CA1238529A - Door assembly with compression molded skins - Google Patents

Door assembly with compression molded skins

Info

Publication number
CA1238529A
CA1238529A CA000442718A CA442718A CA1238529A CA 1238529 A CA1238529 A CA 1238529A CA 000442718 A CA000442718 A CA 000442718A CA 442718 A CA442718 A CA 442718A CA 1238529 A CA1238529 A CA 1238529A
Authority
CA
Canada
Prior art keywords
skins
compression molded
door assembly
frame
rectangular frame
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000442718A
Other languages
French (fr)
Inventor
John E. Thorn
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Therma Tru Corp
Original Assignee
Therma Tru Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=23812608&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=CA1238529(A) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Therma Tru Corp filed Critical Therma Tru Corp
Application granted granted Critical
Publication of CA1238529A publication Critical patent/CA1238529A/en
Expired legal-status Critical Current

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70Door leaves
    • E06B3/82Flush doors, i.e. with completely flat surface
    • E06B3/822Flush doors, i.e. with completely flat surface with an internal foursided frame
    • E06B3/825Flush doors, i.e. with completely flat surface with an internal foursided frame with a wooden frame
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70Door leaves
    • E06B3/72Door leaves consisting of frame and panels, e.g. of raised panel type
    • E06B3/78Door leaves consisting of frame and panels, e.g. of raised panel type with panels of plastics
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70Door leaves
    • E06B3/7015Door leaves characterised by the filling between two external panels
    • E06B2003/7023Door leaves characterised by the filling between two external panels of foam type
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70Door leaves
    • E06B2003/7096Door leaves with possibilities to alter the extension of the door

Landscapes

  • Engineering & Computer Science (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Securing Of Glass Panes Or The Like (AREA)

Abstract

ABSTRACT
A door assembly with compression molded skins is disclosed. A pair of compression molded skins are mounted on a rectangular perimeter frame which extends outwardly from the edges of the skins. The compression molded skins include a molding resin and reinforcing glass fibers. The outer surface of the skin is essentially devoid of glass fibers. A foamed core is positioned within the frame in adhering relationship to the opposed skins. A texture is molded on the exterior of the skins which simulates the grain and texture of a wood door.

Description

~ 2~ 22236-563 BACKGROUND OF THE IN~ENTION
At-tempts have been made in the past -to construct various -types of door assemblies. A door assembly which is installed as an exterior door should be dimen-tionally stable to reduce energy losses through -the opening. Relatively severe t~mperature differentials occur on such ex-terior door assemblies. One of the major problems with prior art door assemblies has been excessive deflection and warping caused by such temperature differentials. Traditional wood doors suffer from splitting and cracking in addition to long-term moisture absorption which results in warping.
Another problem which has not been resolved by prior art door assemblies is the appearance of the door. In situations where simulated wood door appearances have been desired, attempts have been made to obtain the "wood" appearance -through the use of veneers and other surface trea-tments. Customers are generally familiar with the texture and the differences in graining of a wood door. Therefore, unless this same -type of texture and graining, for example edge graining, is dupli-cated, the wood simula-ted door assembly is unsatisfactory from an appearance viewpoint.
Another problem is the installation of a door assembly.
In the rehabilitation market and even in new construction, it is often necessary to trim the door assembly prior to installation within the door frame. This was often difficult to do when using prior art door assemblies.
SUMMARY OF T~E INVENTION
According to the present invention there is provided a door assembly comprising, in combination, a rectangular frame,
-2-~3~35~2~
22236~-563 a pair of opposed compression molded skins moun-ted on said Erame, and a Eoamed core positioned within said Erame between and adhered -to said opposed compression molded sklns, said skins each having an outer side, an inner side and longi-tudi-nally extending edges, a longitudinally extending projection posi-tioned on each said edge of said inner side of said compression molded skins, said projections engaging said rectangular frame, said compression molded skins being integral, including resin and glass fibers, said outer sides of said skins defining a textured pa-ttern simulating the grain and texture of a wooden door, said textured pattern having a pattern depth between 0.003 inch and 0.009 inch, but not in excess of such predetermined depth.
The present inven-tion has as its primary object a door assembly having compression molded skins so that the door provides a close simula-tion on its exterior to a wood door, both in texture and grain.
Another object of the present invention is to provide a door assembly having compression molded skins, which can be trimmed for insertion in an opening.
Still another object of the present invention is a door assembly with compression molded skins which resists permanent deflection and warping when exposed to temperature and humidity differentials.
DETAILED DESCRIPTION OF THE DRAWINGS
. _ . .
Figure 1 is an eleva-tional view of a door assembly with compression molded skins, according to the present invention, showing the simulated wood texture in the lower right-hand corner;
Figure 2 is the reverse side of one panel or skin of the door assembly shown in Figure 1 and further showing an inner texture in the lower right-hand corner;

` '' ~ 29 22236-563 Figure 3 is an enlarged :Eragmentary sect:ion view taken along the line 3-3 oE Figure l;
Figure 4 is an enlarged fragmentary section view taken along line 4~4 of Figure l;
Figure 5 is an enlarged fragmentary section view taken along the line 5-5 of Figure l;
Figure 6 is an enlarged fragmentary section view taken along the line 6-6 oE Figure l;
Figure 7 is an enlarged fragmentary section view taken along the line 7-7 of Figure l;

-~3a-~

Figure 8, is an enlarged fraymentary section view taken along the line 8-8 of Figure 2; and Figure 9, is an enlarged fragmentary section view taken along the line 9-9 of Figure 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
.
A compression molded door assembly with compression molded skins, according to the present invention, is generally indicated by the reference number 20 in Figure 1. The door assembly 20 includes a pair of opposed compression molded door panels or skins 21,22, which are attached to a perimeter frame 23. The lnterior of the perimeter frame 23 is filled with a foam core 24 which is adhered to the skins 21,22.
Each of the skins 21,22 is a compression molded sheet molding compound (SMC) panel, which includes 15% to 40% fibrous glass reinforcement, by weight, and 10% to 40% inert mineral filler, by weight, in polyester resin. The inert filler can be, for example, calcium carbonate or alumina trihydrate. In some embodiments, the materia:L may also include ultraviolet stabilizers and fire retardant additives in the composition.
Each of the skins 21,22 has a thickness of between .050 inch and .120 inch. The present embodiment shown in Figure 2, has a skin thickness of .070 inch.
Referring to Figure 1, an exterior side 26 of the skin 21 includes a molded wood grained texture 27. The texture 27 simulates both from a texture viewpoint and a graining viewpoint that of a wood doorl which has been assembled from wood components consisting of stiles, rails, raised and carved panels.
The texture 27 on the exterior side 26 is between .003 inches and .009 inches in depth.

i29 Referring to Figure 2, whlch depicts the inner si.de 28 of the skin 21, a random tex-ture 29 is molded into the skin 21. The random texture 29 on the inner side 28 has a depth of between .003 inch and .005 inch. The random texture 29 aids in the adherance of -the foam core 24 to the opposed skins 21,22.
The perimeter frame 23, in the present embodiment, is a wood perimeter frame constructed of finger-jointed pine.
The perimeter frame 23 is adhesively bonded -to the inner and outer compression molded polyester skins 21,22. The core 24 comprises a rigid urethane foam having a density of .8 pounds per cubic foot to 3.5 pounds per cubic foot.
Referring to Figure 1, the perimeter frame 23 extends outwardly from -the edge 31 of the panels or skins 21,22. The extension is 1/4 inch from the vertical edge 31 of the skin 21.
This permits the trimming of the door assembly 20 with conventional woodworking -tools.
The perimeter frame 23 includes horizontal rails 33 and vertical stiles 34. Referring to Figures 2 and 9, a plurality of horizontally extending grippers 37 having sharp outer edges, are molded on the inner sides 28 of the skins 21 and 22. A rail positioning member 38 also projects inwardly from the top and bottom surfaces of the inner sides 28 of the skins 21,22. As shown in Figures 3 and 4, -the rails 33 about the rail positioning member 38. The grippers 37 pierce the surface of the rails 33 and aid in preventing undesired relative motion between the rails 33 and the skins 21,22.
A plurality of vertically extending projections 40 are positioned inwardly from the inner sides 28 of the skins 21,22. As best shown in Figures 5 and 6, the pro~ections 40 ~;~3~

engage -the stiles 3~ of -the perimeter f.rame 23. In the present embodiment, a pair of -the vertically extending projections ~0 are provided or defined along each edge of the skin 21 or 22.
It has been found that a door assembly 20 with compre-ssion molded skins, as described above, provides a door assembly which has dimensional stability in various environmental conditions together with a pleasing appearance.
It has been found that the exterior surface of -the door assembly 20 may be stained with a wood stain or with a topcoat, such as urethane topcoat.
While the present embodiment shown in Figure 1, is directed to a nine unit "raised panel" design, simulating a wood door having a similar appearance, it is understood that various other designs may be constructed in accordance with the present invention without departing f.rom the appended claims.

Claims (8)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A door assembly comprising, in combination, a rectangular frame, a pair of opposed compression molded skins mounted on said frame, and a foamed core positioned within said frame between and adhered to said opposed compression molded skins, said skins each having an outer side, an inner side and longitudinally extending edges, a longitudinally extending projection positioned on each said edge of said inner side of said compression molded skins, said projections engaging said rectangular frame, said compression molded skins being integral, including resin and glass fibers, said outer sides of said skins defining a textured pattern simulating the grain and texture of a wooden door, said textured pattern having a pattern depth between 0.003 inch and 0.009 inch but not in excess of such predetermined depth.
2. A door assembly according to claim 1, wherein said inner side of each of said compression molded skins defines a molded textured pattern, said foamed core adhering to said textured pattern on said inner side.
3. A door assembly, according to claim 1, wherein said skins are constructed of a fiber reinforced polyester resin, said skins having a thickness of between .050 inch and .120 inch.
4. A door assembly, according to claim 1, wherein said foamed core comprises a rigid urethane foam having a density between .8 and 3.5 lbs./ft.3
5. A door assembly, according to claim 1, wherein said rectangular frame is constructed of wood, a plurality of transversely extending grippers defined on said inner side of said compression molded skins adjacent said rectangular frame, said grippers piercing said wood frame, whereby relative motion between said frame and said skins is sub-stantially prevented.
6. A door assembly, according to claim 1, including transversely extending rail stops extending inwardly from said inner side of said compression molded skins, said rail stops engaging the rails of said rectangular frame.
7. A door assembly, according to claim 1, including longitudinally extending projections positioned inwardly from said inner side of said compression molded skins, said projections engaging the stiles of said rectangular frame.
8. A door assembly, according to claim 1, wherein a pair of longitudinally extending projections are defined along each longitudinal edge of the inner side of each skin.
CA000442718A 1983-01-07 1983-12-07 Door assembly with compression molded skins Expired CA1238529A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US45640083A 1983-01-07 1983-01-07
US456,400 1983-01-07

Publications (1)

Publication Number Publication Date
CA1238529A true CA1238529A (en) 1988-06-28

Family

ID=23812608

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000442718A Expired CA1238529A (en) 1983-01-07 1983-12-07 Door assembly with compression molded skins

Country Status (2)

Country Link
CA (1) CA1238529A (en)
GB (1) GB2133069B (en)

Families Citing this family (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2166788A (en) * 1984-11-03 1986-05-14 Tighe Jack Desmond Door
US4864789A (en) * 1988-06-02 1989-09-12 Therma-Tru Corp. Compression molded door assembly
US4922674A (en) * 1988-06-15 1990-05-08 Therma-Tru Corp. Compression molded door assembly
GB2236346A (en) * 1989-09-28 1991-04-03 Permadoor International Limite Insulated door and manufacturing method
GB2237040B (en) * 1989-10-20 1994-04-20 Masonite Corp Wainscot panel and system
GB2237835B (en) * 1989-10-31 1994-06-01 Manchester City Council A security door
GB2258683B (en) * 1991-08-14 1995-04-05 Hsieh Wu Chang Door panel
GB2264522A (en) * 1992-02-04 1993-09-01 P V C Products Limited A door and method of producing a door
GB2267529B (en) * 1992-05-30 1996-09-04 Robert Wright Edwards Doors and methods of forming doors
US5644870A (en) * 1995-06-14 1997-07-08 Nan Ya Plastics Corporation Compression molded door assembly
US6389768B1 (en) * 1999-07-27 2002-05-21 The Stanley Works Molded plastic door skin
CN104179430B (en) * 2014-08-15 2016-08-24 浙江红利富实木业有限公司 A kind of pin-connected panel wood door structure

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1420244A (en) * 1973-05-09 1976-01-07 Marsden Co Ltd W Laminate-faced timber-framed structures
GB1487309A (en) * 1973-11-01 1977-09-28 Newbourne Watson Ltd Doors

Also Published As

Publication number Publication date
GB2133069B (en) 1986-04-03
GB2133069A (en) 1984-07-18
GB8332199D0 (en) 1984-01-11

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