United States Patent 19
`Hoffman
`
`||||||||||||||||||
`USOO5147486A
`11)
`Patent Number:
`5,147,486
`(45) Date of Patent:
`Sep. 15, 1992
`
`54 BUILDING PLYWOOD PRODUCT AND
`METHOD
`75 Inventor: Harry O. Hoffman, 4411
`adoro Dr. Youngstown, Ohio
`73) Assignees: Harry O. Hoffman; Kathleen A.
`Hoffman, Youngstown, Ohio
`(21) Appl. No. 620,143
`22 Filed:
`Nov. 30, 1990
`
`Related U.S. Application Data
`Division of ser. No.324,611, Mar 17, 1989, Pat. No.
`62)
`5,071,688.
`int. Cl. ............................................... B27D 1/04
`(51)
`52 U.S.C. .................................... 156/154; 144/346;
`428/106; 428/114
`58 Field of Search ............... 144/332, 330, 351, 346;
`156/154,94; 428/106, 535, 537.1, 114; 52/311,
`312, 313
`
`4,971,537 11/1990 Hoffman et al. ................ 156/94
`FOREIGN PATENT DOCUMENTS
`S5-44685 11 /1980 Japan ................................... 56/154
`62-28204 2/1987 Japan ................................... 44/332
`OTHER PUBLICATIONS
`American Plywood Association Product Guide, Form
`No. B360F/Revised May 1988/4000.
`"U.S. Product Standard PS 1-83', American Plywood
`Association, Form No. 1 t850 cARevised Jun.
`1987/6000.
`Prosales, for Dealers and Distributors Serving the Pro
`fessional Contractor. The Second Coming of Engi
`neered Trim” pp. 56-57, Mar. 1991.
`Primary Examiner-Michael W. Ball
`Assistant Examiner-Daniel J. Stemmer
`Attorney, Agent, or Firm-Clifford A. Poff
`TRA
`57
`ABS
`CT
`The disclosure relates to a medium density overlay
`plywood panel used as an exterior trim product for a
`residential building having a relatively high number of
`References Cited
`plies to total board thickness, and exposed edges with
`U.S. PATENT DOCUMENTS
`void free sanded surfaces having a predetermined pat
`2,720,478 10/1955 Hogg................................... 156/154
`tern coarseness, and in which said overlay and edge
`3,362,379 1/1968 Knudtson ..
`...
`8/670
`surfaces are covered with an acrylic paint, whereby the
`3,595.2037/1971 Fabulich.
`...
`18/415
`trim product is characterized with the appearance of a
`3,618,646 11/1971 Lewis ........
`" /
`E. A: Fran".
`as E. solid wood product and the painted surfaces as highly
`3,967,581 7/1976 Zirbel ........
`1768,
`weather resistant.
`4,105,816 8/1978 Hori ......
`... 427A28
`4,114,233 9/1978 Hamilton ............................ 16/95 R
`11 Claims, 2 Drawing Sheets
`
`56)
`
`
`
`3O
`
`2
`
`)
`
`7
`-
`
`34
`
`Louisiana-Pacific Corporation, Exhibit 1044
`IPR of U.S. Pat. No. 8,474,197
`Page 1
`
`

`

`U.S. Patent
`
`Sep. 15, 1992
`
`Sheet 1 of 2
`
`5,147,486
`
`
`
`22t
`Snsane
`224
`
`Louisiana-Pacific Corporation, Exhibit 1044
`IPR of U.S. Pat. No. 8,474,197
`Page 2
`
`

`

`U.S. Patent
`
`Sep. 15, 1992
`
`Sheet 2 of 2
`
`5,147,486
`
`Louisiana-Pacific Corporation, Exhibit 1044
`IPR of U.S. Pat. No. 8,474,197
`Page 3
`
`

`

`5
`
`5
`
`1.
`
`BUILDING PLYWOOD PRODUCT AND METHOD
`
`The present application is a divisional application of
`U.S. Ser. No. 07/324,611, filed on Mar. 17, 1989, now
`U.S. Pat. No. 5,071,688.
`BACKGROUND OF THE INVENTION
`The present invention pertains to a method of pro
`ducing a plywood product and the product itself used
`10
`for certain applications in the residential and commer
`cial building industries, and more particularly as a trim
`and/or wall covering product for either exterior or
`interior use.
`For the purpose of explaining the invention, its adap
`tation for use as an exterior wood trim product has been
`selected for domestic structures (homes) since at present
`it is the preferred application.
`It has been almost exclusively the practice of archi
`tects and builders to employ solid wood, for exterior
`20
`trim members, such as redwood and cedar for example,
`the trim being placed around doors, windows, wall
`sections, overhangs, sofits, etc. mostly for accent or to
`give a "finishing touch' to the homes.
`The selection in the past of the solid types of woods
`25
`was mainly done because of the desire to achieve a solid
`wood appearance, notwithstanding the inherent serious
`disadvantage of upkeep, in that such woods required
`repeated painting or staining and were subject to the
`ever constant problems of peeling, flaking and cracking.
`30
`The disadvantages of these solid wood products were
`exacerbated by the continuous rise in cost of the wood
`involved, particularly due to the increase scarcity of
`cedar and redwood.
`While the attempts to employ a plywood product in
`35
`place of the solid wood was attractive due to the obvi
`ous substantial cost saving, plywood trim was not well
`received. This was due mainly because of the failure to
`give the appearance that the trim was a solid wood
`product, particularly as to the edges where not only the
`several plies were visible but also the customary edge
`openings could not be adequately filled and covered
`with paint or stain. This disadvantage when considered
`along with the fact that the plywood trim from a main
`tenance standpoint was no better, if not worse, than the
`45
`solid wood trims led to a rejection of the plywood trim
`product.
`Despite the failure of these earlier attempts to satisfy
`the industry's needs for an acceptable plywood trim
`product, because of the substantial cost saving it repre
`50
`sented, the present invention sought to overcome each
`of the above mentioned drawbacks and others, and in
`fact has been successful in doing so.
`This solution started with the recognition of selecting
`as the base plywood product a plywood generally simi
`55
`lar to the type already on the market for other industrial
`uses, howbeit not for a trim product, such a product is
`manufactured and sold by Simpson Timber Company of
`Shelton Washington and marketed under the registered
`Trademark "Two Step" MDO, MDO being an acro
`60
`nym for a plywood base panel having a medium density
`overlay on one or both of its planar surfaces and em
`ploying a marine plywood type adhesive. A discussion
`of this product can be found in the American Plywood
`Association's brochure, Forn No. B360F/Revised May
`65
`1988/4000. This product in the form employed by the
`present invention is known sometimes as a scarfed
`jointed panel, which is discussed and illustrated, along
`
`5,147,486
`2
`with other pertinent characteristics of the base plywood
`panel in a publication of the American Plywood Associ
`ation entitled "U.S. Product Standard PS 1-83' Form
`No. H 850C/Revised, June 1987/6000. The term den
`sity refers to the amount of resin in the overlay, the resin
`being used for proper coating adhesives and the high
`content for moisture resistance.
`The multi-step product generally is made by the se
`lection of Douglas fir plies to form the substrate in a
`conventional manner, repairing any surface defects,
`sanding one or both of the planar surfaces and then
`covering these surfaces with a resin impregnated over
`lay by a hot pressing operation. This product is charac
`terized by having a planar smooth surface, a surface that
`holds paint extremely well and a plywood substrate
`with a minimum of core gaps.
`Such a product while having some very attractive
`features as a potential base board as a trim, still pres
`ented the problem of not giving the requisite solid wood
`appearance, particularly as to the ply edges on the long
`sides of the panel and even if the edge problem could be
`solved, there was no acceptable manner of being able to
`apply a paint, glaze or stain that would assure that both
`the planar surface and the edges would give the appear
`ance of being a solid piece of wood and that both por
`tions would yield a uniform maintenance free product.
`BRIEF SUMMARY OF THE INVENTION
`Against the above described backdrop, the present
`invention provides a method of producing a plywood
`product and the product thereof characterized by a
`relatively high number of plies to total board thickness
`to minimize core gaps, having one planar sanded sur
`face with a medium density overlay, where the other
`wise core gaps and other imperfections of the edges
`have been treated, and the intended exposed surface and
`edges have been coated to give the unquestionable ap
`pearance of a solid wood board, and when used for
`external application possesses a maintenance free qual
`ity much superior to existing solid wood trim products.
`More, particularly the invention provides an article
`of manufacture comprising a plywood building trim
`product consisting of between five to eleven plies hav
`ing a ratio offive plies per five eighth inch of total board
`thickness and an approximately similar ratio for in
`crease thicknesses of boards and having Douglas fir for
`the wood and the ply adherent being a marine glue, the
`article being further made up of two or more end to end
`lengths of said boards joined together by a transverse
`diagonal scarfed joint, forming a relatively long length
`narrow width trim product, the thickness difference
`between said two joined boards in the area of said
`joined ends being limited to no more than approxi
`mately one thirty second of an inch, said trim product
`having an appearance side, an opposite construction
`side and two opposite long length exposed ply edges,
`said appearance side being covered entirely by a me
`dium density fiber overlay, said ply edges being charac
`terized by void free sanded surfaces formed by applying
`a void filler putty, and post filler sanding, the sanded
`surfaces being characterized by having a predetermined
`coarseness pattern of the order of 40 to 60 grit and an
`overall coarseness comprising alternate plies having
`different degrees of coarseness for purposes of good
`coating adherence, said appearance side and said ply
`edges being covered by an acrylic paint, wherein said
`appearance side and said ply edges are characterized by
`high resistance against conditions affecting appearance
`
`Louisiana-Pacific Corporation, Exhibit 1044
`IPR of U.S. Pat. No. 8,474,197
`Page 4
`
`

`

`O
`
`5
`
`5,147,486
`3
`4.
`and longevity, and having the appearance as to said
`made to look like solid wood and both the overlay
`painted surfaces of a solid integral wood trim product.
`surface and the longitudinal edges when painted or
`stained will give the appearance of three identical ex
`BRIEF DESCRIPTION OF THE DRAWINGS
`posed surfaces, which will be far superior from a main
`tenance standpoint than existing trim products for a
`FIG. 1 thru FIG. 4 are similar sequence views of one
`of the longitudinal edge surfaces of a trim product for
`wide range of different outdoor regions and conditions.
`the purpose of illustrating the conditions of the edge
`With reference now to FIG. 1, which is the first of
`four sequential views of a portion of one of the longitu
`surface at various stages of the treatment thereof in
`producing a plywood trim product in accordance with
`dinal sides or edge surfaces of a 5 ply Douglas fir multi
`step scarf jointed thin core MDO plywood trim of the
`the teaching of the present invention,
`FIG. 5 is a perspective view of a portion of a finished
`type described above, before the side has been treated in
`external plywood trim product corresponding to FIG.
`accordance with the teaching of the present invention.
`The plies have generally equally approximately 0.09
`4, and
`FIG. 6 is a layout plan view for the purpose of illus
`inch thicknesses, as shown in FIG. 1. As one views
`trating the sequential method steps of the present inven
`FIG. 5, it is to be understood that the top and two
`opposite long sides or edges 9, will be treated portions
`tion.
`of the trim and the short sides or edges and the bottom
`DETAIL DESCRIPTION OF THE INVENTION
`surface will remain untreated. The trim 8, as viewed
`As noted previously, the preferred base plywood
`from one of its edge surfaces 9, comprising of two end
`panel, based on what is presently available on the mar
`to end boards 10 and 12 constructed according to cus
`20
`tomary practice of five plies 14, the left hand end 10
`ket, is a structural 1 multi-step MDO, of the type of
`fered to the trade by the Simpson Timber Company, in
`being joined to the right end 12 by a well known scarfed
`which to make the required lengths two boards that
`joint 16, in a manner that any thickness differential is
`make up the panel are joined by a scarfed joint such as
`made to appear all at the lower surface 18, at the loca
`depicted on page 31 of the aforesaid American Plywood
`tion 19, which will be the non exposed i.e. construction
`25
`Association's publication of June 1987/6000. This type
`side of the finished trim. The thickness difference be
`of joint is important to the product of the present inven
`tween the two joined products in the area of the joined
`ends is limited to no more than approximately plus or
`tion because all of the thickness differential between the
`two boards can be taken up on common sides of the
`minus one thirty second of an inch. Those skilled in the
`boards opposite the overlay sides so that the overlay
`art will appreciate the trim need not be made up of two
`30
`sides can be made substantially flat, i.e. there being no
`or more boards and that if joined, the joint need not be
`a scarfed joint, but a fingered or other type of joint can
`gap or space between adjacent surfaces of the boards
`be employed.
`and nothickness differences, which surfaces when cov
`ered by the overlay assure an extremely flat appearing
`To the top surface 25 of the trim 8 there is formed the
`medium density overlay 22 of the type previously dis
`face.
`Just as important to the present invention is the selec
`cussed. Also shown in FIG. 1 are several of the custom
`ary edge imperfections in the form of irregular openings
`tion of a plywood generally similar to the MDO Doug
`las fir product because it may be constructed to have a
`24, which may range in depth or extent from a mere
`preferred limited and tight core gap condition per a
`surface indentation to a opening clear through the
`given thickness of panel along with the high structural
`board. Not shown, is the full extent of the core gaps
`40
`qualities. Equally important is the advantage given by
`which exist between each adjacent surface or layer of
`the medium density overlay as a superior smooth paint
`the plies 14, which gaps require treatment as do the
`openings 24, if the objectives of the present invention
`able long lasting surface because, in part, of its pre sand
`ing operation resulting in a minimum of wood grain and
`are to be realized.
`repair show-throughs. The medium density overlay
`Turning now to FIG. 2, where like references indi
`45
`while available in a number of different weights, for the
`cate similar elements, as is true in the remaining views,
`this sequential view is designed to depict the improved
`purpose of the present invention 61 lbs/M sq. ft.
`28-38% resin is preferred of the impregnated cellulose
`condition of the edges of the trim board after it has been
`fiber type applied by heat and pressure. As noted above,
`treated with a void filling substance 26 as the first step
`these characteristics and others of the MDO products as
`of the invention to create a solid wood like trim prod
`manufactured by the Simpson Timber Company are
`uct. In the preferred form of the invention, the filler
`discussed in the aforesaid publication Form No. B 360
`substance takes the form of a wood putty water base
`similar to 120 spackling paste sold by the Synkoloid
`F.
`This plywood product employs a well known marine
`Company, Inc. of Atlanta, Ga. under its trade name
`plywood glue.
`"SYNKO". Important factors in selecting the filler is
`55
`For present day exterior trim, the multi-step MDO
`the technic employed to effectively apply the filler and
`panel according to the present invention is cut from a
`how the filler holds up after drying and cooling. Some
`fillers were found to not fill the voids satisfactory, par
`standard 4 ft. width, 8 to 12 feet long panel to the re
`quired narrow widths of approximately between 3 to 12
`ticularly when applied to a vertical surface, others
`which acceptably filled the gaps, upon drying formed
`inches and between to 1 inches in thickness depend
`ing on the particular end use. The inch thickness
`"dimples' or "mud cracks'. The putty found most ac
`board would preferably be a 7 ply board, 9 ply for a
`ceptable was one that contained relatively high solids,
`for example, approximately 70% solids in which the
`inch board, 11 ply for a 1 inch thickness board and 13
`ply for the 1 inch board.
`solids, consisted substantially of resins but yet had the
`One of the important aspects of the invention is the
`necessary viscosity for effective application and flexibil
`65
`development of the above described cut MDO product
`ity, i.e., resilience when dried. Because of the need to
`into a trim that will give the appearance of a solid wood
`balance these various factors it was found that the main
`board, in which the longitudinal edges, in particular, are
`tenance of the temperature of the putty was important.
`
`50
`
`35
`
`Louisiana-Pacific Corporation, Exhibit 1044
`IPR of U.S. Pat. No. 8,474,197
`Page 5
`
`

`

`5
`
`10
`
`5,147,486
`5
`6
`ducing an acceptable trim product requires care in se
`In this regard it is desirable that the putty be maintained
`at a temperature so as not to fall below approximately
`lecting the correct type or kind of sealer in terms of
`60 F. and preferably at approximately between 60 and
`achieving the solid board appearance and assuring a
`80' F. Depending on the type and contents of the putty,
`superior maintenance free product. In this regard as to
`the conditions of the edges and the ambient conditions
`the selection of a paint, a paint of the industrial machine
`of the manufacturing plant, the viscosity of the putty
`applied acrylic latex type is preferred. The paint should
`may vary substantially.
`have a medium solid content by volume and evidence
`FIG. 2 is designed to indicate that the putty has com
`good adhesive qualities when subject to an adhesive
`pletely filled any and all openings, including the core
`tape test immediately after wet painting and oven dry
`gaps and the scarfed joint, wherein the entire surface, in
`ing, one such paint being that sold by the Perry and
`addition to the openings and gaps, is covered with a
`Derrick Company of Cincinnati, Ohio as its 87382
`relatively thin uniform coating of the putty. In this
`Latex Primer.
`covering and filling it will not be necessary to com
`FIG. 5 is designed to illustrate the finished trim prod
`pletely fill the extensive openings and only necessary to
`uct 29, in which one of the two finished exposed edges
`provide enough filling to assure a smooth flat edge
`9 and the exposed finished overlay side 22 are shown, in
`surface. Such openings, however, may have an overage
`addition to one of the non-exposed untreated ends 28,
`of putty tending to protrude outwardly from the other
`non-exposed in the sense that when secured to the house
`portions of the covered edge surface, the former condi
`the end is covered by another part of the building. The
`tion being depicted by the area marked 28.
`treated portions constituting a plywood product have
`In addition to a putty filler which could be either a
`20
`been made to appear as a solid wood product for the
`water or solvent base product, depending on the
`purpose intended.
`weather conditions with which the trim is to be used
`With reference to FIG. 6, which illustrates the
`and the machinery employed, if any, to apply the filler
`method steps of the present invention, there is indicated
`and commercial consideration, the filler may be one of
`a multi-step MDO panel 30 of the type above described,
`several available caulking compounds, or one of the
`25
`as being the basic plywood product from which the
`wood filler products now on the market when altered, if
`final trim is formed. This panel 30 is cut into a number
`necessary, to fit the particular purpose. While the filler
`of narrower width full length trim boards 32, such as
`can be applied by hand, in which case a less liquid type
`previously noted, one of such trim boards being identi
`product can be used, the preferred manner is by me
`fied at 34. This trim board is then transferred to a putty
`chanical means where both edges of the trim are treated
`30
`station 36 where the long opposite edge surfaces 38 are
`at the same time.
`passed between opposed putty applicators, as indicated
`In the third sequential view shown in FIG. 3, the
`by the two opposed arrows, to simultaneously apply
`putty treated edge of the trim 8 has been given a
`putty to all openings, including the core gaps as de
`smoothing treatment such as by sanding, the preferred
`scribed above.
`treatment being a sanding treatment, in which both
`35
`From the putty station 36, the partially processed
`opposite edge surfaces of the trim are subject to a sand
`trim board 34 is passed to a sanding station 38 where the
`ing operation such as by dual edge sanding machine.
`two puttied edge surfaces are simultaneously sanded by
`This treatment is preferred after the filler has been dried
`being passed between two opposed sanding devices
`either by allowing it to dry naturally or by applying
`indicated by opposed arrows, to remove any excessive
`heat in a controlled manner.
`putty and create a uniform surface and a uniform prede
`It is important according to the present invention in
`termined coarseness, i.e. the teeth condition as previ
`the sanding or similar treatment to create a teeth condi
`ously explained.
`tion i.e. a controlled desired degree of roughness
`From the sanding station 38, the trim board 34 is
`throughout the entire edge surface for the purpose of
`transferred to a paint station 40 where paint is applied
`assuring a good bonding surface for a surface coating.
`45
`simultaneously to both of the two previously treated
`In the development of the invention two factors were
`edge surfaces and the overlay top surface 42, as indi
`found to be significant, the first was the recognition that
`cated by three arrows. As explained above, a second
`the alternate plies that make up the board and appear at
`coat may be applied, if desired, in which each coat will
`both the long and short edges or sides of the product
`be of the approximate order of 2 to 3 wet mils per coat.
`and particularly the edge 9 and its opposite edge. In this
`SO
`This last step, with the benefit of the earlier steps, cre
`arrangement, one ply is the "end" cross ply and the
`ates a plywood board having the appearance, as to the
`other the "edge' cross ply which create alternate differ
`three treated surfaces, of a solid wood trim product
`ent teeth conditions across the edge 9 and its opposite
`possessing all of the other desired characteristics previ
`edge of the product from ply to ply, and secondly that
`ously noted.
`depending on the coarseness effected by the sanding
`55
`In accordance with the patent statutes, I have ex
`operation an excellent bonding surface could be ob
`plained my invention in terms of its preferred embodi
`tained. This alternate teeth condition creates a highly
`ment, however, it will be readily understood by those
`desirable surface pattern due to the reaction of the end
`skilled in the art to which the invention pertains that it
`grain and the edge grain when subject to a certain sand
`ing operation. A sand paper belt may be employed hav
`may be practiced other than illustrated and described.
`ing a coarseness range of number 40 to 60 grit, prefera
`I claim:
`1. A method of manufacturing an exterior plywood
`bly number 50 grit, the grit being the amount and tex
`building trim product comprising the steps of:
`ture of the sand on the paper.
`forming a base plywood board of an odd number of
`With reference now to the fourth sequential view
`plies between 7 to 13 inclusive, said board having a
`shown in FIG. 4, the sanded edge surface of FIG.3 has
`65
`ratio of 7 plies per five-eights inch of total board
`been treated with a sealer primer of paint or stain and if
`thickness and an approximately equal ratio for
`desired a second or finished coat, each coat being an
`approximately 2 to 3 mils wet coat. This step in pro
`increased thicknesses of boards, by:
`
`Louisiana-Pacific Corporation, Exhibit 1044
`IPR of U.S. Pat. No. 8,474,197
`Page 6
`
`

`

`5,147,486
`7
`8
`arranging each ply so that its grain is positioned per
`arranging each ply so that its grain is positioned per
`pendicularly to an adjacent ply to form alternately
`pendicularly to an adjacent ply to form alternately
`arranged plies having alternating degrees of edge
`arranged plies having alternating degrees of edge
`COarSeneSS,
`COarseneSS,
`forming the board to have appearance and construc
`forming the board to have appearance and construc- 5
`tion side plies and interior plies,
`tion side plies and interior plies,
`forming said interior plies so that each ply thereof has
`providing said interior plies so that each ply thereof
`substantially the same uniform thickness, and
`has substantially the same uniform thickness,
`forming the plies out of Douglas fir,
`adhering adjacent said plies together,
`O
`adhering adjacent said plies together by a marine glue
`forming the board to have a length substantially 1
`joining together two or more end to end lengths of
`greater than its width, and to have two exposed ply
`said boards by a transverse diagonal scarfed joint to
`edges opposite each other extending the length of
`form a length substantially greater than the width
`the board, wherein said ply edges will have edge
`of the joined boards, wherein the joined boards will
`openings and edge core gaps;
`have two exposed ply edges opposite each other
`15
`sanding said appearance side ply to reduce show
`extending the length of the joined boards, and
`through imperfections;
`wherein said ply edges will have edge openings
`covering said appearance side ply with a fiber over
`and edge core gaps;
`lay;
`limiting the thickness difference between the joined
`filling said edge openings and edge core gaps with a 2O
`boards in the area of said joined ends to no more
`filler compound to fill at least the outside portions
`than approximately plus or minus one thirty second
`of said openings and gaps and to cover the entire
`of an inch;
`surfaces of said ply edges to an extent sufficient
`forming said appearance side ply and said construc
`only to create substantially uniformly covered
`tion side ply having the same grain directions;
`25
`edges;
`sanding said appearance side ply to reduce show
`sanding said covered edges so that the sanded edges
`through imperfections;
`have a predetermined degree of overall coarseness
`covering said appearance side ply with a medium
`created by said sanding, wherein the coarse sand
`density fiber overlay;
`ing and said different degrees of edge coarseness of
`filling said edge openings and edge core gaps with a
`said alternately arranged plies form a strong bond 30
`filler compound to fill at least the outside portions
`between said ply edges and a covering of paint or
`of said openings and gaps and to cover the entire
`stain; and
`surfaces of said ply edges to an extent sufficient
`covering said sanded edges and said covered appear
`only to create substantially uniformly covered
`edges;
`ance side ply with paint or stain, wherein said ap
`sanding said covered edges to give the sanded edges
`pearance side ply and said ply edges are substan- 35
`tially resistant to conditions affecting appearance
`a predetermined coarseness of the order of number
`40 to 60 grit, wherein the coarse sanding and said
`and longevity and have the appearance as to said
`different degrees of edge coarseness of said alter
`covered edges and appearance side ply of a solid
`nately arranged plies form a strong bonding surface
`integral wood product.
`for purposes of good coating adherence; and
`2. In a method according to claim 1, the additional 40
`covering said sanded edges and said covered appear
`step of immediately prior to applying said void filling
`ance side ply with an acrylic latex paint coating,
`compound maintaining said compound at a temperature
`wherein said covered appearance side ply and said
`so as not to fall below approximately 60' F.
`ply edges are substantially resistant against condi
`3. In a method according to claim 1, the additional
`tions affecting appearance and longevity, and have
`step of immediately prior to applying said void filling
`45
`the appearance as to said painted surfaces of a solid
`compound maintaining the compound at a temperature
`integral wood trim product.
`between approximately 60 to 80 F.
`8. In a method according to claim 7, the additional
`4. In a method according to claim 1, wherein said
`step of immediately prior to applying said putty main
`void filling compound comprises a wood putty having
`taining said putty at a temperature so as not to fall
`50
`as an ingredient a substantial amount of solids and when
`below approximately 60' F.
`dried has a high resistance to dimpling and mud cracks.
`9. In a method according to claim 7, wherein said
`5. In a method according to claim 1, said sanding step
`putty comprises a wood putty having as an ingredient a
`further comprising creating a coarseness of the order of
`substantial amount of solids and when dried has a high
`number 40 to 60 grit.
`55
`resistance to dimpling and mud cracks.
`6. In a method according to claim 1, the additional
`10. In a method according to claim 7, the additional
`step of forming said interior plies out of plies having a
`step of forming said interior plies out of plies having a
`thickness of approximately 0.09 inch.
`thickness of approximately 0.09 inch.
`7. A method of manufacturing an exterior plywood
`11. In a method according to claim 7, the additional
`building trim product comprising the steps of:
`60
`steps of arranging, for several different thickness build
`forming at least two base plywood boards of an odd
`ing trim products, seven said plies to form a five-eighths
`number of plies between seven to thirteen inclu
`inch total thickness said board, nine said plies to form a
`sive, said boards having a ratio of seven plies per
`three quarter inch total thickness said board, eleven said
`five eights inch of total board thickness and an
`plies to form a one inch total thickness said board, and
`approximately equal ratio for increased thicknesses 65
`thirteen said plies to form a one and a quarter inch total
`of boards, wherein each board has the same num
`thickness said board.
`ber of plies, by:
`
`Louisiana-Pacific Corporation, Exhibit 1044
`IPR of U.S. Pat. No. 8,474,197
`Page 7
`
`