Molded wood composites having non-blistering profile with uniform paintability and nesting

摘要

A molded wood composite article man-made from wood fibers or wood particles on at least an upper, molded surface of the article, and a method of manufacturing the article to include a relatively uniform density, detailed design contours and textured aesthetics on one or more molded depression-interior inclined surfaces, while preventing embrittlement, softness and blistering of the article along the depression-interior inclined surfaces. These attributes are achieved by molding one or more depressions (20) into an initially planar layer of cellulosic material, wherein the molded depressions have one or more inclined walls (60) that have upper surfaces (62), along essentially an entire inclined span, that include detailed design contours, including adjacent curved and planar portions (64,66,) e.g. bead and cove. In one embodiment the angle of inclination of inclined upper wall surface (62) is 38° or less, e.g. about 25° to 38°. In another, the thickness of the inclined wall varies 20% or less in relation to the mean thickness which in turn is preferably about 2 to 15% thinner than the adjacent planar walls (46,72). The ends (68,70) of the inclined wall are preferably e.g. 1 to 12% less thick than the mean thickness of the wall between the ends.