FURNITURE MATERIAL
FIELD OF INVENTION :
The present invention in general, relates to a decorative sheet for its application as furniture
material and in particular to decorative sheet comprising plywood and decorative veneer having
special texture on the surface of finished product and adapted for use as a decorative material
for the making of the furniture and/ or other fancy structural panels which is durable, simple
and cost effective apart from being decorative.
BACKGROUND OF THE INVENTION :
Wood has been known traditionally as a useful material, for making of furniture and other wood
based structural panels. Due to the scarcity of wood with some statutory limitations for
ecological purposes, it has become a very expensive affair to manufacture furniture from wood
only. The plywood is found to be an effective substitute for wood and economical as well
However, furniture's made of plywood only can not provide the aesthetic outlook and are not
able to meet the standard norms and customer satisfaction in respect of durability, simplicity
and cost effectiveness.
To overcome the above limitations different kinds of decorative sheets have been developed
with different modes of preparation to create fancy look for the purpose of decorative material
to manufacture furniture and other fancy items. The use of paper based laminates as decorative
material with various preconceived decision and colours pasted on the other surface of the
furniture made of plywood is comparatively cheaper but that does not ensure attractive outlook,
durability and simplicity and therefore, fail to meet the customers demands in all respects.
To avoid the aforesaid limitations of plywood, decorative veneers came into existence. Such
decorative veneers are usually pasted on the plywood by adhesive. The standard veneer is
manufactured by the process of pasting decorative veneer on the surface of plywood with the
help of adhesives. Patent number 201376 of the same applicants' application of MITT sheet,
being a tissue paper that is treated to have adhesive properties, thus providing uniform
bonding all across on application of pressure. This process results in a decorative veneer which
is plain and standard in nature i.e. it gives the veneer surface the feel of standard wood which
customers have been using this form for quite some time. In general, the technology protected
by the said patent numbered 201376 is as follows:

But with time, customer's needs are also evolving. They look for more innovative options which
are durable, simplified, cost effective and simultaneously make their interiors look different
from the rest and aesthetically beautiful. The technology protected by the patent number
201376, did not coherently meet the customer satisfaction in terms of providing a solution
which is durable, simplified, cost effective and is simultaneously aesthetically improved.
Hence, there was a long felt need to provide such solution which is durable, simplified, cost
effective and simultaneously aesthetically improved.
The present invention meets the aforesaid long felt need.
OBJECTS OF THE INVENTION :
It is the principal object of the present invention to provide a method for manufacturing a
decorative sheet for its application as furniture material which is durable, simplified, cost
effective and simultaneously aesthetically improved.
It is the further object of the present invention to provide a method for manufacturing a
decorative sheet for its application as furniture material which is adapted to withstand load and
other adverse conditions during its application
It is yet another object of the present invention to provide a method for manufacturing a
decorative sheet for its application as furniture material which conforms to the statutory
standards set for ecological/environmental purposes.
It is another object of the present invention to provide a method for manufacturing a decorative
sheet for its application as furniture material which meets the customer's needs for variety of
decorative options, to provide for the aesthetic requirements.
It is another object of the present invention to provide a decorative sheet for its application as
furniture material which is durable, simplified, cost effective and simultaneously aesthetically
improved.
It is the further object of the present invention to provide a decorative sheet for its application
as furniture material which is adapted to withstand load and other adverse conditions during its
application.
It is yet another object of the present invention to provide a decorative sheet for its application
as furniture material, which conforms, to the statutory standards set for
ecological/environmental purposes.
It is another object of the present invention to provide a decorative sheet for its application as
furniture material meets the customer's needs for variety of decorative options, to provide for
the aesthetic requirements.
How the foregoing objects are achieved and the other aspects of the present invention, will be
clear from the following description which is purely by way of understanding and not by way of
any sort of limitation.
SUMMARY OF THE INVENTION :
Accordingly, the present invention provides a method for manufacturing a decorative sheet
including assembling over at least a base plywood, at least an overlay alpha cellulose paper
and at least a decorative veneer layer in that order, pressing the assembly so obtained under
suitable pressure and temperature by suitable means fitted with suitable moulds and further
hot pressing the resultant with embossed moulds under suitable hydraulic pressure and
temperature to obtain decorative sheet having special texture impression
In accordance with preferred embodiments of the method of the present invention:
-said base plywood is of thickness between 3mm and 4mm and said plywood is obtained by
peeling off from hard wood logs to thickness of 3 to 4mm and by drying and coating with
phenol formaldehyde resin.
-said decorative veneer is obtained by peeling off or slicing in thickness of 0.3mm to 0.6mm
from teak and other species having decorative look, said veneer being dried before use.
-said embossed moulds are made of various materials such as steel, iron, jute being transferred
on surface of said decorative veneer on application of heat and pressure and said special
texture includes any one or any two or more of or all of Halo, Tartan, Quill, Bristol, Hexad and
Honeycomb.
-said overlay paper is low GSM paper preferably in the range of 16 to 22 gm/irf
-said GSM paper is preferably impregnated applying a melamme formaldehyde resin on an
impregnator, consisting of a high pressure doctor roll.
-said resin contained in the overlay is maintained in the range of 70-74% with a volatile content
of 6-7%.
The present invention also provides a method for manufacturing a decorative sheet including .
—assembling over a base plywood/core veneer obtained by peeling off from hardwood logs,
melamine formaldehyde impregnated overlay alpha cellulose low GSM paper in the range of 16
to 22 gm/m7 and decorative veneer in that order,
— bonding together the assembly so obtained by pressing the assembly under pressure of 80-
105Kg/cm'> for 70-80 seconds in hydraulic press fitted with steel moulds heated to a
temperature of 130-160°C such that in the process, said melamine resin get cured to provide
the durable pressure bonded decorative sheet,
—pressing the compressed unit so obtained at 85°C with hydraulic pressure of 230kgs/cm?
with embossed moulds to obtain decorative sheet with desired texture.
The present invention also provides a decorative sheet including at least a base plywood, at
least an overlay alpha cellulose paper applied thereon, followed by at least a decorative veneer
layer in that order, said paper adapted to bond said base plywood and said decorative veneer
layer, said decorative veneer layer having further applied thereon a special texture obtained by
application of embossed mould.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING :
The nature and scope of the present invention, will be better understood from the
accompanying drawing, which is by way of illustration of some preferred embodiments and not
by way of any sort of limitation. In the accompanying drawing:
Figure 1 illustrates a cross-sectional view of the decorative sheet in accordance with a
preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION :
The present invention is directed to a process for manufacturing a decorative sheet for its
application as furniture material and to the decorative sheet obtained by the method Its main
aim to substantially reduce/nullify the drawbacks discussed under the heading "Background of
the Invention" as discussed hereinbefore.
As illustrated in the cross-sectional view of a preferred embodiment of the decorative sheet
according to the present invention, it comprises a base plywood/core veneer layer(l), followed
by a layer of overlay paper(2) and that of a decorative veneer(3) in that sequence There is also
provided a layer of embossed moulds(4) applied on the layer of decorative veneer(3) which
renders a special texture thereon. These features coherently provide a decorative veneer
according to the present invention which is durable, simplified, cost effective and
simultaneously aesthetically improved, is adapted to withstand load and other adverse
conditions during its application and conforms to the statutory standards set for
ecological/environmental purposes.
It should be understood to persons skilled in the art that the thickness of each layer of the
decorative veneer, according to the present invention is not constant and can be varied,
depending upon the customer requirement and the present invention encompasses all such
variations. Similarly, the shape of the decorative veneer according to the present invention is
not constant and can be varied, depending upon the customer requirement and the present
invention encompasses all such variations. The shape and the thickness of the layers illustrated
in the accompanying drawing are non-limiting and have been adopted as an exemplary
embodiment for understanding the present invention.
The overlay paper is preferably low GSM paper in the range of 16-22 gm/m;. The paper is
preferably impregnated using a melamme formaldehyde resin on an impregnator consisting of a
high precision doctor roll. The resin contained in the overlay is kept in the range of 70-74%
with a volatile content of 6-7%. This on application of heat provides bonding of core veneer and
decorative veneer.
The embossed moulds are made of various materials such as steel, iron, jute which has certain
texture on surface which on application of heat and pressure gets transferred to the surface of
decorative veneers. The non-limiting types of special textures that may be applied on the layer
decorative veneer according to the present invention may be any one or any two or more of
Halo, Tartan, Quill, Bristol, Hexad and Honeycomb.
The method for manufacturing the decorative sheet according to the present invention may be
summarized by the following non-limiting steps which are represented below in a schematic
manner for the sake of better understanding:

Non-limiting examples of ingredients and the equipments applied in the technology are as follows:
Hot Press: Hot press equipment allows to obtain bonding of base plywood 3-4 mm and
decorative veneer leaves of 0.3-0.4mm with the help of pressure and heat.
Core Veneer/ Base Plywood: The core veneer is basically peeled off from hard wood logs to
thickness of 3-4 mm. These core veneers are dried and coated with formaldehyde resin.
Decorative Veneer: Such decorative veneer are peeled off or sliced in thickness of 0.3-0.6nim
from teak and other species having decorative look, and such veneer are dried before use.
MITT Paper: It is impregnated overlay paper. It is preferably overlay paper of low GSM
preferably in the range of 16-22 gm/m'. The paper is preferably impregnated using a melamine
formaldehyde resin on an impregnator consisting of a high precision doctor roll. The resin
contained in the overlay is kept in the range of 70-74% with a volatile content of 6-7%. This on
application of heat provides bonding of Core Veneer and Decorative Veneer.
Embossed Moulds: These moulds are the made of various materials such as steel, iron, jute
which has certain texture on surface which on application of heat and pressure gets transferred
to the surface of decorative veneers. The non-limiting types of special textures that may be
applied on the layer decorative veneer according to the present invention may be any one or
any two or more of Halo, Tartan, Quill, Bristol, Hexad and Honeycomb.
Briefly, the essential steps for manufacturing the decorative sheet according to the present
invention comprises: -
— providing ply of desired specifications,
— providing a selective decorative veneer,
— providing resin impregnated overlay paper between the said plywood and the decorative
veneer to together define a decorative sheet/ assembly and subjecting the same to pressure
bonding at elevated temperatures.
— providing embossed moulds on the decorative veneer layer by pressing the compressed unit
so obtained under suitable temperature and pressure, which provides the desired texture, to
the decorative surface of the finished product.
In accordance with a preferred aspect, the method for manufacturing of decorative sheet
comprises assembling one over said plywood, melamine formaldehyde impregnated overlay Alfa
cellulose paper having low GSM preferably 16-22 gm7, paper and decorative veneer in said
sequence and bonding together by pressing the assembly under pressure of 80-105 Kg/cm' for
70-80 sec or more in hydraulic press fitted with steel Moulds heated to a temperature of 130-
160°C and such that in the process the melamine resin get cured to provide the durable
pressure bonded decorative sheet.
Then this compressed unit, is again pressed at 85 degree Celsius temperature with hydraulic
pressure of 230 Kgs/Cm? to give texture impression with embossed moulds.
The decorative sheet thus obtained comprising said plywood with decorative veneer and
involving the overlay impregnated with melamine formaldehyde and embossing moulds is
finally trimmed followed by sanding of the decorative sheet.
The present invention contributes a decorative sheet made of core veneer, decorative veneer,
tissue paper and with special textures on the surface. This was hitherto not known or conceived
by persons skilled in the art, from knowledge on existing art.
The decorative sheet obtained in accordance with the invention as above
was subjected to tests to ascertain its characteristics as a decorative sheet, the results being
self explanatory are represented in the table below.

It would be well apparent to the art that following the inventive disclosure different
embodiments of the invention are possible involving the impregnated overlay paper bonded
decorative veneer with plywood and many modifications, variations and adaptations may be
carried out without departing from the spirit of the inventive disclosure and the scope of the
invention should be governed accordingly.
WE CLAIM :
1. A method for manufacturing a decorative sheet including assembling over at least a base
plywood, at least an overlay alpha cellulose paper and at least a decorative veneer layer in that
order, pressing the assembly so obtained under suitable pressure and temperature by suitable
means fitted with suitable moulds and further hot pressing the resultant with embossed moulds
under suitable hydraulic pressure and temperature to obtain decorative sheet having special
texture impression.
2. The method as claimed in claim 1, wherein said base plywood is of thickness between 3mm
and 4mm and said plywood is obtained by peeling off from hard wood logs to thickness of 3 to
4mm and by drying and coating with phenol formaldehyde resin.
3. The method as claimed in claim 1 wherein said decorative veneer is obtained by peeling off
or slicing in thickness of 0.3mm to 0.6mm from teak and other species having decorative look,
said veneer being dried before use.
4. The method as claimed in claim 1, wherein said embossed moulds are made of various
materials such as steel, iron, jute being transferred on surface of said decorative veneer on
application of heat and pressure and said special texture includes any one or any two or more
of or all of Halo, Tartan, Quill, Bristol, Hexad and Honeycomb.
5. The method as claimed in claim I. wherein said overlay paper is low GSM paper preferabl} in the
range of 16 to 22 gm/m6. The method as claimed in claim 5 wherein said GSM paper is preferably impregnated
applying a melamine formaldehyde resin on an impregnator, consisting of a high pressure
doctor roll.
7. The method as claimed in claim 6 wherein said resin contained in the overlay is maintained
in the range of 70-74% with a volatile content of 6-7%.
8. A method for manufacturing a decorative sheet including .
— assembling over a base plywood/core veneer obtained by peeling off from hardwood logs,
melamine formaldehyde impregnated overlay alpha cellulose low GSM paper in the range of 16
to 22 gm/m; and decorative veneer in that order,
— bonding together the assembly so obtained by pressing the assembly under pressure of 80-
105Kg/cnV for 70-80 seconds in hydraulic press fitted with steel moulds heated to a
temperature of 130-160°C such that in the process, said melamine resin get cured to provide
the durable pressure bonded decorative sheet,
— pressing the compressed unit so obtained at 85°C with hydraulic pressure of 230kgs/cm?
with embossed moulds to obtain decorative sheet with desired texture.
9. A decorative sheet obtained by the method as claimed in any preceding claim.
10. A decorative sheet including at least a base plywood, at least an overlay alpha cellulose
paper applied thereon, followed by at least a decorative veneer layer in that order, said paper
adapted to bond said base plywood and said decorative veneer layer, said decorative veneer
layer having further applied thereon a special texture obtained by application of embossed
mould.

A method for manufacturing a decorative sheet including assembling over at least a base
plywood, at least an overlay alpha cellulose paper and at least a decorative veneer layer in that
order, pressing the assembly so obtained under suitable pressure and temperature by suitable
means fitted with suitable moulds and further hot pressing the resultant with embossed moulds
under suitable hydraulic pressure and temperature to obtain decorative sheet having special
texture impression.