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Title:
THREE DIMENSIONAL BENDING WOODEN VENEER
Document Type and Number:
WIPO Patent Application WO/2016/133454
Kind Code:
A1
Abstract:
A three dimensional bending wooden veneer (1 ) for a home furnishing object has a front side (2) adapted to be visible in the final home furnishing object, and a back side (10) adapted for mounting the veneer (1 ) to a support layer of the home furnishing object. The veneer (1 ) has a veneer thickness (VT) of 0.5 to 2.5 mm. Parallel recesses (12, 14, 16, 18) are formed in the back side (10) of the veneer (1 ) to such a recess depth (RD) that a remaining thickness (RT), which is that part of the veneer thickness (VT) that remains after making the respective recess (12,14, 16, 18), is 0.02-0.3 mm. The invention comprises also a method of producing such a veneer and an apparatus for producing such a veneer and a method of producing a home furnishing object.

Inventors:
KARLSSON BERNT-OVE (SE)
ZIB NILS-OLE (DK)
ANDERSSON LARS PAUL (SE)
Application Number:
PCT/SE2016/050127
Publication Date:
August 25, 2016
Filing Date:
February 18, 2016
Export Citation:
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Assignee:
IKEA SUPPLY AG (CH)
KARLSSON BERNT-OVE (SE)
International Classes:
B27D1/08; B27D5/00; B27H1/00; B27M1/00
Domestic Patent References:
WO2011096886A12011-08-11
WO1998023422A11998-06-04
WO2011096886A12011-08-11
WO1998023422A11998-06-04
Foreign References:
GB840640A1960-07-06
JP2001001313A2001-01-09
DE202008004011U12008-06-12
GB840640A1960-07-06
JP2001001313A2001-01-09
DE202008004011U12008-06-12
Other References:
See also references of EP 3259104A4
Attorney, Agent or Firm:
STRÖM & GULLIKSSON AB (Malmö, SE)
Download PDF:
Claims:
CLAIMS

1 . A three dimensional bending wooden veneer for a home furnishing object, the veneer having a front side (2) adapted to be visible in the final home furnishing object , and a back side (10) adapted for mounting the veneer to a support layer (26) of the home furnishing object, the back side (10) being provided with a plurality of parallel recesses (12, 14, 16, 18),

c h a r a c t e r i s e d in that the veneer (1 ) has a veneer thickness (VT) of 0.5 to 2.5 mm, wherein the recesses (12, 14, 16, 18) have a recess depth (RD) leaving a remaining thickness (RT), being that part of the veneer thickness (VT) that remains after making the respective recess (12, 14, 16, 18), which is 0.02-0.3 mm.

2. A veneer according to claim 1 , wherein the back side (10) of the veneer (1 ) is provided with a plurality of reinforcing threads (22) being non-parallel to the direction of the recesses (12, 14, 16, 18) and extending on top of the recesses.

3. A veneer according to claim 2, wherein the veneer (1 ) has a first segment (4) which is adapted for being exposed to a first degree of three

dimensional bending when forming a home furnishing object, and at least a second segment (6) which is adapted for being exposed to a second degree of three dimensional bending when forming a home furnishing object, wherein the first degree of bending is larger than the second degree of bending, wherein the first segment (4) has a first concentration of reinforcing threads (22), and the second segment (6) has a second concentration of reinforcing threads (22), wherein the first concentration of threads (22) is larger than the second concentration of threads (22).

4. A veneer according to claim 3, wherein the veneer (1 ) is adapted for

forming a chair (28), wherein the first segment is a backrest segment (4) of the veneer (1 ) and the second segment is a seat segment (6) of the veneer (1 ), wherein the veneer (1 ) comprises at least one third segment (8), the third segment being a transition segment (8) located between the backrest segment (4) and the seat segment (6), wherein the transition segment (8) is adapted for being exposed to a third degree of three dimensional bending, which is higher than the first and second degrees of three dimensional bending, and wherein the transition segment (8) has a third concentration of reinforcing threads (22), wherein the third concentration of threads (22) is larger than the first and second concentrations of threads (22).

5. A veneer according to any one of the preceding claims, wherein the veneer (1 ) comprises a first region (SR) which is adapted for being exposed to a first degree of three dimensional bending, and at least a second region (CR) which is adapted for being exposed to a second degree of three dimensional bending when forming a home furnishing object, wherein the first degree of bending is smaller than the second degree of bending, wherein the parallel recesses (12, 14, 16) are arranged at first mutual distances (MD1 ) at the first region (SR) and wherein the parallel recesses (18) are arranged at second mutual distances (MD2) at the second region (CR), wherein the first mutual distances (MD1 ) are larger than the second mutual distances (MD2).

6. A veneer according to claim 5, wherein the veneer (1 ) is adapted for

forming a chair (28), wherein the first region is a first side region (SR) of the veneer (1 ) and the second region is a central region (CR) of the veneer (1 ), wherein the veneer (1 ) comprises a second side region (SR) being similar to the first side region and located on the opposite side of the central region (CR).

A veneer according to any one of the preceding claims, wherein a mutual distance (MD1 ; MD2) between recesses (12, 14, 16, 18) is in the range of 1 -12 mm, more preferably in the range of 1 .5-8 mm.

8. A method of producing a three dimensional bending wooden veneer for a home furnishing object, the veneer having a front side (2) adapted to be visible in the final home furnishing object, and a back side (10) adapted for mounting the veneer to a support layer (26) of the home furnishing object, the back side (10) being provided with a plurality of parallel recesses (12, 14, 16, 18), the method comprising:

forming a veneer with a veneer thickness (VT) of 0.5 to 2.5 mm, cutting a plurality of parallel recesses (12, 14, 16, 18) in the back side (10) of the veneer (1 ), wherein the cutting is made to such depth (RD) that a remaining thickness (RT), which is that part of the veneer thickness (VT) that remains after cutting the respective recess, is 0.02-0.3 mm.

9. A method according to claim 8, wherein the method includes, prior to said step of cutting the parallel recesses, a step (30) of softening a log of wood and a step (32) of slicing veneer from the thereby softened log of wood, and wherein the method further includes, subsequent to said step (36) of cutting the parallel recesses (12, 14, 16, 18), a step (38) of drying the veneer.

10. A method according to any one of claims 8-9, wherein, after said step (36) of cutting the recesses, a plurality of reinforcing threads (22) are attached to the back side (10) of the veneer on top of the recesses and such as to extend in a direction being non-parallel to the direction of the recesses (12, 14, 16, 18).

1 1 . A method according to claim 10, wherein the veneer (1 ) has a first

segment (4) which is adapted for being exposed to a first degree of three dimensional bending when forming a home furnishing object, and at least a second segment (6) which is adapted for being exposed to a second degree of three dimensional bending when forming a home furnishing object , wherein the first degree of bending is larger than the second degree of bending, wherein reinforcing threads (22) are attached at a first concentration to the first segment (4), and reinforcing threads (22) are attached at a second concentration to the second segment (6), wherein the first concentration of threads (22) is larger than the second concentration of threads (22).

12. A method according to any one of claims 9-1 1 , wherein reinforcing threads (22) are attached to the back side (10) of the veneer (1 ) non-parallel to the direction of the recesses (12, 14, 16, 18) after said step (38) of drying the veneer.

13. A method according to any one of claims 8-12, wherein the veneer

comprises a first region (SR) which is adapted for being exposed to a first degree of three dimensional bending, and at least a second region (CR) which is adapted for being exposed to a second degree of three

dimensional bending when forming a home furnishing object, wherein the first degree of bending is smaller than the second degree of bending, wherein said step (36) of cutting the parallel recesses (12, 14, 16) involves cutting recesses at first mutual distances (MD1 ) at the first region (SR) and cutting the recesses (18) at second mutual distances (MD2) at the second region (CR), wherein the first mutual distances (MD1 ) are larger than the second mutual distances (MD2).

14. A method of producing a home furnishing object, the method comprising applying a veneer (1 ) according to any one of claims 1 -7, or a veneer formed according to the method of any one of claims 8-13, to a support layer (26) with the back side (10) of the veneer (1 ) facing the support layer (26), and pressing the veneer (1 ) and the support layer (26) to a desired three dimensional shape.

15. An apparatus for producing a three dimensional bending wooden veneer for a home furnishing object, the veneer (1 ) having a front side (2) adapted to be visible in the final home furnishing object, and a back side (10) adapted for mounting the veneer (1 ) to a support layer (26) of the home furnishing object, the back side (10) being provided with a plurality of parallel recesses (12, 14, 16, 18), c h a r a c t e r i s e d in that the apparatus comprises a plurality of parallel cutting blades (50) arranged with blade dividers (74) between them to form a veneer recess cutting roller (66), the cutting blades (50) being adapted to cut recesses against an anvil (68) in a veneer having a veneer thickness (VT) of 0.5 to 2.5 mm, to such a recess depth (RD) that a remaining thickness (RT), which is that part of the veneer thickness (VT) that remains after making the respective recess, is 0.02-0.3 mm.

16. Apparatus according to claim 15, wherein the apparatus further comprises a cutting roller anvil roller (70) provided with pressure surfaces (78) adapted for pressing on the blade dividers (74) of the cutting roller (62).

Description:
THREE DIMENSIONAL BENDING WOODEN VENEER

Field of the Invention

The present invention relates to a three dimensional bending wooden veneer for a home furnishing object, the veneer having a front side adapted to be visible in the final home furnishing object, and a back side adapted for mounting the veneer to a support layer of the home furnishing object, the back side being provided with a plurality of parallel recesses.

The present invention also relates to a method of producing a three dimensional bending wooden veneer and an apparatus for producing such a veneer.

Background of the Invention

Chairs and other home furnishing objects may often be provided with a thin wooden veneer applied to a central support layer, a support layer which may in itself be a laminate formed from a plurality of veneers. The thin wooden veneer provides the home furnishing object with a surface having an attractive feeling and visual appearance. The wooden veneer may, for example, be made from birch, beech, oak or another desired type of wood. The veneer is bendable, but does not easily stretch without being cracked. Therefore, it is rather difficult to form more complicated structures in which the veneer is to be pressed to a three-dimensional shape in, e.g., the seating of a chair.

WO 201 1/096886 discloses a three dimensional bending veneer and a method of manufacturing such a bending veneer. It has been found, however, that this veneer is not suitable for the more complicated structures, having a relatively large degree of three dimensional bending. In such structures, having a relatively large degree of three dimensional bending, the veneer described in

WO 201 1 /096886 may suffer cracks in its surface structure. Summary of the Invention

An object of the present invention is to provide an improved three dimensional bending wooden veneer which more readily adapts to large degrees of three dimensional bending.

This object is achieved by means of a three dimensional bending wooden veneer for a home furnishing object, the veneer having a front side adapted to be visible in the final home furnishing object, and a back side adapted for mounting the veneer to a support layer of the home furnishing object, the back side being provided with a plurality of parallel recesses, wherein the veneer has a veneer thickness of 0.5 to 2.5 mm, wherein the recesses have a recess depth RD leaving a remaining thickness RT, being that part of the veneer thickness VT that remains after making the respective recess, which is 0.02-0.3 mm.

An advantage of this invention is that with this very thin remaining thickness

RT, the veneer will adapt good also to relatively large degrees of three

dimensional bending without the formation of large cracks in the front side of the veneer.

According to one embodiment the final veneer, which is ready for being exposed to three dimensional bending, has a substantially flat front side, with no or only few recesses formed therein, and the back side is provided with the plurality of recesses. An advantage of this embodiment is that the veneer will provide a pleasant appearance, as its front side will have the appearance of an unbroken or almost unbroken veneer surface. Still more preferably, the final veneer, which is ready for being exposed to three dimensional bending, has a flat front side, with no recesses formed therein. This provides for an even better appearance, and a further reduced risk of formation of large cracks during the bending process.

According to one embodiment the veneer thickness is 0.8-2.0 mm. An advantage of this veneer thickness is that it increases the ability of the veneer to adapt to large degrees of three dimensional bending without the formation of large cracks.

According to one embodiment the remaining thickness RT is 0.05-0.2 mm. An advantage of this veneer thickness is that it further enhances the ability of the veneer to adapt to large degrees of three dimensional bending without the formation of cracks.

According to one embodiment the recesses each have a largest width RW which is 0-0.5 mm, more preferably 0-0.3 mm. An advantage of this embodiment is that recesses have a relatively limited volume, which reduces the amount of adhesive that may enter the respective recess during the bending process.

Thereby, the risk is reduced that adhesive unintentionally leaks through recesses and reaches the front side of the veneer.

According to one embodiment the back side of the veneer is provided with a plurality of reinforcing threads being non-parallel to the direction of the recesses and extending on top of the recesses. An advantage of this embodiment is that the threads hold together those ribs that are formed between adjacent recesses, such that those ribs will be hindered from moving apart from each other in the process of three dimensional bending. Thereby, the veneer can be exposed to larger degrees of three dimensional bending without the formation of large cracks.

According to one embodiment the plurality of reinforcing threads extend perpendicular to the direction of the recesses. This embodiment provides a further improved holding together of ribs formed between adjacent recesses.

According to one embodiment the veneer has a first segment which is adapted for being exposed to a first degree of three dimensional bending when forming a home furnishing object, and at least a second segment which is adapted for being exposed to a second degree of three dimensional bending when forming a home furnishing object, wherein the first degree of bending is larger than the second degree of bending, wherein the first segment has a first concentration of reinforcing threads, and the second segment has a second concentration of reinforcing threads, wherein the first concentration of threads is larger than the second concentration of threads. An advantage of this embodiment is that the cost of the veneer is reduced, since a higher number of threads is used in that segment where there is a larger degree of three dimensional bending, while a smaller number of threads is used in that segment where there is a lower degree of three dimensional bending, and, hence, a lower need for reinforcing the veneer.

According to one embodiment the veneer is adapted for forming a chair, wherein the first segment is a backrest segment of the veneer and the second segment is a seat segment of the veneer, wherein the veneer comprises at least one third segment, the third segment being a transition segment located between the backrest segment and the seat segment, wherein the transition segment is adapted for being exposed to a third degree of three dimensional bending, which is higher than the first and second degrees of three dimensional bending, and wherein the transition segment has a third concentration of reinforcing threads, wherein the third concentration of threads is larger than the first and second concentrations of threads. An advantage of this embodiment is that a chair with veneer can be formed at a low cost, and the veneer still has the ability to adapt to the relatively high degree of three dimensional bending that occurs in the transition segment that connects the backrest segment to the seat segment.

According to one embodiment the veneer comprises a first region which is adapted for being exposed to a first degree of three dimensional bending, and at least a second region which is adapted for being exposed to a second degree of three dimensional bending when forming a home furnishing object, wherein the first degree of bending is smaller than the second degree of bending, wherein the parallel recesses are arranged at first mutual distances at the first region and wherein the parallel recesses are arranged at second mutual distances at the second region, wherein the first mutual distances are larger than the second mutual distances. An advantage of this embodiment is that the cost of forming the veneer is reduced, as fewer recesses are made in the first region where there is a lower degree of three dimension bending. In addition to reducing the cost for forming the veneer, there is also a reduced influence on the veneer itself.

According to one embodiment the veneer is adapted for forming a chair, wherein the first region is a first side region of the veneer and the second region is a central region of the veneer, wherein the veneer comprises a second side region being similar to the first side region and located on the opposite side of the central region. An advantage of this embodiment is that a chair with veneer having three dimensional bending can be formed at a low cost, and with minimum impact to the integrity of the veneer.

According to one embodiment the mutual distance between recesses is in the range of 1 -12 mm, more preferably in the range of 1 .5-8 mm, and still more preferably in the range of 2-6 mm. An advantage of this embodiment is that efficient production of a three dimensional bending wooden veneer can be obtained, wherein the veneer is provided with recesses sufficiently adjacent to each other to provide for efficient three dimensional bending, but wherein the recesses are not so dense as to increase cost and negatively affect the integrity of the veneer.

A further object of the present invention is to provide an improved method of producing a three dimensional bending wooden veneer for a home furnishing object.

This object is achieved by means of a method of producing a three dimensional bending wooden veneer for a home furnishing object, the veneer having a front side adapted to be visible in the final home furnishing object, and a back side adapted for mounting the veneer to a support layer of the home furnishing object, the back side being provided with a plurality of parallel recesses, the method comprising:

forming a veneer with a veneer thickness of 0.5 to 2.5 mm, and having the back side and the front side,

cutting a plurality of parallel recesses in the back side of the veneer, wherein the cutting is made to such depth RD that a remaining thickness RT, which is that part of the veneer thickness VT that remains after cutting the respective recess, is 0.02-0.3 mm.

An advantage of this method is that with this very thin remaining thickness RT, a veneer that will adapt efficiently also to relatively large degrees of three dimensional bending can be produced at a low cost.

According to one embodiment the method further includes, prior to said step of cutting the parallel recesses, a step of softening a log of wood and a step of slicing veneer from the thereby softened log of wood, and wherein the method further includes, subsequent to said step of cutting the parallel recesses, a step of drying the veneer. An advantage of this method is that the recesses can be cut with lower force and with lower risk of damaging the veneer, since the veneer is still, after said step of softening the log of wood and prior to said step of drying, relatively soft.

According to one embodiment, wherein after said step of cutting the recesses a plurality of reinforcing threads are attached to the back side of the veneer on top of the recesses and being non-parallel to the direction of the recesses. An advantage of this embodiment is that the veneer is reinforced such that it can better withstand the three dimensional bending. According to one embodiment the threads are attached perpendicular to the direction of the recesses. This embodiment provides for a further improved capability of the veneer to withstand the three dimensional bending.

According to one embodiment the veneer has a first segment which is adapted for being exposed to a first degree of three dimensional bending when forming a home furnishing object, and at least a second segment which is adapted for being exposed to a second degree of three dimensional bending when forming a home furnishing object, wherein the first degree of bending is larger than the second degree of bending, wherein reinforcing threads are attached at a first concentration to the first segment, and reinforcing threads are attached at a second concentration at the second segment, wherein the first concentration of threads is larger than the second concentration of threads. An advantage of this embodiment is that production of the veneer becomes cheaper, as the threads are attached in a lower concentration in those locations where a high concentration is not needed.

According to one embodiment, reinforcing threads are attached to the back side of the veneer non-parallel to the direction of the recesses after said step of drying the veneer. An advantage of this embodiment is that it is easier to ensure a proper attachment of the threads when applied on a dried veneer. Preferably, the threads are attached perpendicular to the direction of the recesses, to obtain a further improved capability of the veneer to be three dimensionally bent without the formation of large cracks.

According to one embodiment, the veneer comprises a first region which is adapted for being exposed to a first degree of three dimensional bending, and at least a second region which is adapted for being exposed to a second degree of three dimensional bending when forming a home furnishing object, wherein the first degree of bending is smaller than the second degree of bending, wherein said step of cutting the parallel recesses involves cutting recesses at first mutual distances at the first region and cutting the recesses at second mutual distances at the second region, wherein the first mutual distances are larger than the second mutual distances. An advantage of this embodiment is that the number of recesses formed is minimized.

According to one aspect a method of producing a home furnishing object is provided, the method comprising applying a veneer as described above, or a veneer formed according to the method described above, to a support layer with the back side of the veneer facing the support layer, and pressing the veneer and the support layer to a desired three dimensional shape. This method is very efficient for producing home furnishing objects, so that home furnishing objects can be produced at a low cost.

A further object of the present invention is to provide an apparatus which is efficient for producing a three dimensional bending wooden veneer.

This object is achieved by means of an apparatus for producing a three dimensional bending wooden veneer for a home furnishing object, the veneer having a front side adapted to be visible in the final home furnishing object , and a back side adapted for mounting the veneer to a support layer of the home furnishing object, the back side being provided with a plurality of parallel recesses, wherein the apparatus comprises a plurality of parallel cutting blades arranged with blade dividers between them to form a veneer recess cutting roller, the cutting blades being adapted to cut recesses against an anvil in a veneer having a veneer thickness of 0.5 to 2.5 mm, to such a recess depth RD that a remaining thickness RT, which is that part of the veneer thickness VT that remains after making the respective recess, is 0.02-0.3 mm.

An advantage of this apparatus is that it provides for very accurate forming of well-defined recesses with the desired properties for obtaining a three dimensional bending wooden veneer.

According to one embodiment, the apparatus further comprises a cutting roller anvil roller provided with pressure surfaces adapted for pressing on the blade dividers of the cutting roller. An advantage of this embodiment is that the depth of parallel recesses will be kept constant over the entire surface of the veneer.

Further objects and features of the present invention will be apparent from the description and the claims. Brief description of the Drawings

The invention will now be described in more detail with reference to the appended drawings in which:

Fig. 1 a is a plan view of a front side of a three dimensional bending wooden veneer.

Fig. 1 b is a plan view of a back side of the three dimensional bending wooden veneer.

Fig. 1 c is a cross section as seen along the arrows lc-lc of Fig. 1 b.

Fig. 1 d is a cross section as seen along the arrows Id-Id of Fig. 1 b.

Fig. 2a is three dimensional illustration of layers intended for forming a chair seat.

Fig. 2b is a three dimensional illustration of a chair seat formed by pressing the layers illustrated in Fig. 2a.

Fig. 3 is a process diagram illustrating the steps of forming a veneer.

Fig. 4a illustrates a cutting blade for cutting recesses in a veneer.

Fig. 4b illustrates a cross section of the cutting blade of Fig. 4a.

Fig. 4c illustrates an apparatus for cutting recesses in a veneer.

Fig. 4d is an enlarged side view illustrating a cutting roller veneer release blade.

Description of preferred Embodiments

Fig. 1 a illustrates a three dimensional bending wooden veneer 1 adapted for forming a home furnishing object. The illustration of Fig. 1 a illustrates a front side 2 of the veneer 1 . The front side 2 is that side of the veneer 1 which will be visible in the home furnishing object, and it is the side which will be facing outwards. In the embodiment of Fig. 1 a the veneer 1 is intended for a home furnishing object in the form of a chair.

The veneer 1 is divided, looking at it in a vertical direction, into a first, second and third segment, wherein the first segment is a backrest segment 4, the second segment is a seat segment 6, and the third segment is a transition segment 8, forming the transition between the backrest segment 4 and the seat segment 6. Furthermore, the veneer 1 is divided, looking at it in a horizontal direction, in a central region CR arranged between two side regions SR.

Fig. 1 b illustrates the back side 10 of the veneer 1 . The back side 10 of the veneer 1 is adapted for being attached, e.g. by means of a glue, to a support layer forming an internal force bearing structure of the chair. Hence, the back side 10 of the veneer 1 will not be visible in the final chair.

The back side 10 is provided with a plurality of parallel recesses 12, 14, 16, 18 formed in the veneer 1 . The recesses 12, 14, 16, 18 could be provided with short interruptions 20. The interruptions 20 are formed in different locations along the recesses 12, 14, 16, 18, and the interruptions 20 form an irregular pattern on the back side 10.

According to an alternative embodiment the recesses may be continuous recesses, extending over the entire length of the back side 10, and lacking interruptions.

Preferably, the recesses 12, 14, 16, 18 extend in a direction which is parallel to the fibre direction of the wooden veneer 1 .

The integrity of the veneer 1 should be maintained also during the application to the support layer, and during the forming of a three-dimensional structure. To this end, the back side 10 of the veneer 1 is provided with a plurality of reinforcing threads 22. The reinforcing threads 22 extend along a direction which is non-parallel to the direction of the recesses 12, 14, 16, 18. In the embodiment shown in Fig. 1 b the threads 22 extend along a direction which is perpendicular to the direction of the recesses 12, 14, 16, 18, and on top of these, as will be described in more detail hereinafter. The reinforcing threads 22 are preferably made of a relatively inflexible material, such as glass fiber, and are preferably glued to the back side 10.

Fig. 1 c illustrates a portion of the veneer 1 as seen along the cross-section defined by the arrows lc-lc of Fig. 1 b. As can be seen the front side 2 is a smooth unaffected surface, while the recesses 12, 14, 16, 18 and the threads 22 are arranged at the back side 10.

For the veneer 1 to be bendable in three dimensional manner it preferably has a veneer thickness VT of 0.5-2.5 mm, more preferably 0.8-2.0 mm. The recesses 12, 14, 16, 18 should be formed with such a recess depth RD that a remaining thickness RT, which is that part of the veneer thickness VT that remains after making the recess, is 0.02-0.3 mm, more preferably 0.05-0.2 mm. Hence, for example, if the veneer thickness VT is 1 .5 mm, and the remaining thickness RT is 0.1 mm, then the recess depth RD is 1 .4 mm.

The recesses each have a largest width RW, which is normally located at the entry of the respective recess 12, 14, 16, 18 into the back side 10, which is 0- 0.5 mm, more preferably 0-0.3 mm. The mutual distance MD1 , MD2 between adjacent recesses 12, 14, 16, 18 is preferably in the range of 1 -12 mm, more preferably in the range of 1 .5-8 mm to obtain efficient properties for three dimensional bending.

As can be seen from Fig. 1 c the recesses 12, 14, 16, 18, which extend through the major part of the thickness VT of the veneer 1 , form between them ribs 24, 25 that are only held together by the remaining thicknesses RT and, additionally, the threads 22. The ribs 24 have a first width MD1 which is the same as a first mutual distance MD1 of the recesses 12, 14, 16. During the three dimensional bending process these ribs 24 will at least partly break free from each other, due to the relatively thin thickness RT, to move relatively freely relative to each other in their length direction, thereby adapting to the three-dimensional shape which is intended for the chair.

According to one embodiment, the mutual distance is different for different regions of the veneer 1 , depending on the degree of three dimensional bending that is expected for that region. Hence, for example, the first mutual distance MD1 in the side region SR may be larger than a second mutual distance MD2 in the central region CR, where the degree of three dimensional bending is larger.

Correspondingly, ribs 25 of the central region CR will have a width MD2 which is smaller than the width MD1 of the ribs 24 of the side region SR.

Fig. 1 d illustrates the veneer 1 as seen in the cross-section Id-Id of Fig. 1 b. As described already with reference to Fig. 1 c the front side 2 is smooth, and the back side 10 is provided with recesses, best illustrated in Fig. 1 c, and a number of reinforcing threads 22.

The backrest segment 4, the seat segment 6 and the transition segment 8 will be exposed to different degrees of three dimensional bending and therefore have different concentrations of reinforcing threads 22. The backrest segment 4 will be exposed to a medium degree of three dimensional bending. Therefore, the backrest segment 4 will have a first concentration of reinforcing threads 22. This first concentration could, for example, be 8 threads/meter, meaning that there would be a first thread distance TD1 of 12,5 cm between two adjacent threads 22. The seat segment 6 will be exposed to a low degree of three dimensional bending. Therefore, the seat segment 6 will have a second concentration of reinforcing threads 22. This second concentration could, for example, be 5 threads/meter. Thereby, there would be a second thread distance TD2 of 20 cm between two adjacent threads 22 in the seat segment 6. The transition segment 8 will be exposed to a high degree of three dimensional bending. Therefore, the transition segment 8 will have a third concentration of reinforcing threads 22. This third concentration could, for example, be 20 threads/meter. A third thread distance TD3 between two adjacent threads 22 in the transition segment 8 would hence be 5 cm.

In addition to the segments 4, 6 and 8 having different concentrations of threads 22 between them, it is also possible to vary the concentration of threads 22 within the segment, since also different portions of a segment are exposed to different degrees of three dimensional bending.

Fig. 2a illustrates schematically the three layers used for forming a chair seat. A first layer is the three dimensional bending wooden veneer 1 described hereinbefore with reference to Figs. 1 a-1 d. The veneer 1 , which is ready for being exposed to three dimensional bending, has a substantially flat front side 2, with no or only few recesses formed therein, and the back side 10 is provided with the plurality of recesses 12, 14, 16, 18 as described hereinbefore. The veneer 1 is arranged with its front side 2 facing outwardly, and its back side 10 facing a central support layer 26. The central support layer 26 may, for example, be a plywood sheet, a number of veneers layered on top of each other, a fibre board sheet, e.g. High Density Fibre (HDF) board or Medium Density Fibre (MDF) board, a wooden sheet, or another type of layer that is suitable for providing support for the veneer 1 and giving sufficient strength to the chair or other object. A second veneer 1 1 is arranged below, as seen in the illustration of Fig. 2a, the central support layer 26. The second veneer 1 1 is preferably made according to the same principles as described above with regard to the veneer 1 , although the second veneer 1 1 may, for example, have a different size, thickness, etc. since the requirements thereon may differ slightly from the requirements on the first veneer 1 . Hence, a front side 2 of the second veneer 1 1 faces outwardly, and a back side 10, having thereon recesses 12, 14, etc. and reinforcing threads 22, faces the central support layer 26. An adhesive, such as glue, may be applied to the respective back sides 10, or on the support layer 26, prior to pressing them.

Fig. 2b illustrates a final chair seat 28 having the first veneer 1 facing a person sitting on the chair seat 28, with the smooth front side 2 facing the person sitting in the chair, and having the second veneer 1 1 forming the back of the chair seat 28, with its smooth front side 2 facing outwardly. It is clear from Fig. 2b that the backrest segment 4 has a medium degree of three dimensional bending, that the seat segment 6 has a low degree of three dimensional bending, and that the transition segment 8 has a high degree of three dimensional bending.

Fig. 3 illustrates the steps involved in forming a three dimensional bending wooden veneer, for example the veneer 1 illustrated in Figs. 1 a-1 d.

In a first step 30 a log of wood is softened. The softening of the log could involve soaking in water. The soaking could, for example, involve submerging the wooden log in water at elevated temperature, such as 80-100°C, for a couple of hours. If the log of wood is from a very recently felled tree it may still be sufficiently soft so that soaking time can be reduced, or that soaking can even be dispensed of.

In a second step 32 the log of wood is exposed to veneer slicing. Veneer slicing can be made in different ways, including rotating the log adjacent to a long knife to slice off veneer, or using a reciprocating knife to slice off sheets of veneer from the log.

In a third step 34 the veneer is formatted for its intended end use. This may involve forming e.g. a veneer having the kind of plan view shape illustrated in Fig. 1 a, if the veneer is intended for a chair.

In a fourth step 36 the veneer is subjected to cutting of the recesses 12, 14, 16, 18 illustrated hereinbefore with reference to Figs. 1 b and 1 c. The cutting of the recesses is preferably done while the veneer is still soft after the soaking in the first step 30. In a fifth step 38 the veneer is dried. Such drying can be achieved in various ways, including holding the veneer between hot plates.

In a sixth step 40 the reinforcing threads are applied to the dried veneer. The reinforcing threads 22, best illustrated hereinbefore with reference to Fig. 1 b and 1 d, could be applied manually or by means of an application device. A suitable adhesive, for example hot melt glue, could be used for attaching the threads 22 to the back side 10 of the veneer.

Finally, noted as 42 in Fig. 3, a complete three dimensional bending wooden veneer 1 has been produced, and is ready for forming, e.g., a chair, as illustrated in Figs. 2a-2b.

Fig. 4a illustrates a circular cutting blade 50 adapted for cutting the recesses 12, 14, 16, 18, best shown in Fig. 1 c. The cutting blade 50 has a main body 52 and a peripheral cutting edge 54. The cutting blade 50 also has a central mounting hole 56, making it possible to mount the cutting blade 50 to a shaft to form a cutting roller, as will be described hereinafter.

Optionally, the cutting edge 54 may be provided with one or more slots 58. At the slots 58 no recess is formed in the veneer, and, hence, an interruption 20 is formed in the recess, as shown in Fig. 1 b. If there are no slots in the cutting edge 54, then the cutting blade 50 will form continuous recesses in the veneer.

Fig. 4b illustrates a cross-section of the cutting blade 50, taken along the section IVb-IVb of Fig. 4a. The main body 52 may typically be made of razor blade steel, and may, for example, have a thickness TB of 0.05-1 .0 mm, more preferably 0.1 -0.5 mm. The cutting edge 54 starts at the same thickness TB as the main body 52 and ends with a sharp point 60 to efficiently cut the recesses in the veneer.

Fig. 4c illustrates a recess cutting apparatus 62 for cutting recesses in a veneer blank 64. The apparatus 62 comprises a veneer recess cutting roller 66, a veneer anvil table 68, a cutting roller anvil roller 70, and a cutting roller veneer release blade 72.

The veneer recess cutting roller 66 comprises a plurality of cutting blades

50 mounted on a shaft with circular blade dividers 74 between them. The blade dividers 74 have a smaller outer diameter than the cutting blades 50, and therefore the cutting edges 54 will extend beyond the outer periphery 76 of the blade dividers 74. The blade dividers 74 may have different widths BD1 , BD2 to obtain the different desired mutual distances MD1 , MD2 between recesses, as illustrated in Fig. 1 c.

The cutting blades 50, if having the slots 58, are arranged on the roller 66 such that slots 58 of adjacent cutting blades 50 do not match with each other. Preferably, the slots 58 of all cutting blades 50 are arranged in a random manner, such that interruptions 20 formed in the recesses 12, 14, 16, 18 are randomly spread over the back side 10 of the veneer 1 .

The veneer anvil table 68 is arranged to support the veneer blank 64 during the recess cutting with the roller 66, such that recesses of accurate depth can be cut, thereby obtain the desired remaining thickness RT, as illustrated in Fig. 1 c.

The cutting roller anvil roller 70 is arranged for keeping a high, even and predictable cutting pressure from the roller 66 on the veneer blank 64. The anvil roller 70 is provided with pressure surfaces 78 that exert pressure on the outer peripheries 76 of the blade dividers 74. The anvil roller 70 has edge recesses 80 arranged between the pressure surfaces 78 to accommodate the cutting edges 54 of the cutting blades 50 of the roller 66 such that no pressure is exerted directly on the edges 54.

Fig. 4d illustrates the cutting roller veneer release blade 72 in more detail. The release blade 72 is arranged to ensure that the veneer blank 64 is released from the respective cutting edges 54 after the recess cutting. To this end the release blade 72 comprises a body portion 82 being provided with a number of elongated parallel slots 84, best shown in the A-A view at the lower end of Fig. 4d. The parallel slots 84 match the parallel cutting edges 54 of the parallel cutting blades 50, and the cutting edges 54 extend through the slots 84 and down into the veneer blank 64. Between the parallel slots 84 the body portion 82 has connecting portions 86 that match the widths BD1 , BD2 of the blade dividers 74.

During the cutting of recesses the veneer blank 64 is forwarded in the direction of the arrow VD. During such cutting of recesses in the veneer blank 64 it is possible that the veneer blank 64 becomes attached to the cutting edges 54 by friction between the cutting edges 54 and the side walls of the recesses that are cut in the veneer blank 64. If that would happen the underside 88 of the release blade 72 serves as an anvil that releases the veneer blank 64 from the cutting edges 54.

It will be appreciated that numerous variants of the above described embodiments are possible within the scope of the appended claims.

Hereinbefore it has been described that the recesses 12, 14, 16, 18 are provided with optional interruptions 20. If interruptions are present, they preferably have a length of 1 -5 mm, and preferably occur at mutual distances, as seen along the recesses 12, 14, 16, 18, exceeding 25 mm.

To summarize, a three dimensional bending wooden veneer (1 ) for a home furnishing object has a front side (2) adapted to be visible in the final home furnishing object, and a back side (10) adapted for mounting the veneer to a support layer (26) of the home furnishing object . The veneer (1 ) has a veneer thickness (VT) of 0.5 to 2.5 mm. Parallel recesses (12, 14, 16, 18) are formed in the back side (10) of the veneer (1 ) to such a recess depth (RD) that a remaining thickness (RT), which is that part of the veneer thickness (VT) that remains after making the respective recess (12, 14, 16, 18), is 0.02-0.3 mm.