Veneer tape and method of use

Abstract

Veneer tape for temporarily joining pieces of veneer to be bonded to a substrate, for example, core board. The present invention also provides a method of forming a veneer assembly.

What is claimed is:  
     
         1 . A method of forming a veneer assembly, comprising the steps of: 
 a) aligning a first piece of veneer adjacent a second piece of veneer;    b) applying a veneer tape having a backing and a layer of adhesive disposed on the backing to the juncture between the first piece of veneer and the second piece of veneer so as to form a veneer assembly;    c) bonding the veneer assembly to a substrate; and    d) thereafter peeling the backing of the tape from the veneer assembly while a substantial amount of the layer of adhesive remains on the veneer assembly.    
     
     
         2 . The method of    claim 1   , further including the step of: 
 e) sanding adhesive from the veneer assembly.    
     
     
         3 . The method of    claim 1   , wherein the tape backing includes a first major surface, a second major surface opposite the first major surface, and wherein the layer of adhesive is disposed on the second major surface of the backing for bonding the tape to the veneer, wherein after step c), the layer of adhesive includes a cohesive strength, and wherein the cohesive strength is such that upon peeling of the backing from the veneer in step d) the layer of adhesive undergoes cohesive separation.  
     
     
         4 . The method of    claim 3   , wherein step d) includes peeling the entire backing in substantially one piece.  
     
     
         5 . The method of    claim 3   , wherein the tape backing includes a delamination strength, and wherein the delamination strength is greater than the cohesive strength of the layer of adhesive.  
     
     
         6 . The method of    claim 1   , wherein step d) includes peeling the backing of the tape from the veneer assembly while substantially all of the layer of adhesive remains on the veneer assembly.  
     
     
         7 . The method of    claim 6   , where wherein the tape backing includes a first major surface, a second major surface opposite the first major surface, and wherein the layer of adhesive is disposed on the second major surface of the backing for bonding the tape to the veneer with a first adhesive strength, wherein the layer of adhesive is bonded to the second major surface of the backing with a second adhesive strength, wherein the layer of adhesive includes a cohesive strength, and wherein after step c): 
 1) the cohesive strength is greater than second adhesive strength; and    2) the first adhesive strength is greater than the second adhesive strength.    
     
     
         8 . The method of    claim 7   , wherein step d) includes peeling the entire backing substantially in one piece.  
     
     
         9 . The method of    claim 7   , wherein the tape backing includes a delamination strength and wherein the delamination strength is greater than the second adhesive strength of the layer of adhesive.  
     
     
         10 . The method of    claim 1   , wherein the layer of adhesive of the veneer tape comprises poly(alpha-olefin) adhesive.  
     
     
         11 . The method of    claim 1   , wherein the layer of adhesive of the veneer tape comprises an acrylic-based adhesive.  
     
     
         12 . The method    claim 1   , wherein the backing of the veneer tape comprises paper.  
     
     
         13 . The method of    claim 1   , wherein the backing of the veneer tape comprises film.  
     
     
         14 . The method of    claim 1   , wherein the first piece of veneer and the second piece of veneer are selected from a group consisting of oak, maple, pine, cherry, walnut, ash, mahogany, teak, birch and hickory.  
     
     
         15 . The method of    claim 1   , wherein step c) further includes applying a pressure of 75-250 psi to the veneer assembly.  
     
     
         16 . The method of    claim 15   , wherein step c) further includes applying the pressure of 75-250 psi for at least 30 seconds.  
     
     
         17 . The method of    claim 14   , wherein step c) further includes applying a temperature of 250° to 325° F. to the veneer assembly.  
     
     
         18 . The method of    claim 3   , wherein step d) includes leaving 30-70% of the layer of adhesive on the veneer assembly.  
     
     
         19 . The method of    claim 6   , wherein step d) includes leaving at least 90% of the layer of adhesive on the veneer assembly.  
     
     
         20 . The method of    claim 1   , wherein prior to step c), the veneer tape is repositionable on the veneer assembly.  
     
     
         21 . A veneer assembly comprising: 
 a) a first piece of veneer;    b) a second piece of veneer adjacent said first piece of veneer; and    c) a veneer tape bonded to said first piece of veneer and to said second piece of veneer, wherein said tape includes: 
 i) a backing, including a first major surface and a second major surface opposite said first major surface; and  
 ii) a layer of adhesive disposed on the second major surface of said backing;  
 wherein said layer of adhesive is selected such that after bonding said veneer assembly to a substrate with an application of either:  
   i) 100 psi for 45 minutes at 68° F.; or    ii) 75 psi for 1 minute at 250° F.,    the bond between said veneer tape and said first piece of veneer and said second piece of veneer is high enough such that upon removing said backing from said veneer assembly, a substantial amount of said layer of adhesive remains on said veneer assembly and wherein said entire backing is removable in substantially one piece after an application of either:    i) 100 psi for 45 minutes at 68° F.; or    ii) 75 psi for 1 minute at 250° F.,    to bond said veneer assembly to a substrate.    
     
     
         22 . The veneer assembly of    claim 21   , wherein said layer of adhesive includes a cohesive strength, and wherein after bonding said veneer assembly to said substrate with an application of either: 
 i) 100 psi for 45 minutes at 68° F.; or    ii) 75 psi for 1 minute at 250° F.,    said cohesive strength is such that upon removal of said backing from said veneer assembly the layer of adhesive undergoes cohesive separation.    
     
     
         23 . The veneer assembly of    claim 21   , wherein after bonding said veneer assembly to said substrate with an application of either: 
 i) 100 psi for 45 minutes at 68° F.; or    ii) 75 psi for 1 minute at 250° F.,    upon removal of said backing from said veneer assembly, substantially all of said layer of adhesive remains on said veneer assembly.    
     
     
         24 . The veneer assembly of    claim 23   , wherein said layer of adhesive is bonded said first and second pieces of veneer with a first adhesive strength, wherein said layer of adhesive is bonded to the second major surface of said backing with a second adhesive strength, wherein the layer of adhesive includes a cohesive strength, and wherein after bonding said veneer assembly to a substrate with an application of either: 
 i) 100 psi for 45 minutes at 68° F.; or    ii) 75 psi for 1 minute at 250° F.,    a) said cohesive strength is greater than said second adhesive strength; and    b) said first adhesive strength is greater than said second adhesive strength.    
     
     
         25 . The veneer assembly of    claim 21   , wherein said tape backing includes a delamination strength high enough such that when said backing is removed from said veneer assembly, said entire backing is removed substantially in one piece.  
     
     
         26 . The veneer assembly of    claim 21   , wherein said layer of adhesive comprises poly(alpha-olefin) adhesive.  
     
     
         27 . The method of    claim 21   , wherein the layer of adhesive of the veneer tape comprises an acrylic-based adhesive.  
     
     
         28 . The veneer assembly of    claim 21   , wherein said tape backing of said veneer tape comprises paper.  
     
     
         29 . The veneer assembly of    claim 21   , wherein said tape backing of said veneer tape comprises a film.  
     
     
         30 . The veneer assembly of    claim 21   , wherein said veneer tape is initially repositionable on said first and second pieces of veneer.  
     
     
         31 . The veneer assembly of    claim 21   , wherein said first and said second pieces of veneer are selected from the group consisting of oak, maple, pine, cherry, walnut, ash, mahogany, teak, birch and hickory.  
     
     
         32 . A veneer tape, comprising: 
 a) a unprimed backing including a thickness of 0.001 to 0.005 inches; and    b) a pressure sensitive poly(alpha-olefin) adhesive disposed on said backing.    
     
     
         33 . The veneer tape of    claim 32   , wherein said unprimed backing comprises flat paper.  
     
     
         34 . The veneer tape of    claim 33   , wherein said flat paper includes a thickness of 0.0025 to 0.005 inches.  
     
     
         35 . The veneer tape of    claim 32   , wherein said unprimed backing comprises film.  
     
     
         36 . The veneer tape of    claim 34   , wherein said film includes a thickness of 0.001 to 0.004 inches.