A reverse molded fiberboard panel; a wainscot kit comprising a plurality of differently sized reverse molded panels, and a planar finishing or spacer panel, adapted to completely cover any size wall between a wall base board and a wall chair rail; and a method of reverse molding a loose cellulosic m
A reverse molded fiberboard panel; a wainscot kit comprising a plurality of differently sized reverse molded panels, and a planar finishing or spacer panel, adapted to completely cover any size wall between a wall base board and a wall chair rail; and a method of reverse molding a loose cellulosic mat, in a single pressing step, to provide one or more relatively high density, raised panels without requiring preliminary pressing, or other pre-shaping step, such as scalping. The reverse-molded panels are molded in a conventional, multi-opening fiberboard press, in a single pressing step process, while achieving excellent transfer of mold detail (embossing fidelity) without visually noticeable fiber fracture.
대표청구항▼
What is claimed is: 1. A wood composite article having an exterior surface adapted to be exteriorly disposed and an opposite interior surface adapted to be interiorly disposed, said wood composite article reverse molded from a mat of refined cellulosic fibers and sufficient binder to adhere the cel
What is claimed is: 1. A wood composite article having an exterior surface adapted to be exteriorly disposed and an opposite interior surface adapted to be interiorly disposed, said wood composite article reverse molded from a mat of refined cellulosic fibers and sufficient binder to adhere the cellulosic fibers together into a structurally sound article, said wood composite article comprising: planar surface portions lying in a first plane for adhering to a planar surface of a substrate, the planar surface portions having a first thickness and a first specific gravity, and a contoured portion simulating natural wood millwork and having a rounded top portion that has an increased density at a rounded apex and extending outwardly from said planar surface portions toward a second plane, the contoured portion having a second thickness that is less than the first thickness, the contoured portion further having a second specific gravity that is greater than the first specific gravity, said refined cellulosic fibers at said exterior surface of said contoured portion stretched more than said refined cellulosic fibers at said interior surface of said contoured portion. 2. A wood composite article in accordance with claim 1, wherein the article includes less than 5% by weight resin binder. 3. A wood composite article in accordance with claim 2, wherein the resin binder is homogeneously distributed throughout the article. 4. A wood composite article in accordance with claim 3, wherein the article does not include a thermoplastic coating material on the cellulosic mat, and does not include a resin-impregnated paper overlay. 5. A wood composite article in accordance with claim 1, wherein the mat of cellulosic fibers is made by the dry process and has a smooth planar back surface. 6. A wood composite article in accordance with claim 1, wherein the contoured portion extends outwardly from the surrounding planar surface portions a distance of 5-10 mm. 7. A wood composite article in accordance with claim 1, wherein the cellulosic mat includes at least 40% by weight softwood fibers, based on the total weight of cellulosic fibers in the article. 8. A wood composite article in accordance with claim 7, wherein the softwood fibers are selected from the group consisting of pine, spruce and a mixture thereof. 9. A wood composite article in accordance with claim 8, wherein the cellulosic fibers are about 100% by weight softwood fibers. 10. A wood composite article in accordance with claim 1, wherein the contoured portion extends outwardly and inwardly from a surrounding planar surface at an angle in the range of 25-35°. 11. A wood composite article in accordance with claim 10, wherein the contoured portion extends outwardly and inwardly from a surrounding planar surface at an angle in the range of 30-35°. 12. A wood composite article in accordance with claim 1, wherein the planar surface portions are separable from the contoured portion. 13. The wood composite article of claim 1, wherein the second specific gravity of the contoured portion is in a range of 1.02 to 1.08, and wherein the first specific gravity of the planar surface portions is in a range of 0.98 to 1.00. 14. The wood composite article of claim 1, wherein the mat of refined cellulosic fibers is formed from at least 80% by weight fibrillated cellulosic fibers refined from wood chips, based on the total dry weight of the fibers in the mat. 15. The wood composite article in accordance with claim 1, wherein the contoured portion includes a plurality of raised, planar steps ascending upwardly and inwardly integral with rounded contours to the rounded top portion. 16. A wood composite article in accordance with claim 1, wherein the contoured portion has substantially uniform density in all but the rounded apex. 17. A wall structure comprising: a wood composite article in accordance with claim 1; and a planar wall substrate adhered to said interior surface of said planar surface portions of said article. 18. A wall structure in accordance with claim 17, wherein the planar wall substrate is secured to said interior surface of said article without a shim spacer disposed between said planar wall substrate and said planar surface portions of said article. 19. A reverse molded wood composite panel having an exterior surface adapted to be exteriorly disposed and an opposite interior surface adapted to be interiorly disposed, said wood composite panel reverse molded from a mat of refined cellulosic fibers and sufficient binder to adhere the cellulosic fibers together into a structurally sound article, said reverse molded wood composite panel comprising: a major planar portion lying in a first plane, the interior surface of said major planar portion being a back surface adapted to be interiorly disposed in order to be adhesively secured to a surface, said major planar portion having a first thickness and a first specific gravity, a planar panel portion lying in a second plane different than the first plane of said major planar portion, and a contoured portion having a rounded top portion that has an increased density at a rounded apex and extending outwardly from and relative to said first plane and interconnecting and integral with said major planar portion and said planar panel portion, said contoured portion having a second thickness that is less than said first thickness, said contoured portion further having a second specific gravity that is greater than the first specific gravity, said refined cellulosic fibers at said exterior surface of said contoured portion stretched more than said refined cellulosic fibers at said interior surface of said contoured portion. 20. The reverse molded wood composite panel of claim 19, wherein said planar panel portion is disposed outwardly relative to said major planar portion. 21. The reverse molded wood composite panel of claim 19, wherein said contoured portion includes a plurality of raised planar steps interposed between said major planar portion and said rounded top portion. 22. The reverse molded wood composite panel of claim 21, wherein rounded top portion that has increased density at a rounded apex. 23. The reverse molded wood composite panel of claim 22, wherein the contoured portion has substantially uniform density in all but the rounded apex. 24. The reverse molded wood composite panel of claim 19, wherein said contoured portion includes first and second contoured portions, said first contoured portion includes said rounded top portion and is proximate said major planar portion and said second contoured portion is proximate said planar panel portion. 25. The reverse molded wood composite panel of 24, wherein said first contoured portion extends outwardly relative to said planar panel portion and said second contoured portion extends inwardly relative to said planar panel portion. 26. The reverse molded wood composite panel of claim 19, wherein said planar panel portion is rectangular. 27. The reverse molded wood composite panel of claim 19, wherein said exterior surface includes a wood grain pattern. 28. The reverse molded wood composite panel of claim 19, wherein the second specific gravity of the contoured portion is in a range of 1.02 to 1.08, and wherein the first specific gravity of the major planar portion is in a range of 0.98 to 1.00. 29. The reverse molded wood composite panel of claim 19, wherein the mat of refined cellulosic fibers is formed from at least 80% by weight fibrillated cellulosic fibers refined from wood chips, based on the total dry weight of the fibers in the mat. 30. A supported wood composite article, comprising: a structural support having a planar support surface; and the wood composite article of claim 1 having the interior surface of said planar surface portions secured to the planar support surface of said structural support. 31. The supported wood composite article of claim 30, wherein said structural support comprises a wall. 32. The supported wood composite article of claim 30, wherein the interior surface of said planar surface portions is adhered to said planar support surface of said structural support without a shim spacer disposed therebetween. 33. A supported reverse molded wood composite panel, comprising: a structural support having a planar support surface; and the reverse molded wood composite panel of claim 19 having the interior surface of said major planar portion secured to the planar support surface of said structural support. 34. The supported reverse molded wood composite panel of claim 33, wherein said structural support comprises a wall. 35. The supported reverse molded wood composite panel of claim 33, wherein the interior surface of said major planar portion is adhered to said planar support surface of said support structure without a shim spacer disposed therebetween. 36. The supported reverse molded wood composite panel of claim 33, wherein said planar panel portion is disposed outwardly relative to said major planar portion, and wherein said interior surface of said planar panel portion is spaced apart from said structural support. 37. The supported reverse molded wood composite panel of claim 36, wherein a portion of the interior surface corresponding to said contoured portion is co-planar with a portion of the interior surface corresponding to said major planar portion.
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