to say either or both of striations Il and/or li could be imposed on pre-sanded faceplies which had been thermochemically toned and an ordinary scrummage used instead of plaster. In such a case it would be advisable to seal the thermochemic tones with a clear lacquer or the like, before applying the scrummage; thus insuring a cleaner subsequent wipe-off before normally protectively re-sealing the surface.

The decoration of. panel lil of Fig. 7 calls for a different but equally simple procedure, the tinsanded natural grain pattern of the rough rotary cut face-ply being utilized. In this instance, however, the smoother side of the face-ply is often preferred to the extreme roughness characteristic of some rotary-cut veneers. Individual selection is advisable, according to the effect desired.

Panel lo as in the case of panels l and Ill, is assumed to be comprised of edge-bonded boards as exemplified by elements ll, l2 and i3or the same laminated crosswiseto which has been bonded, preferred side up, the rough, unsanded, rotary-cut face-ply M As usual, the latter includes certain relatively smooth areas 5| alongside relatively the rougher pitted or shallowly indented areas 52; the latter, however, being irregularly different in every specimensome presenting extremely attractive whorls and lacy effects while others are of simpler, less ornate pattern. And some are to be admired for one form of design, others for variantly different reasons.

It is important to observe, however, that in nearly all cases the irregular high-low surface structure is not very deep-much shallower, in fact, than the slightly comparable but deeper configurations obtained as one step in the aforesaid augmented Sugi method, wherein the surface is first heavily blow-torched and then rubbed over with a wire brush or equivalent mean to remove the charred soft grain before coloring. This latter method (or, alternatively, the said sand-blasting) generally removes substantially all of the soft surface wood, leaving only the hard grain in relief; and this is particularly true wherein rotary-cut wood stratas overlap one another, as they usually do in Douglas fir veneers, so that practically only one ring-growth of hard wood remains overlappin another.

Such a pattern is very desirable when utilized in wholly different final surface treatments, as dealt with co-pendingly. But for effects comparable to the extended Sugi method, the sanding or the alternative charring-and-brushing procedure obviously destroys the surface soft wood, wherein some of the most attractive, most delicate veining and truly naturalistic wood patterns are present.

In brief, an infinitely superior visual result (over the augmented Sugl method) is obtained by merely uti1izing the rough but selected rotarycut veneers; and in volume production it is obvious that the cost of surfacingsandingthe wood is eliminated, as is also the cost of either sandblasting or of charring-and-brushing as the case may be. This is not to say, however, that an extremely light preliminary sanding treatment could not be applied to some of the rougher sides of the face-plies, so long as the high-low relief pattern is merely rendered less rugged, and not obliterated altogether. In practice, however, no preliminary sanding is really essential to the process herein described; it being assumed that some selection and grading was initially employed in laying up the face-plies.

The pueblo finish In order to avoid any possible confusion between panel boards Hl and wood surfaces treated by the augmented Sugi method, as well as to herein distinguish the same from the previously named species, the effect to be now described in connection with Fig. 7 is conveniently identified as the pueblo finish.

In the further treatment of panel lU certain options may be carried out. One preferred treatment is to run the panels through roller-coater 49 or the like, Fig. 13, whereby to apply a coat of air-drying lacquer sanding-sealer, but only for the purpose of sealing the wood against further suctioncapillary absorptionand not, as is customary, incidental to an immediate sanding operation.

According to this formula, the panels are then re-run through a similar roller-coater for the application of an opaque coat of pigmented White lacquer enamel or the like; and it will be obvious that the two operations may be combined by utilizing a pigmented white sealer material in the first instance, applied in the required consistency. By option, of course, an appropriate tint color may be used instead of white.

When the opaque ground coat is dry-as desirably facilitated by a treatment according to the infra-red lamp battery of Fig. 11, a not-toohot air blast or its equivalent-the panel lll is ready for the scrummage coat, this last being any of the numerous color combinations preferred by various individuals according to personal preferences. Over a white ground, for example, ivory tones here and there may be obtained by mixtures of raw and burnt sienna; low priced colors ground in linseed oil being usually employed, intermixed to a not too thick creamy consistency in gasoline and applied in any preferred manner. In the small arts and crafts such coats are usually applied manually with a brush.

But in a production line, they are preferably applied by a suitably constructed roller-coater, or merely permitted to trickle in meter quantity from a hopper device 53, Fig. 14, while the panel HT is moving slowly continuously therefrom in the direction of the squeegee-roller 54, having the flippers or yieldable vanes 55. These are rotatably brought to bear against the surface of the panel before the scrummage coat has had time to become so firmly bonded to the lacquer coat as to unduly resist its removal, in large measure, from the relief areas only--leaving unremoved portions of the scrummage embedded in all the deeper areas 52, for example, as well as in many shallower, less prominent areas which are not graphically shown in the drawing but which contribute substantially to the effect desired.

If the panels are squeegeed crosswise of their grain trend, a superior, more delicate result will usually be had, assuming that the panel itself has been Well selected. Thus, unless desired for relatively strong wood grain accent, the medium rough face-plies are likely to produce more satisfactory panel boards. But here, again, there will be many exceptions to seemingly negate any hard and fixed standard.

Needless to say, sundry other tonal combinations may be used-mixtures of yellow and black, blackish blue, black and red with or without yellow added, and so onand it is not even essential that colors ground in oil be used in gasoline mixtures. More expensive Japan oil colors are sometimes employed in gasoline or even benzine but the action of both the vehicle and the solvent, in such applications, is usually considered too rapid. On the other hand, there is a tendency for oil colors to stick too closely to the previously lacquered surface; so that, even when followed immediately by the treatment exemplified by roller 54, the scrummage material does not wipe off to the desired extent. Such a condition can be overcome in part by using a thinner scrummagewith more gasoline added-and by 19 treating the panel quickly thereafter with one or a plurality of squeegee rollers 54, each of which removes its own particular pro-rata of the scrum- .mage, after which a final automatic rotary rubbing treatment or treatments may be applied.

The latter step calls for a roller (schematized by element 56, but see said co-pending case having Serial No. 630,890) which may be encased in carpet material or the like, the panel being rubbed thereby to remove yet other, more tenacious areas of the now relatively dry pigmentation. l have discovered, however, that this latter difficulty can be largely ameliorated by merely making the scrummage mixture from ordinary standard cold water dry colors-such as water-mixable drop black, for example, with portions of iron oxide (Venetian) red and ferric yellow or any desirable other color in combination. A suitable scrummage of this character may, in fact, be applied without even a glue size to promote adhesion; and the squeegee operation can thereafter be performed quite readily. However, as mentioned previously, cross-grain squeegeeing is definitely preferable for reasons which will be understood by skilled operatives in sundry allied crafts.

After passing under one or more squeegeerollers 54, the panel can then be further forcedried by contact with element A? or the like and submitted to the action of an aforesaid rubbing roller, as typified by roller 56, prior to the application of a final top coat of clear airdrying lacquer, preferably, to seal the serummage and complete the processing of the prefinished panel board.

While the above-named method has been found quite satisfactory, it may, of course, be modified according to sundry variations of technique which, in similar but non-analogous arts, are old and well known and need not be detailed here. And wherein the exact timing of the steps, the precise quantities of the ingredients recommended, etc., are not given, such data will not be required by persons who have passed the apprentice stage in crafts which employ such skills.

Other procedures Following the steps given in relation to Fig. 7, the smoother areas 5| will have been restored to a near-whitenessif white lacquer was usedwhile the indentations 52 will be quite dark, with more delicate veinings and lacy effects appearing here and there throughout the surface of the face-ply. The general result is an antiqued surface of an exceptionally well delin eated and exceedingly pleasing character.

Moreover, at relatively small additional cost, such a so-called pueblo effect may be yet further enhanced. For example, if panel i having preferably, for this effect, been submitted to a light scrummage produced from colors ground in linseed oil and mixed with gasolineis thence subjected to the action of the pneumatic sander 48 (before the final top coat, that is, but after the squeegee treatment or treatments), certain unpredictable, less tenacious portions of the ground coat of white will be removed from some but not all of the smoother areas i until the natural wood begins to show through. In a panel having a relatively dark or sun-toned Douglas fir face-ply, the color of this natural wood will usually appear a pale salmon pinkish shade, and this, alongside the somewhat darkened but still more or less whitish adjacent areas in conjunction with still darker zones 52, will now present a '3-tonal aspect curiously suggesting, in some specimens, the appearance of birchbark. Most critics are definitely pleased by this elfect, which obviously is on a more rustic order than the delicately attractive pastel tones and effects of moquette, for example.

And it will now be rather obvious that the aforesaid result can be yet further varied; as, for example, by originally staining the face-ply yellow or some other elected color before application of the sanding sealer and opaque white, white sealer, or the elective variables thereof, as the case may be. As already intimated, the sealing coat may also be varied by the addition of a suitable tint color, instead of the untinted white and a one-coat pigmented sanding sealer is preferable.

In the species of Figs. 1 and 3, incidentally, it is advisable to handle the processed boards with more than ordinary care in order to avoid bending stresses-particularly in large size sheets-- until final assembly. They may, however, be freely sawed or drilled without abnormally wearing the cutting tools.

Special emphasis was earlier placed upon the advent of improved edge-bonding machines. Indeed, prior to the quite recent invention of highspeed automatic devices of this type, having practically instantaneous electronic driers, the cost of edge-bonding alone would doubtless have taken a substantial pro-rata of the potential profit from the products herein described. Using the relatively new, highly eflicient Gillespie Edge-Gluer, however, to mention one of the available automatic devices, group after group of rough-cut boards of sundry widths are fed to the machine at one end, the adhesive is applied thereto instantaneously, and after an exceedingly brief treatment by the electronic drying component, a matter of seconds at the most, the fully bonded and fully dried boards emerge at the other end of the apparatus ready for planing or other handling. Obviously, such machines can be constructed to handle boards and glued-up slabs of any required size and width. They are manufactured for the Gillespie Furniture Co., 3011 E. Pico Blvd., Los Angeles, Calif., owners of the patents thereon.

In the vernacular of the lumber industry, the term dimensional is commonly employed to mean ordinary milled lumber (l by l2s, 2 by 4s, et cetera), whereby the same is clearly distinguished from plywood, which latter is generally fabricated in standard size sheets or so-called panels, and is not, therefore, merchandised according to the terminology associated with board footage. Where used herewithin, the term is to be interpreted according to the foregoing custom.

Likewise, the term fiat-cutwhich literally may mean any milled wood product from the thinnest fiat-cut flitches of veneerwood to the largest dimensional stockis to be construed herein as having been employed more particularly to dimensional board lumber and th like, whether quarter-sawed, slashed, or straightgrained, as distinguished from rotary-cut core- 'plies and other veneers per se, or such veneers when fabricated as standard run-of-the-mill plywood.

Wherein the term pattern-altering is employed-as in the claim section hereinafterthe same is understood to clearly distinguish treatments of a wood surface in such manner as literally to alter the original texture and/or the grain pattern thereof from a treatment wherein said surface is merely transparently stained or bleached in the natural, for illustration, without said natural grain pattern and/or said original texture of the wood having been thereby changed other than chromatically or merely rendered lighter or darker.

The term natural grain is to be construed herein as particularly distinguishing between surfaces wherein at least a portion of the original wood grain is quite visible, even though possibly clouded as would be the case in the moquette finishes. On the other hand, the so-called pueblo effects are not natural wood effects, since opaquely colored, even though the grain figure is again reproduced.

Iclaim:

1. The method of laminating a face-ply of raw, rotary-cut veneerwood to a base means, and subjecting said ply in its originally ruptured, unsanded state to a pattern-altering treatment; which treatment includes: toning the face-ply surface, which procedure comprises impregnating the same with a liquid wood-toner; fiuidly coating the pre-toned surface with a decorative filler material containing inert solids; removing a sufficient upper portion of said filler material to expose the uppermost ruptured, pre-toned surface wood in distinct but variously graduated contrast to the contiguously filled-and hence still variously obscured remaining areas thereof; drying said surface; and applying at least one protective coat of clear sealer material thereover.

2. The method of producing an upgraded, predecorated, and greatly improved article of manufacture from laminatable components thereofincluding low-grade core-ply components thereof-which includes: roughly ripping mill stock to produce therefrom given quantities of flat-cut boards, edge-glueing respective groups thereof to form individual, multiple-type slabs of substantially rigid core stock, laying up these slabs along with upper and lower facings of low-cost rotary-cut veneers to form the primary components of plywood panel stock, completing the lamination of said stock, and subjecting one of the face-ply sides of each laminated unit thereof to a decorative surface-altering treatment-including a thermochemically imposed toning treatment-to complete the upgrading of the respective composites; said thermochemically imposed toning treatment, per se, comprising the impregnation of said face-ply sides with a selected heat-sensitive toner, drying and heating said sides to bring out respective gradations of light and dark thermochemic tones in the outermost surface wood, and stopping said heat treatment short of the stage at which said gradations of tone would be obliterated by overtoning and decolorization.

3. The method which includes laminating a face-ply of rotary-cut veneerwood to a base means and subjecting said ply, in its normally ruptured, unsanded state, to a subsequent pattern-altering treatment; said treatment, per se, comprising: impregnating said face-ply with a selected chemical toner of the heat-sensitive type; drying and heating the impregnated faceply to bring out respective gradations of light and dark thermochemic tones in the outermost surface wood; stopping said heat treatment short of the stage at which said gradations of tone would be obliterated by overtoning; preparing a liquified filler, according to the known proportions of its constituents, to include an inert solid intermixed with a vehicle normal thereto; ap-

22' plying said liquified filler to said face-ply; and the removal of a sufiicient upper portion of this filler coat to expose the uppermost surface wood in distinct tonal contrast with the remaining, more densely filled portions thereof.

4. The method of laminating a face-ply of raw, rotary-cut veneerwood to a base means, and subjecting said ply in its originally ruptured, unsanded state to a pattern-altering treatment, this treatment including: impregnating the faceply surface with liquid means, including at least one heat-sensitive chemical in solution form; drying said surface; heating the same sufliciently to produce a tonal reaction between the dried residuum of said chemical solution and the impregnated wood component of said surface, and until the resultant tone pattern therein reaches a stage at which respective light and dark thermochemically toned portions of the variantly hard and soft grain surface wood present a decidedly contrasty efiect therebetween; stopping the heat treatment before overtoning results in obliterating said contrasty appearance; fluidly coating the thermochemically toned surface with a decorative filler material containing inert solids; removing a sufficient upper portion of said filler material to expose the uppermost ruptured, pre-toned surface wood in distinct but variously gradated contrast to the contiguously fi1led--and hence still variously obscured-remaining area thereof; drying said surface; and protectively sealing it.

5. A new volume production method of ornamenting wall panels and the like having a faceply of veneerwood which includes: imposing a pattern of shallow, high-low configurations on one side of each fully fabricated panel to be ornamented, filling the low areas with casting plaster, and scraping away the excess amount thereof to the common surface level, substantially, of the high configurations.

6. As a new article of commerce: a base means having laminated thereto a facing of rotary-cut veneerwood in its normally raw, originally ruptured state throughout the major portion thereof; which facing bears a substantially solidly opaque, film-forming lower coat of sealer material, and the latter in turn bears on the irregularly disposed lowermost surface portions of the same which lie within the crevasses of the ruptures, a deposit of pigmented filler of a contrasting tone to said first opaque coat a substantial component of which last is distinctly, irregularly exposed and visible through the filler overcoat in the form of an accenting and Wood-grain emphasizing medium; the thus defined facing presenting also the distinctly two-toned aspect and conformation characteristic of filled and wiped surfaces of the order described.

'7. The method which includes: filling a highlow configured wood surface with fluidly applied coating plaster, to lay thereon one component of a multitonal decorative scheme; scraping said surface to remove all possible excess plaster material above the component thereof which has become imbedded below the upper surface level, and before complete solidification takes place; drying the plaster-embedded surface, thereafter, sanding said surface to remove a sufficient further obscuring film of the plaster to more clearly expose the uppermost portions of said surface and, simultaneously, to produce a distinct tonal contrast between the clearly exposed surface References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 361,687 Gardner Apr. 26, 1887 1,117,341 Cross Nov. 17, 1914 1,180,516 McIndoe Apr. 25, 1916 10 Number 24 Name Date Schmid May 13, 1930 Caste Jan. 11, 1938 Casto Apr. 26, 1938 Deskey June 9, 1942 Strang Sept. 29, 1942 Kuehner Sept. 14, 1943 Lehman Apr. 4, 1944 Welch Apr. 29, 1947 Thompson Sept. 28, 1948

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