US4175106A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Post press molding of man-made boards to produce contoured furniture parts
Assignee: Masonite Corp
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Filing: 1977-09-14
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Granted: 1979-11-20
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Expires: 1997-09-14
Abstract
Abstract Six-sided furniture parts are manufactured by pressing a cellulosic fiber-containing mat to consolidate said mat into a unitary blank, cutting the blank to a size larger than interior dimensions of a closed mold in every dimension and with two to four generally shaped or profiled edges disposed between a top surface and a bottom surface of the blank. The cut blank is then molded at a temperature of at least 500° F. for a period of time sufficient to permanently transfer the interior shape and design of the mold cavity to every surface of the blank.
Inventors
- 👤 John T. Clarke
- 👤 Allan J. Luck
- 👤 Roger F. Sutton
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 23:37
CPC Classifications
B; B27; B27N; B27N7/00; B27N5/00; B29; B29K; B29K2311/00; B29K2311/14
Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
146 words
A method of molding a cellulosic fiber containing board to form a three dimensional contoured part comprising: (a) compressing and heating a fibrous mass of cellulosic fibers to bond the fibers into a consolidated blank; (b) cutting the consolidated blank to a shape having a plurality of generally tapered edges and corresponding generally to the interior shape of a closed, contoured mold cavity wherein said cut blank is slightly larger than the interior dimensions of said mold cavity in each of its three dimensions; (c) inserting said cut blank in the open cavity of said contoured mold; (d) closing said mold; (e) hot-pressing said consolidated, cut blank in said mold at a temperature of 500° F. to 650° F. to reshape the blank in all three of its dimensions to form a contoured, molded product; and (f) opening said mold and removing said molded, contoured part.
Claim 2
Independent Claim
146 words
A method of molding a cellulosic fiber containing board to form a three dimensional contoured part comprising: (a) compressing and heating a fibrous mass of cellulosic fibers to bond the fibers into a consolidated blank; (b) cutting the consolidated blank to a shape having a plurality of generally tapered edges and corresponding generally to the interior shape of a closed, contoured mold cavity wherein said cut blank is slightly larger than the interior dimensions of said mold cavity in each of its three dimensions; (c) inserting said cut blank in the open cavity of said contoured mold; (d) closing said mold; (e) hot-pressing said consolidated, cut blank in said mold at a temperature of 500° F. to 650° F. to reshape the blank in all three of its dimensions to form a contoured, molded product; and (f) opening said mold and removing said molded, contoured part.
Claim 3
Dependent Claim
19 words
A method as defined in claim 1 wherein step (e) is carried out at a temperature of 525°-575° F.
Claim 4
Independent Claim
158 words
A method of forming a molded furniture part from a pre-formed cellulosic blank having a density greater than 35 pounds/ft. 3 to form a multisided contoured part, comprising: (a) cutting said pre-formed consolidated blank to a size slightly larger, in each of its three dimensions, than corresponding interior dimensions of a contoured closed mold cavity; (b) forming said consolidated blank with a plurality of generally tapered edges so that a portion of said blank will extend into said mold cavity, without force; and (c) inserting said cut blank into said mold; (d) closing said mold to cause said blank to conform to the contoured cavity of said mold and to reduce the size of said blank along all three dimensions, and to transfer details of said contoured mold cavity to the surface of said blank. (e) heating said closed mold to a temperature of 500° F.-650° F.; and (f) opening said mold and removing said contoured furniture part.
Claim 5
Independent Claim
158 words
A method of forming a molded furniture part from a pre-formed cellulosic blank having a density greater than 35 pounds/ft. 3 to form a multisided contoured part, comprising: (a) cutting said pre-formed consolidated blank to a size slightly larger, in each of its three dimensions, than corresponding interior dimensions of a contoured closed mold cavity; (b) forming said consolidated blank with a plurality of generally tapered edges so that a portion of said blank will extend into said mold cavity, without force; and (c) inserting said cut blank into said mold; (d) closing said mold to cause said blank to conform to the contoured cavity of said mold and to reduce the size of said blank along all three dimensions, and to transfer details of said contoured mold cavity to the surface of said blank. (e) heating said closed mold to a temperature of 500° F.-650° F.; and (f) opening said mold and removing said contoured furniture part.
Claim 6
Dependent Claim
19 words
A method as defined in claim 3 wherein step (e) is carried out at a temperature of 525°-575° F.
Claim 7
Independent Claim
156 words
A method of manufacturing a three dimensional, multi-sided part comprising: (a) pressing a cellulosic fiber-containing mat to consolidate said mat into a unitary blank having a density greater than 35 pounds/cubic foot; (b) cutting said blank to a size larger than interior dimensions of a closed mold in all three dimensions; (c) cutting the consolidated blank to form a plurality of generally tapered edges disposed between a top surface and a bottom surface of said blank; (d) inserting said cut blank into the open cavity of said contoured mold; (e) closing said mold; (f) hot pressing said unitary cut blank in said mold at a temperature of 500° F. to 650° F. for a period of time sufficient to permanently transfer the interior shape and design of the mold cavity to every surface of said blank and to re-shape said blank in all three dimensions; and (g) opening said mold to remove said three-dimensional, multi-sided part.
Claim 8
Independent Claim
156 words
A method of manufacturing a three dimensional, multi-sided part comprising: (a) pressing a cellulosic fiber-containing mat to consolidate said mat into a unitary blank having a density greater than 35 pounds/cubic foot; (b) cutting said blank to a size larger than interior dimensions of a closed mold in all three dimensions; (c) cutting the consolidated blank to form a plurality of generally tapered edges disposed between a top surface and a bottom surface of said blank; (d) inserting said cut blank into the open cavity of said contoured mold; (e) closing said mold; (f) hot pressing said unitary cut blank in said mold at a temperature of 500° F. to 650° F. for a period of time sufficient to permanently transfer the interior shape and design of the mold cavity to every surface of said blank and to re-shape said blank in all three dimensions; and (g) opening said mold to remove said three-dimensional, multi-sided part.
Claim 9
Dependent Claim
20 words
A method as defined in claim 5 wherein step (f) is carried out at a pressure not exceeding 750 p.s.i.
Claim 10
Dependent Claim
19 words
A method as defined in claim 5 wherein step (f) is carried out at a pressure of 30-700 p.s.i.
Claim 11
Dependent Claim
19 words
A method as defined in claim 7 wherein step (f) is carried out at a pressure of 100-500 p.s.i.
Claim 12
Dependent Claim
23 words
A method as defined in claim 5 wherein said mold includes a vent plate for the escape of gases formed in said mold.
Claim 13
Dependent Claim
15 words
The method of claim 1 wherein said three dimensional contoured part is a six-sided part.
References Cited (Backward Citations)
US3268642A
Cited
US4007076A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1982-11-19 | 1983-05-21 | 1983-11-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1986-11-19 | 1987-05-21 | 1987-11-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1990-11-19 | 1991-05-21 | 1991-11-20 | $7700.00 | Window Closed / Lapsed |