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Patent Searching and Data


Title:
PROTECTIVE PANELS AND DOORS
Document Type and Number:
WIPO Patent Application WO/2005/106153
Kind Code:
A1
Abstract:
Protective panel and door structures, and methods for making same are disclosed. The protective panel and door structures incorporate a non­metallic protective sheet connected to one or more building panels. Methods are disclosed for applying various coatings to the protective panels, which may include the transfer of images to one or more surfaces of the protective panels during the fabrication process.

Inventors:
GYEMANT ROBERT E (US)
DANIELS EVAN R (US)
Application Number:
PCT/US2005/014334
Publication Date:
November 10, 2005
Filing Date:
April 26, 2005
Export Citation:
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Assignee:
TRIO IND GROUP INC (US)
GYEMANT ROBERT E (US)
DANIELS EVAN R (US)
International Classes:
B41M3/00; B41M5/035; B41M7/00; B44C5/04; E04C2/00; E04H9/10; E06B3/70; E06B5/10; E06B5/11; E06B5/12; E06B5/16; E06B5/18; (IPC1-7): E04C2/00
Foreign References:
US4404889A1983-09-20
US4732803A1988-03-22
Attorney, Agent or Firm:
Teaney, Douglas B. (LLP 77 West Wacker Drive, Suite 250, Chicago IL, US)
Download PDF:
Description:
Title of the Invention PROTECTIVE PANELS AND DOORS This application claims priority of the filing date of US non-provisional application serial number 60/565,683, filed April 27, 2004. Background of the Invention 1. The Technical Field [0001] The present invention relates generally to the field of building construction, and more particularly to panels and doors that provide protection against blasts, ballistics, storms and the like. 2. The Prior Art

[0002] In recent years, the increased publicity and incidents of drive by shootings, terrorist activities and "killer storms" have caused the government, businesses and individuals to become more concerned about the safety of persons and property at work and home. As described in U.S. Patent No. 5,768,841 to Swartz et al. (incorporated herein by reference in its entirety), the solution to these dangers is the addition of metal layers to buildings and building products. Similarly, U.S. Patent Application Publication No. 20040003546 to Sissons (incorporated herein by reference in its entirety) describes a metal sheet clad cage-like structure to provide protection against storms and earthquakes. Using metal layers or sheets within buildings, however, introduces metal-related problems, such as increased lightning attraction, electrocution risks, weight, structural problems, corrosion and the like. [0003] Other attempts to solve these problems have used complex component structures (e.g., U.S. Patent No. 3,930,452 to Van Laethem et al., U.S. Patent No. 4,567,100 to Pickett et al., U.S. Patent No. 4,822,657 to Simpson, U.S. Patent No. 4,948,673 to Goeury, U.S. Patent No. 5,060,553 to Jones, U.S. Patent No. 5,132,167 to Prato, U.S. Patent No. 5,190,802 to Pilato, U.S. Patent No. 5,326,606 to Labock, U.S. Patent No. 5,469,796 to Koenig, U.S. Patent No. 5,591,933 to Li et al., U.S. Patent No. 5,614,305 to Paine et al., U.S. Patent No. 5,660,021 to Wolgamot et al., U.S. Patent No. 5,668,344 to Bornstein, U.S. Patent No. 5,736,474 to Thomas, U.S. Patent No. 5,814,250 to Dudt et al., U.S. Patent No. 6,240,858 to Mandall, U.S. Patent No. 6,562,435 to Brillhart, III et a!., and U.S. Patent No. 6,568,310 to Morgan (all of which are incorporated herein by reference in their entirety)) or architectures (e.g., U.S. Patent No. 4,709,659 to Quante, III et al., U.S. Patent No. 4,928,468 to Phillips, U.S. Patent No. 5,640,824 to Johnson et al., U.S. Patent No. 6,279,287 to Meadows, U.S. Patent No. 6,363,867 to Tsilevich, U.S. Patent No. 6,4! 5,557 to McCalley (all of which are incorporated herein by reference in their entirety)). All of these solutions are costly to manufacture and install, and difficult to manufacture, install and maintain. As a result they are not generally available to the "common man." [0004] There is, therefore, a need for a protective panel and door that is relatively inexpensive, easy to manufacture, install and maintain, does not introduce the risks associated with metal and yet still provides protection against blasts, ballistics, storms and the like. Summary of the Invention [0005] The present invention provides a protective pane! and door that is relatively inexpensive, easy to manufacture, install and maintain, does not introduce the risks associated with metal and yet still provides protection against blasts, ballistics, storms and the like. [0006] In an embodiment of the invention, the invention comprises a protective panel apparatus, which in turn comprises at least one building panel; and at least one non-metallic protective sheet affixed at least indirectly, to the at least one building panel. [0007] Preferably, the at least one building panels is fabricated from at least one material from the group consisting of: architectural wallboard material; wood; wood composite. The at least one non-metallic protective sheet is preferably fabricated from at least one material, having at least one of the following characteristics: lightweight; impact resistant; bullet resistant; blast resistant; flame resistant; resistant to chemical attack. In a preferred embodiment of the invention, the at leas one non-metallic protective sheet is fabricated from Kevlar®. In a preferred embodiment of the invention, at least one building panel is directly affixed to the at least one protective sheet. The at least one building panel may affixed to the at least one protective sheet with adhesive. [0008] The protective panel apparatus may further comprise at least one layer or coating, fabricated from at least one material from the group consisting of: urethane foam; graphite; wire mesh; an electromagnetically opaque coating; a fire resistant coating or layer; a coating or layer resistant to chemical attack; a radiation resistant coating or layer. A second building panel, disposed so that the at least one protective sheet may be positioned between the at least one building panel and the second building panel. [0009] In another embodiment of the invention, the invention comprises a method for fabricating a protective panel, comprising the steps of: providing at least one building panel; providing at least one protective sheet; affixing the at least one building panel to the at least one protective sheet; placing the at least one building panel into contact with the at least one protective sheet. [0010] The step of affixing the at least one building panel to the at least one protective sheet may further comprise the steps of: applying an adhesive to a surface of at least one of the at least one building panel and the at least one protective sheet; curing the adhesive; and performing one or more finishing steps to the protective panel. [0011] The step of curing the adhesive may further comprise at least one of the following steps: placing an image on a surface of the protective panel; placing a protective coating on a surface of the panel; painting a surface of the protective panel. [0012] In another embodiment of the invention, the invention comprises a doorway structure, incorporating a protective panel. The doorway structure preferably comprises a door panel, including a first building panel; a second building panel; and at least one non-metallic protective sheet affixed to and disposed between the first and second building panels. At least one of the first and second building panels preferably has disposed on a side facing toward the at least one non-metallic protective sheet, a center cavity operably configured for receiving at least a portion of the at least one non- metallic protective sheet. [0013] In an embodiment of the doorway structure, at least one of the first and second building panels has disposed on a side facing toward the at least one non-metallic protective sheet a peripheral cavity operably configured for receiving at least a portion of a door frame structure. [0014] The doorway structure may further comprise a doorjamb structure operably configured to be disposed in a wall of a building, and further operably configured for pivotably supporting the door panel. At least one locking pin actuating/receiving apparatus is disposed in the doorjamb structure, having at least one locking pin therein. The at least one locking pin actuating/receiving apparatus is operably configured, upon actuation, to either deploy the at least one locking pin toward, or retrieve the at least one pin away from, the door panel. At least one locking pin receiving aperture is disposed in a peripheral region of the door panel, operably configured for receiving the at least one locking pin, upon deployment thereof. [0015] In another embodiment of the invention, the invention comprises a method for fabricating a protective panel apparatus, having an image disposed on at least one surface thereof, comprising the steps of: providing at least one building panel; providing at least one protective sheet; affixing the at least one building panel to the at least one protective sheet; applying at least one receptor coat to an outer surface of the at least one building panel; transferring an image onto the at least one receptor coat. [0016] The step of affixing the at least one building panel to the at least one protective sheet may further comprise the steps of: applying an adhesive to a surface of at least one of the at least one building panel and the at least one protective sheet; placing the at least one building panel into contact with the at least one protective sheet; and curing the adhesive, to form a protective panel. [0017] The method may further comprising the step of: applying at least one top coat over the at least one receptor coat. [0018] The step of applying at least one receptor coat may further comprise the step of applying at least one of: a powder, a radiation curable liquid, a solvent borne liquid. [0019] The step of applying at least one receptor coat may further comprise the step of applying at least one of: a liquid opaque base coat followed by a clear coat; an opaque powder followed by a clear powder; an opaque radiation curable liquid followed by a clear powder; an opaque radiation curable liquid followed by a clear radiation curable liquid. [0020] The step of transferring an image onto the at least one receptor coat may be accomplished by one of the following processes: dye sublimation; ink transfer; direct printing; non-contact printing; preprinting saturated paper. [0021] The step of transferring an image onto the at least one receptor coat is preferably one of: registered; staggered. [0022] The method may further comprise the steps of: pre-finishing the protective panel, prior to application of the at least one receptor coat. [0023] The method may further comprise the steps of: cleaning the protective panel, after pre-finishing has been completed. [0024] The method may further comprise the step of: embossing the surface of the protective panel. [0025] The method may further comprise the steps of: using at least one compliant platen to press a transfer material against a surface of the protective panel, for purposes of expelling air which may otherwise become trapped between the transfer material and the protective panel, when a transfer material is used for applying an image to the surface of the protective panel. [0026] Other features and advantages of the present invention will be apparent to those of ordinary skill in the art upon reference to the following detailed description taken in conjunction with the accompanying drawings. Brief Description of the Drawings [0027] FIG. 1 illustrates a perspective view of the elements of a protective panel structure in accordance with the present invention before assembly thereof. [0028] FIG. 2 illustrates a partially broken away cross-sectional view of the assembled protective panel structure of FIG. 1 made in accordance with the present invention. [0029] FIG. 3 illustrates a partially broken away cross-sectional view of a wall stud framework employing a protective panel in accordance with the present invention and a conventional wallboard panel product arranged side by side. [0030] FIG. 4 illustrates a process for making a protective panel in accordance with the present invention. [0031] FIGS. 5A, 5B and SC illustrate various views of a protective door in accordance with one embodiment of the present invention. [0032] FIGS. 6A, 6B and 6C illustrate various views of a protective door in accordance with another embodiment of the present invention. [0033] FIGS. 7A, 7B, and 7C illustrate various views of a protective door in accordance with another embodiment of the present invention. [0034] FIG. 8 illustrates an overall process for producing an image on one or more surfaces 10 of a protective panel or door in accordance with the present invention. [0035] FIG. 9 illustrates a more detailed process for producing an image on one or more surfaces of a protective panel or door in accordance with the present invention. [0036] FIG. 1OA illustrates a dye sublimation process for substantially flat protective panel or doors in accordance with the present invention. [0037] FIG. 1OB illustrates a cross sectional view of a product produced by the dye sublimation process of FIG. 1OA in accordance with the present invention. [0038] FIGS. HA and HB illustrate dye sublimation processes for non- flat protective panel or doors in accordance with the present invention. [0039] FIG. HC illustrates a cross sectional view of a product produced by the dye sublimation process of FIGS. HA and HB in accordance with the present invention. [0040] FIG. 12 illustrates an ink transfer process in accordance with the present invention. [0041] FIG. 13 illustrates a direct printing process in accordance with the present invention. [0042] FIG. 14 illustrates a non-contact ink transfer process in accordance with the present invention. [0043] FIGS. 15A and 15B illustrate cross sectional views of a product produced by an ink transfer, direct transfer or non-contact transfer process in accordance with the present invention. Detailed Description of the Invention

[0044] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not limit the scope of the invention. [0045] Now referring to FIGS. 1 and 2, a perspective view of the elements of a protective panel before assembly (FIG. 1) and a partially broken away cross-sectional view of the assembled protective panel after assembly (FIG. 2) made in accordance with the present invention are shown. The protective panel 100 includes a building panel 102 and non-metallic protective sheet 104 with an adhesive 106 there between. The building panel 102 may be: (1) any architectural wallboard product which is currently available or developed in the future and used to sheath wall studs in building or housing construction, such as gypsum wallboard, cementitous boards, fiber reinforced gypsum or such other architectural wallboard panel products which are used for building architectural finishes; (2) any wood or wood composite protective panel or door, which may include any type of man-made boards of bonded wood sheets and/or lignocellulosic materials such as veneer, fiberboard, particleboard, hardboard, waferboard, cardboard, strandboard, plywood, or any combination of these materials; or (3) floor or ceiling products, which may be a wallboard product, wood or wood composite protective panel or door, or tile. Note that building panels 102 made of wallboard or cement board may also have paper, fiber glass mesh or cardboard sheets disposed over a center or core material, which core materials are generally brittle, low strength materials. Likewise, building panels 102 made of wood or wood composites may have one or more surfaces that are horizontal or vertical (planar or substantially planar), or vary in two dimensions (contoured, molded or profiled). [0046] The building panel 102 may be of any shape depending on how and where the protective panel is to be installed. Typically, the building panel 102 is rectangular shaped. Non-metallic protective sheet 104 is selected to have an overall extent similar to that of building panel 102 to which it will be mated. Non-metallic protective sheet 104 may be made of any suitable light weight, non-metallic protective sheet material, such as Kevlar® by DuPont or other advanced composite material (woven, semi-rigid or rigid) that is impact resistant, bullet resistant or blast resistant. The non-metallic protective sheet 104 may also be flame and chemical resistant. The thickness of the non- metallic protective sheet 104 will depend on the properties of the non- metallic protective sheet material, the desired protective level (e.g., storm rated, ballistic rated, blast rated, etc.), the maximum desired thickness of the protective panel 100, the associated material costs, etc. As a result, FIG. 2 is not to scale because the non-metallic protective sheet 104 can be same thickness or thicker than the building panel 102. The protective panels are designed to satisfy various impact and fire related specifications, such as ASTM Fire Ratings, FEMA Standard 320, MIL-L-62472, MIL-L-62474, MIL-C- 44050, MIL 0108, UL 752, etc. [0047] Non-metallic protective sheet 104 is affixed to building panel 102 by an adhesive 106 applied to one of the mating major surfaces. The type of adhesive 106 used will depend on the material properties of the building panel 102 and the non-metallic protective sheet 104, and where the building panel 100 is to be installed (wall, partition, ceiling, floor, temporary installation, permanent installation, etc.). The adhesive 106 may be epoxy or glue, and may be applied by various means such as brushing or spraying, for example. A double sided tape may also be employed for some applications. The adhesive 106 may be applied to a portion or portions of one or both of the major surfaces. The adhesive 106 is, however, preferably spread over the extent of one of the major surfaces of one of either building panel 102 or non-metallic protective sheet 104 and is a water soluble latex based glue, isocyanate resin/glue, catalyzed glue (e.g., epoxies and contact cements) or urethane-based resin. The amount of adhesive 106 applied to adhere the building panel 102 and non-metallic protective sheet 104 together is an amount at least sufficient to hold these two members together such that the protective panel 100 can be handled and installed into its final application. In other words, the adhesive 106 applied between the building panel 102 and non-metallic protective sheet 104 must be of sufficient quantity to hold these two members together while the protective panel 100 is being handled, shipped and attached in place using typical building construction processes. The outward facing surface 108 can be finished to suit the environment in which the protective panel 100 is being installed, such as spackling, painting, covering by a plastering material or wallpaper, etc. [0048] Other layers or coatings may be added to the protective panel 100. For example, a layer of urethane foam can be added to reduce weight and sound transmission. Moreover, a graphite layer, pattern, coating or wire mesh can be added to the protective panel 100 to restrict electronic surveillance or stop electromagnetic pulses. Likewise, fire resistant, chemical resistant and radiation resistant coatings or layers can be added to the protective panel 100. [0049] Now referring to FIG. 3, a protective panel 100 attached to studs 300 of a skeletal framing structure of a building is shown. The protective panel 100 may be attached to studs 300 by adhesive, bolts, nails, rivets, screws or other fasteners 302. The protective panel 100 may also include pre-drilled holes for installation via nails, screws or similar fasteners. The protective panel 100 can be fabricated in special sizes or cut to fit on the building site using carbide or diamond tools. A wallboard panel 304 is shown attached next to the protective panel 100 illustrating one of the advantages of this invention, namely the relatively little change in thickness of the wall. As previously discussed, the thickness of the non-metallic protective sheet 104 and the resulting protective panel 100 will vary depending on the desired protection level. As a result, FIG. 3 is not to scale because the non-metallic protective sheet 104 can be same thickness or thicker than the building panel 102. The exterior surface provided by the protective panel 100 and wallboard panel 304 may be worked in any manner desired to provide a quality finished surface. For example, the exterior surface can be finished with a plastering material 306 such as stucco to provide a uniform finished surface. [0050] The non-metallic protective sheet 104, which is secured adjacent to the framing studs 300, will assist the building framework in resisting in-plane or shear loading stresses that are exerted on the building structure due to environmental conditions such as wind and earthquakes, or man-made conditions such as blasts. The non-metallic protective sheet 104 thus will help keep the building panel 102 from cracking due to in-plane or shear loads. The protective panels 100 can also be attached to building supports, such as studs, columns and cross members, using mechanical locking mechanisms in order to provide stronger blast ratings. [0051] Referring now to FIG. 4, a process 400 for making the protective panel 100 is shown. The building panel 102 and non-metallic protective panel 104 are prepared in block 402. The preparation process may include inspection, cleaning, priming, etc. An adhesive 106 is then applied to the surface of the building panel 102 that the non-metallic protective panel 104 is to be attached to in block 404. The non-metallic protective panel 104 is laid or brought into contact with the adhesive 106 in block 406. The adhesive 106 is then catalyzed or cured by heat, pressure, L)V or a combination thereof in block 408. The resulting protective panel 100 is finished in block 410, which may include additional processes, such as imaging, protective coatings, electromagnetic resistant coatings, painting, etc. This process can be automated and can be added to the end of a building panel 102 production line. [0052] The protective panels 100 having a building panel 102 of wood or wood composite protective panel or door as described above can be incorporated into many items, such as a drawer front, header, passage door, table top, counter top, tray, molding, flooring, display, shelving, shutters, furniture, boards for ready to assemble furniture, cabinet, pedestal, lectern, wall covering, panels and boards for construction, or any other wood product or object or part thereof. These applications can be used to protect important property, such as documents, computer and other equipment. The protective panels 100 can be used to make furniture so that an individual can hide under or behind the protective furniture in case of an emergency. [0053] Now referring to FIGS. 5A (top view), 5B (front view) and 5C (exploded view), various views of a protective door 500 in accordance with one embodiment of the present invention are shown. The protective door 500 includes a non-metallic protective layer 502 (woven, semi-rigid or rigid) disposed between two exterior panels (first exterior panel 504 and second exterior panel 506). As shown, the non-metallic protective layer 502 is a 3/8 inch sheet of Kevlar® and the exterior panels 504 and 506 are 3/4 inch medium density fiberboard ("MDF"). As previously described, other materials can be used. Moreover, the thickness of the nonmetallic protective layer 502 and the two exterior panels 504 and 506 may vary depending on the desired level of protection. The interior side of the exterior panels 504 and 506 has a center cavity 508 and 510, respectively to receive the non-metallic protective layer 502. The interior side of the exterior panels 504 and 506 also has a perimeter cavity 512 and 514, respectively to receive a door frame 516. The center cavity 508, 510 and perimeter cavity 512, 514 are machined using standard techniques and processes. The exterior panels 504, 506, non- metallic protective layer 502 and frame 516 are assembled and kept together using an adhesive, which is catalyzed or cured by heat, pressure, UV or a combination thereof. Standard fasteners can also be used. [0054] Other layers or coatings may be added to the protective door 500. For example, a layer of urethane foam can be added to reduce weight and sound transmission. Moreover, a graphite layer, pattern, coating or wire mesh can be added to the protective door 500 to restrict electronic surveillance or stop electromagnetic pulses. Likewise, fire resistant, chemical resistant and radiation resistant coatings or layers can be added to the protective door 500. [0055] Referring now to FIGS. 6A (top view), 6B (front view) and 6C (exploded view), various views of a protective door 600 in accordance with another embodiment of the present invention are shown. The protective door 600 includes a non-metallic protective layer 602 (woven, semi-rigid or rigid) disposed between two exterior panels (first exterior panel 604 and second exterior panel 606). As shown, the non-metallic protective layer 602 is a 3/8 inch sheet of Kevlar® and the exterior panels 604 and 606 are 7/8 inch MDF. As previously described, other materials can be used. Moreover, the thickness of the non-metallic protective layer 602 and the two exterior panels 604 and 606 may vary depending on the desired level of protection. The interior side of the exterior panels 604 and 606 has a center cavity 608 and 610, respectively to receive the non-metallic protective layer 602. The interior side of the exterior panels 604 and 506 also has a perimeter cavity 612 and 614, respectively to receive a door frame 616. The center cavity 608, 610 and perimeter cavity 612, 614 are machined using standard techniques and processes. The exterior panels 604, 606, non-metallic protective layer 602 and frame 616 are assembled and kept together using an adhesive, which is catalyzed or cured by heat, pressure, UV or a combination thereof. Standard fasteners can also be used. [0056] Other layers or coatings may be added to the protective door 600. For example, a layer 25 of urethane foam can be added to reduce weight and sound transmission. Moreover, a graphite layer, pattern, coating or wire mesh can be added to the protective door 600 to restrict electronic surveillance or stop electromagnetic pulses. Likewise, fire resistant, chemical resistant and radiation resistant coatings or layers can be added to the protective door 600. [0057] Now referring to FIGS. 7A, 7B, and 7C, various views of a protective door 700 in accordance with another embodiment of the present invention are shown. Protective door 700 is similar to protective doors 500 and 600, except that it contains several holes in the sides and top extending into the frame to receive locking pins 702. The locking pins 702 retract into the pin actuating box/receiver 704 when the protective door 700 is unlocked and extend into the protective door 700 with the protective door is locked. The locking pins 702 structurally tie the protective door 700 to the door frame 706, frame supports 708 and wall 710 to provide maximum protection against explosive blasts. The keypad 712 or other security authentication device is used to unlock the protective door 700. [0058] Other layers or coatings may be added to the protective door 700. For example, a layer of urethane foam can be added to reduce weight and sound transmission. Moreover, a graphite layer, pattern, coating or wire mesh can be added to the protective door 700 to restrict electronic surveillance or stop electromagnetic pulses. Likewise, fire resistant, chemical resistant and radiation resistant coatings or layers can be added to the protective door 700. [0059] The present invention also provides a method and system that produces a high quality, durable and economical protective panel or door having an image on at least one surface, in addition, this method and system can be implemented as a relatively high throughput production line process. Moreover, the present invention is applicable to a variety of coating processes, image transfer processes and types of image to be transferred. The specific coating and image transfer processes used are selected based on the type of image to be transferred and the specifications of the resulting protective panel or door. In all cases, the present invention provides improved reliability and registration of the image transfer. Inline processing also permits the imaging to be performed on partly cured or gel-stage coatings. [0060] Referring now to FIG. 8, an overall process 800 for producing an image on one or more surfaces of a protective panel or door in accordance with the present invention is shown. The process 800 begins in block 802 by providing a protective panel or door (as described above in reference to FIGS. 1-7) for processing. A receptor coat is then applied to at least the one or more surfaces of the protective panel or door in block 804. The receptor coat can be a clear or opaque coating and is used to ensure a quality image transfer to the protective panel or door. Clear receptor coats can be applied using a powder, a radiation curable liquid or traditional solvent borne liquid, which may include water. The powder can be applied using various electrostatic processes. The application of powder coatings typically requires the sub-steps of preheating, coating, curing and cooling. The application of radiation curable liquid coating requires the sub-steps of coating and curing. The application of traditional solvent coatings typically requires the sub-steps of coating and drying. Opaque receptor coats can be applied using any of the following dual coat process: a liquid opaque base coat followed by a clear coat; an opaque powder followed by a clear powder; an opaque radiation curable liquid followed by a clear powder; or an opaque radiation curable liquid followed by a clear radiation curable liquid. Opaque receptor coats may include white or colored pigments. In addition, opaque receptor coats can be applied using an integral pigmented coating of powder, radiation curable liquid or traditional solvent. [0061] The material chosen for the receptor coat should exhibit a moderate surface tension allowing "wetting" of the protective panel or door surface while subsequently allowing the ink/dye from the imaging process and the topcoat to "wet" the receptor coat. In addition, the material should exhibit a sufficiently high glass transition temperature (Tg) to prevent flow during the imaging process and the topcoat curing process. Partial cure of the receptor coat may be acceptable if receptor coat material Tg is sufficiently high. For example, a material exhibiting a maximum Tg of 1500C may be partially cured to a point at which the Tg measures HO0C. If the Tg of 1100C is sufficiently high, then the time and energy saved by the reduction of 4O0C provides a cost savings. Further curing and subsequent processing can raise the hardness to that required in the end use. In addition, an optional sanding and cleaning step may be performed prior to the image transfer process to remove artifacts from the receptor coat and improve adhesion of ink and/or topcoat. [0062] Thereafter the image is transferred to the one or more surfaces of the protective panel or door in block 806. The image transfer process may include dye sublimation, ink transfer, direct printing, non-contact printing or preprinting saturated paper. These processes will be described in more detail in relation to FIGS. 10A-10B, HA-HC and 12-15. The transferred image can be any graphic, such as a picture, pattern or coloration, etc. The image transfer process can be a registered (all imaged parts are the same) or staggered (adjacent imaged parts vary) process. The ink or dye used to transfer the image to the protective panel or door should exhibit a surface tension lower than that of the receptor coat and higher than that of the intended topcoat. In other words, the ink should "wet" the receptor coat and the topcoat should "wet" the ink. [0063] A topcoat is then applied to at least the one or more surfaces of the protective panel or door in block 808 to provide the finished product in block 810. Note that the topcoat is not required if the receptor coat has satisfactory properties. The topcoat may be applied using powder, radiation curable liquid, solvent or over-laminate. The topcoat should be transparent, non-yellowing, durable and provide sufficient adherence to the receptor layer. The topcoat may also have either a flat or glossy appearance. The material chosen for the topcoat should exhibit a sufficiently low surface tension to "wet" both the ink or dye laid down in the imaging process and those regions of the receptor coat that are not bearing ink or dye from the imaging process. In addition, the chosen material should exhibit acceptable adhesion to the ink or dye from the image transfer process and the receptor coat so that the topcoat will not "peel" or pull away from the ink or dye and the receptor coat. This is one factor in maintaining the high quality of the resulting product. [0064] Alternatively, the topcoat may be chosen to be receptive to stain so that the final color of the imaged part can be selected at a later date. Such coating may then be separately over-coated with a durable clear top coating formulation. It would need to be sufficiently durable to withstand the rigors of stacking and transportation, but these are typically less than those contemplated for the topcoat in final use. [0065] Proper cure conditions should be established for a through (100%) cure. Since the topcoat is used as a protective coating, it should exhibit maximal physical properties that are achieved only at advanced curing stages (i.e., highest possible molecular weights provide optimal mechanical properties). The material chosen should also be capable of providing the necessary tensile and compression strengths, mar and scratch resistance, etc. Moreover, appropriate film thickness should be established for the intended use of the resulting wood or wood composite product. A larger film thickness will be required for objects receiving extensive physical contact resulting in abrasion of the topcoat film. Appropriate application conditions for the topcoat can be established once the appropriate film thickness is established for the intended use of the wood or wood composite product. [0066] Now referring to FIG. 9, a more detailed process 900 for producing an image on one or more surfaces of a protective panel or door in accordance with the present invention is shown. The protective panel or door 902 is prepared in block 904 and pre-finished in block 906. Protective panel or door preparation 904 may include such things as shaping, edging, forming, routing, drilling, creating hardware recesses, sanding and/or cutting of the raw wood or wood composite protective panel or door 902. Protective panel or door pre-finishing may include such things as cleaning, polishing, sanding, sealing, staining and/or fillcoat/sanding. Note that sealing the wood or wood composite protective panel or door 902 at this stage of the process can reduce the thickness required for the receptor coat. Depending on the protective panel or door pre finishing 906 performed, the protective panel or door 902 is cleaned in block 908 by any typical process, such as brush, vacuum,-air jets, ionized air, static bars or any combination thereof. Thereafter, a receptor or base coat is applied to one or more surfaces of the protective panel or door in block 910. For example, the receptor coat can be applied to two sides of the wood or wood composite protective panel or door 902 by sending it vertically through the coater to coat both sides in one booth. The ends and sides of the protective panel or door 902 can also be coated during this process. Certain areas of the protective panel or door 902 may require a "touch up" depending on how the protective panel or door 902 is transported through the coater. Protective panel or doors in this orientation need to be coated by powder or spray, whereas horizontally oriented protective panel or door may be coated also by roll or curtain methods. [0067] As previously described, the receptor coat can be a dear or opaque coating and is used to ensure a quality image transfer to the protective panel or door. Clear receptor coats can be applied using powder, a radiation curable liquid or traditional solvent. The powder can be applied using various electrostatic processes. The application of powder coatings typically requires the sub-steps of preheating, coating, curing and cooling. The application of radiation curable liquid coating requires the sub-steps of coating and curing. The application of traditional solvent coatings typically requires the sub-steps of coating and drying. Opaque receptor coats can be applied using any of the following dual coat process: a liquid base coat followed by a clear coat; an opaque powder followed by a clear powder; an opaque radiation curable liquid followed by a clear powder; or an opaque radiation curable liquid followed by a clear radiation curable liquid. Opaque receptor coats may include white or colored pigments. In addition, opaque receptor coats can be applied using an integral pigmented coating of powder, radiation curable solvent or traditional solvent. Moreover, an optional sanding and cleaning step may be performed prior to the image transfer process 912 to remove artifacts from the receptor coat and improve adhesion of ink and/or topcoat. [0068] The image is then transferred to the one or more surfaces of the protective panel or door in block 912. The image transfer process may include dye sublimation, ink transfer, direct printing, non-contact printing or saturating paper. These processes will be described in more detail in relation to FIGS. 10A-10B, 1 IA-11C and 12-15. The sequencing of the protective panel or door 902 from the application of the receptor coat 910 to the image transfer process in 912 will vary depending on the type of image transfer process 912 used. For example, whenever a dye sublimation imaging process is used, such as is described below in reference to FIGS. 1OA, 1OB, HA, HB and HC, the immediate sequencing of the image transfer process 912 (dye sublimation) immediately after receptor coating 910 takes advantage of the energy imparted into the protective panel or door 902 by the drying or curing required in the receptor coating step 910. [0069] More specifically, a powder receptor coating process 910 typically raises the surface temperature of the protective panel or door 902 to 2500F — 35O0F and the UV cure can raise the temperature to 1500F to 2500F. Note that the drying of conventional receptor coatings can produce a similar result. It is well known that dye sublimation transfer on hot protective panel or doors 902 proceeds more effectively than on cool protective panel or doors 902, and gives a crisper more uniform and higher density image in a shorter time, often at lower temperature and/or pressure. Hence, preheating is commonly practiced. As a result, the delivery of a hot part (protective panel or door 902) from the receptor coating process 910 presents the protective panel or door 902 in a preferred condition. Ink transfer can also benefit from the protective panel or door 902 being at greater than ambient temperature, but to a lesser extent. There is little advantage for direct or non-contact printing, yet saturation may require this to suitably liquefy the saturating liquid. [0070] The transferred image can be any graphic, such as a picture, pattern or coloration, etc. The image transfer process 912 can be a registered (all imaged parts are the same) or staggered (adjacent imaged parts vary) process. The reality of the appearance of an image or pattern can be enhanced when the surface is embossed with a like pattern. This is especially true with wood grains and other natural patterns. Patterns can be readily embossed when the protective panel or door surface is soft. This occurs in the present invention described herein when the coatings are either hot, and therefore soft, or when they are in the gel form As a result, the final surface can be embossed with an embossing roll at the appropriate point in the process to produce a surface texture that compliments the transferred image. [0071] Note that if protective panel or doors 902 imaged by dye sublimation are stacked one atop the other immediately after the image transfer process 912, there is often an offsetting or ghosting of the image on the face side to the rear side of the protective panel or door 902. This effect can be minimized by either chilling the protective panel or door 902 so that the dye is trapped in the solidified matrix, or by placing a barrier material such as thick Kraft paper between the freshly imaged protective panel or doors 902. Chilling is, therefore, an optional step, which may be added to the system 900. The final topcoat, though, when well cured serves a similar purpose. Indeed, its composition may be chosen so that it is not a good solvent for the dye and so it will serve to trap the dye at elevated temperatures, negating the need for a barrier or a chiller. [0072] Accordingly, the topcoat is applied to at least the one or more surfaces of the protective panel or door in block 914 to provide the finished product in block 916. The topcoat may be applied using powder, radiation

curable liquid, solvent or over-laminate. The topcoat should be transparent,

non-yellowing, durable and provide sufficient adherence to the receptor layer.

The topcoat may also have either a flat or glossy appearance. The topcoat

may contain UV light absorbing chemicals and anti-oxidants to protect itself

and the underlying image from degradation.

[0073] The processes 800 and 900 can be implemented in a horizontal

or vertical production line or combination of both. The horizontal production

line can be implemented as a series of platens connected by a chain moving

on rollers on a floor level track. The protective panel or doors are laid flat on

the platen. In one embodiment of a completely horizontal production line, the

chain moves the platen and protective panel or door through the following

stations:

Step 1. Loading Step 2. Cleaner Step 3. Pre-heater Step 4. Receptor coat application Step 5. Receptor coat cure Step 5A. Sand and clean (optional) Step 6. Image transfer Step 7. Top coating Step 8. Final cure Step 9. Unloading

[0074] Preferably, such a production line will operate at a speed of

approximately 50 feet per minute with the protective panel or doors being

spaced approximately 50 inches apart. The exact operating speed and

spacing will depend on the coating and image transfer processes that are

selected. Note that the present invention is also applicable to low speed

production lines often used to produce specialty or single unit products.

[0075] As previously stated, the image transfer process 912 may

include any of the following processes: dye-sublimation transfer; ink or toner

transfer; lamination of a saturating (porous) printed paper; direct printing (e.g., flexography, gravure or letterpress); or non-contact printing (e.g.,

inkjet). For each imaging process 912 there are a large number of factors to

take into account when designing the process and developing the materials.

Some of these factors include: surface temperature during the imaging step;

gel degree of cure at the imaging step; base and top coating formulation;

residence time for transfer; pressure during transfer or imaging; ink

composition; carrier paper properties; printing process for the transfer

material; composition and properties of the saturating printed paper;

orientation of the wood or wood composite protective panel or door; support

and registration of the protective panel or door; yield and scrap propensity;

number of surfaces to be imaged; and productivity. The difference of these

imaging processes are further illustrated in the following table:

Consequently, it can be seen that each imaging process will have its

advantages and disadvantages.

[0076] Dye sublimation printing is named for the dyes used-these dyes

will enter the gas phase at elevated temperature, and so become very

mobile. When adjacent to a material in which they are very soluble, the dyes

will migrate there. For example, polyester at 3500F, above its glass transition

temperature, is an excellent receptor for these dyes. Articles made from or coated with polyester, polyamides and similar polymers, can be imaged by dye sublimation. The imaging is carried out by first printing the image in mirror form onto a donor or transfer sheet, usually paper, laying the paper on to the polyester layer, then pressing the sandwich at elevated temperature for a suitable time. An example of the process conditions typically used for imaging hot rigid protective panel or doors is 30 to 60 seconds at 4000F at 10 psi. [0077] Typical conditions for dye sublimation imaging hot rigid protective panel or doors are 20 to 60 seconds, 4000F, 10 psi. There are three primary processes for the transfer: flat bed, continuous belt and rotary presses. The flat bed press is used solely for piece goods, both flexible and rigid. Continuous belt presses, such as described below in reference to FIGS. 1OA and HB, may be used for both piece and web goods. They are particularly suited for piece goods being imaged from web transfer paper. Rotary presses are suitable only for flexible protective panel or doors whether piece or continuous. In the flat bed press, such as described below in reference to FIG. HA, the sandwich of the protective panel or door and the printed transfer paper is placed between the platens of the press. The top platen is always heated-the bottom may be also, and is typically heated when the protective panel or door is prone to warp age from uneven top and bottom heating. It may also assist with the rate of dye transfer. The press is closed for the required duration and the transfer proceeds. On opening the paper is removed from the protective panel or door and the protective panel or door from the press. [0078] Presses are typically loaded and unloaded manually, although automated systems are available. The continuous belt press comprises two endless belts each rotating about two rollers. The belts are mounted so that one is directly above the other, and the top of the lower belt is in close proximity to the bottom of the belt. The two belts are driven in opposite rotation so that where they meet they run together. Pressure is applied to the belts in the area between the drive rolls by pads or rollers. The rollers and the pressure device may also apply heat, or the whole assembly may be heated. Image transfer is affected by passing the sandwich of the printed transfer paper and the protective panel or door through the press. Both piece goods and continuous webs may be processed. Loading and unloading are typically automatic. Belt presses are preferred for high volume production. [0079] Referring now to FIG. 1OA, a dye sublimation process 1000 for substantially flat protective panel or doors 1002 in accordance with the present invention is shown. The process includes a continuous belt press having an upper endless metal belt 1004 wrapped around first and second upper hot rollers 1006 and 1008, and a lower endless metal belt 1010 wrapped around first and second lower rollers 1012 and 1014, all of which are contained within an oven (not shown). The first and second lower rollers 1012 and 1014 may or may not be heated to a small degree, so that a realistic finish is achieved when the edges and ends of a protective panel or door are also receptor coated and imaged. Indeed this attribute distinguishes this invention from both veneer and lamination, which must show edge joints. A donor or transfer material 1016 is unwound from a supply roll 1018, transported through the oven via contact with the upper endless metal belt 1004 and rewound on take up roll 1020. The donor or transfer material 1016 is a paper, fabric, PET film or other suitable medium in either sheet (good for pictures) or web (good for continuous repeating patterns) form containing dyes 1022 representing the images to be transferred. Web offset printed paper or transfer material 1016 offers pictures on a web and may be preferred for certain high volume applications. In addition, there are a variety of digital and traditional processes for the initial printing of the transfer material 1016. [0080] Registration of the image on the protective panel or door 1002 is a frequent requirement. For this, the transfer material 1016 is typically provided with registration marks that can be distinguished by automated systems and used to control the position of the transfer material 1016 relative to the protective panel or door 1002. Such systems are available and well known. The pattern-repeat distance on continuous pattern transfer material 1016 is typically different from the dimensions of the protective panel or door 1002. At the operator's option, the registration can be adjusted so that the images on all protective panel or doors 1002 are identical, or the registration can be staggered or randomized so there is continual variability in the placement of the pattern on the protective panel or doors 1002. In particular, processing the protective panel or door 1002 so that the short edge is parallel to the chain direction may ensure that where the repeat distance is long, there is no visible repeating pattern of the image on the protective panel or door 1002. This is considered advantageous for the production of wood grain and other natural patterns. The availability of digitally printed dye sublimation transfer material 1016 allows short runs, demonstrations, prototype manufacture and proofing using this process to be relatively inexpensive. Yet, because the transfer material 1016 can also be printed by flexography, gravure or offset it is also very economical for very large production runs. If two sided imaging is desired, a second donor or transfer material 1024 is unwound from a supply roll 1026, transported through the oven via contact with the lower endless metal belt 1010 and rewound on take up roll 1028. In this case, the first and second lower rollers 1012 and 1014 should be heated. [0081] The wood or wood composite protective panel or door 1002a, which comprises at least a base protective panel or door 1030 and receptor coat 1032, enters the image process 1000 at point A. As the protective panel or door passes though the image process 1000, the donor or transfer material 1016 is heated and pressed against the receptor coat 1032 by the upper endless metal belt 1004 wrapped and the first and second upper hot rollers 1006 and 1008. The lower endless metal belt 1010 and the first and second lower rollers 1012 and 1014 maintain pressure against the base protective panel or door 1030. Good contact between the transfer material 1016 and the receptor coating surface 1032 is required, which may be difficult to achieve if the surface is rough or ragged. At point B, the dye 1022 is transferred to and permeates the receptor coat 1032 in gaseous form 1034. At point C, the wood or wood composite protective panel or door 1002b exits the process having an image 1036 within the receptor coat 1032. Residual dye components 1038 remain on the donor or transfer material 1016. [0082] The dye sublimation process 1000 produces images that are very vivid and crisp. In addition, the image adds no real thickness and does not stand above the surface, which is a deficiency of direct printing. As a result, the surface is usually little changed by the imaging process. The gamut is wide and the selection of graphics is extremely broad. This image transfer process can be used to transfer images to both the top and bottom of horizontal wood or wood composite protective panel or door at same time. In addition, both sides at can be done at one time, and both ends can be done at another time. As a result, putting separate images on all these surfaces will make a more realistic wood imitation. The image can be applied cross-wise on the wood or wood composite protective panel or door so that there will be no repeat pattern visible on any protective panel or door. Staggering the start point will allow subsequent protective panel or doors to be different rather than duplicates. Note that the image can wrap edges and ends to a small degree. [0083] For example, the printed transfer paper or material 1016 is normally wider than the protective panel or door 1002 to be imaged. When using either dye sublimation or ink transfer (FIG. 12), the excess width may be chosen so that it is greater than the depth of the side of the protective panel or door 1002. The transfer material 1016 can, therefore, be wrapped around the side and processed in a like manner to the first surface so that the image is transferred onto the sides of the protective panel or door 1002. In this way, three of the six faces of a protective panel or door 1002 can be imaged in one process sequence. Should the two primary faces of a protective panel or door 1002 need to be imaged, then the sealer (if any) and receptor coating 1032 should be applied to both faces. The image is then transferred to the first face by the method selected from those described herein, the protective panel or door 1002 is flipped and the second surface imaged by whichever method is most appropriate for the second face. The protective panel or door 1002 then moves on to top coating. If four of the six faces of the protective panel or door 1002 are to be imaged, then a sequence of imaging the first face, the first two sides, flipping the protective panel or door 1002 and then imaging the final face can be followed. If required, the protective panel or door 1002 can be rotated through 90 degrees so that the ends can be imaged by a similar process. The protective panel or door then moves on to top coating. [0084] If the protective panel or doors are moved with the short edge parallel to the chain direction, there need be no repeating pattern visible on any part as long as it is sufficiently small, such as 36 inches. Changing the register of the print on the board can be used to make each top a little bit different in appearance. Short runs, demonstration, prototype manufacture and proofing using this process are relatively inexpensive. Note that the relatively long dwell time required for the diffusion of the dye 1022 from the transfer material 1016 into the receptor coat 1032 makes continuous belt transfer presses preferable for large volume production of large items as contemplated in this invention. Alternatively, flat bed presses with automated loading and unloading may also be used for high volume production if they operate at very high pressure so that the rate of diffusion of the dye 1022 is accelerated. [0085] To ensure a good quality image, the receptor coat should be made of polyester, polyamide or coated with polyester, polyamide or a similar material. Formulations that accept disperse dyes are well known. The dye sublimation process 1000 allows the use of receptor coat formulations that function at 300 to 3500F, rather than 4000F if the ink on the transfer material 1016 and the press conditions are optimized. Such formulations tend to be soft and tacky, or in the so-called gel state. Often the receptor coat 1032 is incompletely or only partially cured. Typically, the transfer material 1016 will become irreversibly bonded to the receptor coat 1032 during the image transfer press step. This may be prevented by laying a very thin film of, polyethylene for example, on the surface of the receptor coat 1032 before the image is transferred. The film is removed after the image transfer with the used transfer material 1016. Alternatively the ink layer 1032 on the printed transfer material 1016 can be over coated with a thin layer of film forming material that also allows the sublimation dye to pass through, but which will not itself adhere to the receptor coat 1032 in its gel or soft state. Moreover, the protective panel or door and coatings must stand high temperatures for extended times. The process is also relatively slow compared to some of the other image processes. Metallic colors do not reproduce very well using this process. Furthermore, disperse dyes are sensitive to UV induced fade. Note that the image properties are not all discernible on the transfer paper-transfer onto the receptor of choice is often necessary. [0086] Now referring to FIG. 1OB, a cross sectional view of a product 1050 produced by the dye sublimation process 1000 of FIG. 1OA in accordance with the present invention is shown. The finished product 1050 includes a base wood or wood composite protective panel or door 1052 that has a layer of stain 1054 on the top surface of the protective panel or door 1052 and a layer of sealant 1056 on the top surface of the stain layer 1054. Note that the stain layer 1054 and the sealant layer 1056 are optional layers applied during the protective panel or door pre-finishing process 906 (FIG. 9). The receptor coat 1058 is applied to the top surface of the sealant layer 1054 during the receptor coating process 910 (FIG. 9). As described in reference to FIG. 10A, the dyes 1060 forming the desired image are within the receptor coat 1058. The topcoat 1062 is then applied on the top surface of the receptor coat 1062 during the top coating process 914 (FIG. 9). The receptor coat 1058, dyes 1060 and topcoat 1062 are required for the present invention. Although reference is made to the top surface of the various layers, the applicable surface is any portion of the base protective panel or door 1052 on which an image is to be transferred. In other words "top surface" could actually refer to the top, bottom, sides, ends or other surface of the base protective panel or door 1052. In addition, the layers described above may apply to some or all surfaces of the base protective panel or door 1052. [0087] Referring now to FIGS. HA and HB, dye sublimation processes 1100 and 1150 for non-flat protective panel or doors 1110 and 1168 in accordance with the present invention is shown. Non-flat protective panel or doors 1110 and 1168 can be separated into two categories — those with consistent cross-sections in the direction of process flow, such as moldings and trims, and those with cross-sections that vary in both the direction of process flow, and across the direction of process flow, such as panel doors. As shown in FIG. HA, an image can be produced by process 1100, which includes a flat bed press having a heated top platen 1102 and a bottom platen 1102. The top platen 1102 is substantially planar except for a long stationary transfer nip, protrusion or reverse impression 1106. The transfer nip 1106 is a long heated molded plate that conforms in cross-section closely to the cross-section of the protective panel or door 1110 (including recess 1108). The top platen 1102 and transfer nip 1106 are preferably, but not necessarily, coated with a non-stick material, such as Teflon®, to allow the non-flat protective panel or door 1110 to move smoothly. [0088] The non-flat protective panel or door 1110 includes base protective panel or door 1112 and receptor coat 1114. The recess 1108 can be any multi-dimensional surface, such as moldings or trims, as long as proper contact and pressure can be maintained to transfer the image. Moreover, the term recess can included multi-dimensional surfaces that extend above the "main" surface of the protective panel or door 1110. A donor or transfer material 1116 is unwound from a supply roll 1118, transported along the upper platen 1102 and rewound on take up roll 1120. The donor or transfer material 1116 is a paper, fabric, PET film, or other suitable medium in either sheet (good for pictures) or web (good for repeating patterns) form containing dyes 1122 representing the images to be transferred. Note that the type of transfer material 1116 will depend greatly on the complexity of the recess 1108 and the image to be transferred. It may be advantageous to use a treated transfer material 1116 so that its side in contact with the top platen 1102 contains slip and non-stick agents. Such materials are well known. When the protective panel or door 1110 has a consistent cross-section in the longitudinal direction, paper is the preferred transfer material 1116 because it is not required to, and preferably should not, stretch. As a result, paper will not be a good transfer material 1116 for most three-dimensional recesses 1108. [0089] Once the protective panel or door 1110 is properly positioned within the press, the top platen 1102 descends and forces the transfer material 1116 into contact with the receptor coat 1114 to transfer the image at specific time, temperature, and pressure. The dye 1122 is transferred to and permeates the receptor coat 1120 in gaseous form. Residual dye components 1124 remain on the donor or transfer material 1116. On exiting the transfer zone the transfer material 1116 is removed by mechanical or vacuum means. It may be advantageous to slit the transfer material 1116 and use two or more removal flows for higher process efficiency. The protective panel or door 1110 at this point is imaged and ready for top coating. [0090] With respect to FIG. HB, the process 1150 includes a Hymmen press having an upper endless metal belt 1152 wrapped around first and second upper hot rollers 1154 and 1156, and a lower endless metal belt 1158 wrapped around first and second lower rollers 1160 and 162, all of which are contained within an oven (not shown). The first and second lower rollers 1160 and 1162 may or may not be heated. The upper endless metal belt includes one or more protrusions or reverse impressions 1164 that are designed to mate with the recess 1166 in the non-flat protective panel or door 1168. The non-flat protective panel or door 1168 includes both protective panel or door 1170 and receptor coat 1172. The recess 1166 can be any multidimensional surface, such as moldings, routing, or insets, as long as proper contact and pressure can be maintained to transfer the image. Moreover, the term recess can include multidimensional surfaces that extend above the "main" surface of the protective panel or door 1168. A donor or transfer material 1174 is unwound from a supply roll 1176, transported through the oven via contact with the upper endless metal belt 1152 and rewound on take up roll 1178. The donor or transfer material 1174 is a paper, fabric, PET film or other suitable medium in either sheet (good for pictures) or web (good for repeating patterns) form containing dyes 1180 representing the images to be transferred. As described in reference to FIG. 1OA, two sided imaging can be accomplished using a second donor or transfer material (not shown) and the lower endless metal belt 1158, and first and second lower rollers 1160 and 1162. In addition, the actual image transfer mechanism is the same as described in reference to FIG. 1OA, including dyes 1182 in gaseous form and residual dye components 1184. [0091] Alternatively, the upper endless belt can be replaced with a device, which ensures proper transfer material to receptor coating contact for the required dwell at a suitable pressure and temperature. The device may include one or more rollers shaped to match the profile of the protective panel or door being imaged and operating at suitable pressure and temperature. The additional steps required to ensure the transfer material conforms to the protective panel or door contours are preferentially completed before the high temperature transfer step begins. A continuous web transfer material works especially well for this process. The transfer material is unwound from the supply roll and fed through a series of angled compliant rollers so that its shape is gradually brought to match that of the protective panel or door cross-sectional topography. An extended series of rolls is preferred when the features of the protective panel or door are deep and/or steep, so that the transfer material is molded to the protective panel or door in a series of small steps. This avoids creasing or wrinkling. When the transfer material is properly fitted to the protective panel or door, the resulting sandwich can then be pressed by the molded platen of a stationary press as shown FIG. HA, or by a continuous transfer press as shown in FIG. HB. so that the ink adheres permanently to the receptor coating. A radiant or hot air heater may be applied to the back of transfer material before the transfer roll to aid in heating the ink to the preferred operating temperature and/or to dry the transfer material. When the protective panel or door has a consistent cross-section in the longitudinal direction, paper is the preferred transfer material because it is not required to, and preferably should not, stretch. On exiting the transfer zone the transfer material is removed by mechanical or vacuum means. It may be advantageous to slit the transfer material and use two or more removal flows for higher process efficiency. The protective panel or door at this point is imaged and ready for top- coating. [0092] When the protective panel or door cross-section varies both in the direction of process flow, and across the direction of process flow, the dye sublimation transfer process again requires that the transfer material be matched with the protective panel or door to form a sandwich prior to the transfer. The matching requires the transfer material to take on a three- dimensional shape, which in turn requires it to stretch and/or shrink to conform. A transfer material derived from cellulosic materials is generally unsuited for this use as it lacks suitable stretch. Transfer materials derived from plastic materials such as polyolefins and polyesters are preferred, whether in film or fibrous form. This matching to form the sandwich is accomplished with a top platen, or series of top platens, that closely fits the shape of the protective panel or door. When there is only one platen and it also-functions as the heated platen which effects the conditions for dye sublimation transfer, that is, a dwell at 3000F to 4000F, 20 to 60 sec and 5 to 100 psi. Alternatively, and preferably, the conforming is effected by a first platen or a first series of platens that operates at a temperature and pressure sufficient to mold the transfer material to the shape of the protective panel or door yet not initiate transfer. When the transfer material is a polyolefin this may occur at temperatures between 2000F and 3000F. The sandwich of transfer material and protective panel or door then is inserted or drawn into the press where there is a top platen which presses the transfer material to the protective panel or door under the conditions preferred for dye sublimation transfer, 3000F to 4000F, 20 to 60 seconds and 5 to 50 psi. After this the sandwich is removed from the press, the spent transfer material is removed and the object is ready to move to the next stage, typically top coating. [0093] When pressing objects with variable topography, removal of the air between the transfer material and the receptor coat becomes more difficult. While it may be considered advantageous to use a porous transfer material carrier, this approach tends to contaminate the platen with dye that may interfere with subsequent images, especially if the pattern in use is not being repeated in tight registration. The steps in bringing the transfer material into close conformation with the non-planar surface of the protective panel or door are, therefore, chosen so that air is expelled and not trapped. Such a pre-application system may be a relatively soft compliant platen, or it may be a series of compliant platens, shaped so that air is steadily squeezed out. Alternatively, the pre-application system may be in the form of a roll or series of rolls that progressively squeezes out the air. When a pre-application system is not used, the top platen may comprise a relatively conformable material, such as a silicone rubber shaped so that contact is made in a way that does not trap air, or it may be a flexible platen attached to a belt so that the air is sequentially squeezed from between the transfer material and the receptor coating of the protective panel or door. Note that an electrostatic charge can be used to assist adhering the image transfer material web to the protective panel or door — the two are charged oppositely by ionized air or similar charging device. [0094] As will be appreciated by those skilled in the art, the size and shape of the contours of the protective panel or door affect both the speed at which the protective panel or door can be processed and the quality of the transferred image. For example, grooves with walls at low angle to the plane of the top surface can be processed readily, but those with steep walls are more difficult. Similarly, angles and corners that are rounded process more readily than those that are square or sharp. The balance between design and process efficiency will in large part dictate which of the above described image transfer methods are acceptable for a given project. [0095] Now referring to FIG. HC, a cross sectional view of a product 1130 produced by the dye sublimation processes 1100 and 1150 of FIGS. HA and HB in accordance with the present invention is shown. The finished product 1130 includes a base wood or wood composite protective panel or door 1132 having a recess 1134, which can be any multidimensional surface, such as moldings, routings or inserts, that are above or below the main surface of the base protective panel or door 1132. A layer of stain 1136 is on the top surface of the base protective panel or door 1132 and a layer of sealant 1138 is on the top surface of the stain layer 1136. Note that the stain layer 1136 and the sealant layer 1138 are optional layers applied during the protective panel or door pre-finishing process 906 (FIG. 9). The receptor coat 1140 is applied to the top surface of the sealant layer 1138 during the receptor coating process 910 (FIG. 9). As described in reference to FIG. 1OA, the dyes 1142 forming the desired image are within the receptor coat 1140. The topcoat 1144 is then applied on the top surface of the receptor coat 1140 during the top coating process 914 (FIG. 9). The receptor coat 1140, dyes 1142 and topcoat 1144 are required for the present invention. Although reference is made to the top surface of the various layers, the applicable surface is any portion of the base protective panel or door 1132 on which an image is to be transferred. In other words, "top surface" could actually refer to the top, bottom, sides, ends or other surface of the base protective panel or door 1132. In addition, the layers described above may apply to some or all surfaces of the base protective panel or door 1132. [0096] Referring now to FIG. 12, an ink transfer process 1200 in accordance with the present invention is shown. In the ink transfer process 1200, all the ink 1202 is transferred from the transfer material 1204 to the receptor coat 1206 by hot lamination. More specifically, the receptor-coated wood or wood composite protective panel or door 1208 enters the process 1200 at point A. At point B, ink 1202 is transferred from the transfer material 1204 to the receptor coat 1206 by means of a heated roller 1210 that applies sufficient pressure to transfer material 1204 and receptor coat 1206 to cause the ink 1202 to transfer to the receptor coat 1206. The transfer material 1204 is unwound from a supply roll 1212, transported across roller 1210 and rewound on take up roll 1214. At point C, the image formed by inks 1202 has been transferred to the receptor coat 1206 of protective panel or door 1208. [0097] Transfer materials 1204 may be printed by traditional analog means (gravure or 25 flexography) as well as now by digital processes (e.g., ink jet) so the advantages of each process can be considered in determining that which is most appropriate for any situation. A clear coating may also be transferred from the transfer material 1204 to give a wear coat or a coating for later staining. The wear coat will be sufficiently durable to ensure the image is not damaged during subsequent processing or transportation, yet be amenable to over-coating with a highly durable topcoat. Either a plastic film or a paper may be used as the transfer material 1204 to carry the transfer image. Paper is preferred for economy. It is important that the transfer material 1204 be processed without wrinkles or creases. The means to achieve this have been previously described. The transfer material 1204 has a release surface which has sufficient adhesion to hold the ink during manufacture and processing, yet sufficient release to allow complete transfer of the image when the ink is firmly bonded to the receptor coat 1206 during the image transfer step. Such transfer materials 1204 are said to have "tight release" and are well known to those familiar with the art. [0098] This process provides good resolution, crisp images, a very large color gamut and true metallic colors. In addition, any heat stable colorant can be used. For example, if the colorants typically chosen for automotive and exterior building paints are selected, the finished article can be used for extended long term outdoor applications. Ink transfer also allows the designer to select both opaque and transparent inks. Thus, an opaque white ink may be used as background for a pattern when it is not desired to have a fully white protective panel or door. This can obviate the need to apply an opaque white base coat which can be used to advantage for cost or design purposes, for example when a picture is desired over a part of a simulated wood grain surface. A further advantage is that the transfer material 1204 for the ink is itself a release sheet. Therefore, it will not adhere to a gel, soft or partially cured receptor coating and so the method may be used to image or decorate surfaces with such characteristics. Ink transfer is typically applied with a rubber covered roll 1210, which extends the image a small distance around corners of small radius. Thus, if two adjacent surfaces are imaged, the pattern need not show a seam or joint, and this advantageously differentiates this process from veneer or lamination. The image can wrap edges and ends and is thin-seldom more than 0.5 mils. Moreover, this process 1200 only requires moderate processing conditions (from room temperature to 3000F depending on the materials used). The process 1200 is readily processed at moderate speed on roll transfer equipment. [0099] Ink transfer typically is processed at what are considered moderate conditions — typically 2000F to 3000F, and at speeds up to 100 fpm. It is, therefore, not stressful on most of the protective panel or door compositions contemplated in this invention. Nevertheless, steps such as differential heating from top to bottom may be required to ensure flatness and stability of the protective panel or door 1208. The transfer material 1204 for ink transfer imaging can be prepared by digital means such as ink jet or electrography (in which case the toner functions identically to ink). Thus proofs, prototypes, demonstration articles and short runs can all be produced economically. [0100] Now referring to FIG. 13, a direct printing process 1300 in accordance with the present invention is shown. In the direct printing by contact process 1300 (e.g., flexography or gravure), the image is from a roll 1302 to the receptor coat 1304. Gravure printing uses a hard metal surfaced roll and has the advantages of high life and high resolution graphics. However, the hard roll is unforgiving of variations in the thickness of planarity of the protective panel or door and so is prone to misses and gaps. Flexography uses rubber rolls for the transfer and so is less susceptible to the consequences of slight protective panel or door deformation. However, it is more likely to demonstrate wear from extended use. More specifically, the receptor-coated wood or wood composite protective panel or door 1306 enters the process 1300 at point A. At point B, ink 1308 is transferred from the roller 1302 to the receptor coat 1304 by direct contact. At point C, the image formed by inks 1308 has been transferred to the receptor coat 1304 of protective panel or door 1306. [0101] Referring now to FIG. 14, a non-contact ink transfer process 1400 in accordance with the present invention is shown. In the non-contact image transfer process 1400 (e.g., inkjet), a large number of nozzles contained in a print head 1402 that transfer ink 1404 directly to the receptor coat 1406. More specifically, the receptor-coated wood or wood composite protective panel or door 1408 enters the process 1400 at point A. At point B, ink 1404 is transferred from the print head 1402 to the receptor coat 1406. At point C, the image formed by inks 1404 has been transferred to the receptor coat 1406 of protective panel or door 1408. Note that this process 1400 does not work well with non-planer surfaces and tends to be slow relative to the other processes. Nozzle problems may also occur from time to time. Nevertheless, ink jet printing will be the preferred process for select applications. In particular it will be chosen when a small amount of variable data or imagery is to be added to an otherwise repeating image. It may therefore be used in conjunction with any of the above-mentioned imaging methods. [0102] Now referring to FIG. 15, a lamination transfer process 1500 in accordance with the present invention is shown. In the lamination image transfer process 1500, the laminates are typically produced by first printing the image 1502 directly on to the face of a special grade of paper called saturating paper 1504, then saturating the paper with the liquid form of the polymer used for the laminate, laying the paper on the protective panel or door, and then curing the sandwich. A suitably saturated paper 1504 can be laminated onto the gel formed from partial cure of the receptor coat 1506 and the topcoat prior to final curing. More specifically, the wood or wood composite protective panel or door 1508 enters the process 1500 at point A. At point B, the saturating paper 1504 is transferred from the roller 15 10 to the receptor coat 1504 by direct contact. The saturating paper 1504 is then cut to fit the protective panel or door 1508. At point C, the saturating paper 1504 containing the image 1502 has been transferred to the receptor coat 1506 of protective panel or door 1508. Note that since a layer of paper applied to the wood or wood composite protective panel or door 1508, edge effect can occur unless the paper is applied full width. In addition, the saturating paper 1504 inherently has a lower resolution than some of the other image transfer processes. [0103] The embodiments and examples set forth herein are presented to best explain the present invention and its practical application and to thereby enable those skilled in the art to make and utilize the invention. However, those skilled in the art will recognize that the foregoing description and examples have been presented for the purpose of illustration and example only. The description as set forth is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching without departing from the spirit and scope of the following claims.