US3731443A - Carved doors - Google Patents
Carved doors Download PDFInfo
- Publication number
- US3731443A US3731443A US3731443DA US3731443A US 3731443 A US3731443 A US 3731443A US 3731443D A US3731443D A US 3731443DA US 3731443 A US3731443 A US 3731443A
- Authority
- US
- United States
- Prior art keywords
- panel
- carved
- frame
- panels
- door
- 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 - Lifetime
Links
- 238000000034 method Methods 0.000 claims abstract description 21
- 239000011120 plywood Substances 0.000 claims abstract description 14
- 229920002635 polyurethane Polymers 0.000 claims abstract description 14
- 239000004814 polyurethane Substances 0.000 claims abstract description 14
- 239000004616 structural foam Substances 0.000 claims abstract description 8
- 238000000465 moulding Methods 0.000 claims description 19
- 239000006260 foam Substances 0.000 claims description 13
- 238000004519 manufacturing process Methods 0.000 claims description 7
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 6
- 229920002554 vinyl polymer Polymers 0.000 claims description 6
- 238000000576 coating method Methods 0.000 claims description 4
- 239000013521 mastic Substances 0.000 claims description 4
- 239000000463 material Substances 0.000 claims description 4
- 239000011347 resin Substances 0.000 claims description 4
- 229920005989 resin Polymers 0.000 claims description 4
- 230000004888 barrier function Effects 0.000 claims description 3
- 239000011248 coating agent Substances 0.000 claims description 3
- 239000011094 fiberboard Substances 0.000 claims description 3
- 238000002347 injection Methods 0.000 claims description 3
- 239000007924 injection Substances 0.000 claims description 3
- 238000007789 sealing Methods 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- 230000001680 brushing effect Effects 0.000 claims description 2
- 238000003780 insertion Methods 0.000 claims description 2
- 230000037431 insertion Effects 0.000 claims description 2
- 239000002023 wood Substances 0.000 abstract description 9
- 229920003023 plastic Polymers 0.000 abstract description 3
- 239000004033 plastic Substances 0.000 abstract description 3
- 238000001746 injection moulding Methods 0.000 abstract description 2
- 239000000203 mixture Substances 0.000 description 5
- 239000000047 product Substances 0.000 description 5
- 235000019640 taste Nutrition 0.000 description 4
- -1 Polyoxypropylene Polymers 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 229920005830 Polyurethane Foam Polymers 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- 238000009432 framing Methods 0.000 description 2
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 239000011496 polyurethane foam Substances 0.000 description 2
- 230000000135 prohibitive effect Effects 0.000 description 2
- HOVAGTYPODGVJG-UVSYOFPXSA-N (3s,5r)-2-(hydroxymethyl)-6-methoxyoxane-3,4,5-triol Chemical compound COC1OC(CO)[C@@H](O)C(O)[C@H]1O HOVAGTYPODGVJG-UVSYOFPXSA-N 0.000 description 1
- 239000004604 Blowing Agent Substances 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- UEEJHVSXFDXPFK-UHFFFAOYSA-N N-dimethylaminoethanol Chemical compound CN(C)CCO UEEJHVSXFDXPFK-UHFFFAOYSA-N 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- XIWFQDBQMCDYJT-UHFFFAOYSA-M benzyl-dimethyl-tridecylazanium;chloride Chemical compound [Cl-].CCCCCCCCCCCCC[N+](C)(C)CC1=CC=CC=C1 XIWFQDBQMCDYJT-UHFFFAOYSA-M 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000001413 cellular effect Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 229960002887 deanol Drugs 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 125000005442 diisocyanate group Chemical group 0.000 description 1
- 239000012972 dimethylethanolamine Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 238000010097 foam moulding Methods 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000012948 isocyanate Substances 0.000 description 1
- HOVAGTYPODGVJG-UHFFFAOYSA-N methyl beta-galactoside Natural products COC1OC(CO)C(O)C(O)C1O HOVAGTYPODGVJG-UHFFFAOYSA-N 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 229920001451 polypropylene glycol Polymers 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 229920002379 silicone rubber Polymers 0.000 description 1
- 239000004945 silicone rubber Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 239000012974 tin catalyst Substances 0.000 description 1
- CYRMSUTZVYGINF-UHFFFAOYSA-N trichlorofluoromethane Chemical compound FC(Cl)(Cl)Cl CYRMSUTZVYGINF-UHFFFAOYSA-N 0.000 description 1
- 229940029284 trichlorofluoromethane Drugs 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B3/00—Window 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
- E06B3/70—Door leaves
- E06B3/7001—Coverings therefor; Door leaves imitating traditional raised panel doors, e.g. engraved or embossed surfaces, with trim strips applied to the surfaces
-
- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B3/00—Window 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
- E06B3/70—Door leaves
- E06B3/82—Flush doors, i.e. with completely flat surface
- E06B3/86—Flush doors, i.e. with completely flat surface of plastics without an internal frame, e.g. with exterior panels substantially of plastics
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24496—Foamed or cellular component
- Y10T428/24504—Component comprises a polymer [e.g., rubber, etc.]
- Y10T428/24512—Polyurethane
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249987—With nonvoid component of specified composition
Definitions
- a release agent Prior to injection of the polyurethane into the mold cavity, a release agent is applied to the internal surfaces of the mold, all in well known manner. Thereafter, the polyurethane is injected into the mold for expansion therein to form the carved panels of a particular configuration.
- the general molding procedure may be, for example, more or less in accordance with Angel U.S. Pat. No. 3,268,636 or 3,436,446.
- the polyurethane foams are generally formed from compositions which include polymers containing three hydroxy groups, such as hydroxyl terminated polyester or polyether, an organic diisocyanate, and a small amount of water.
- a catalyst preferably an amine catalyst, a tin catalyst and an em ulsifier are also included.
- Such compositions may be formed or otherwise treated in a manner known in the art to produce the desired cellular product.
- FIG. 1 is a front elevational view of a door having decorative foam panels disposed in the openings thereof and showing a plurality of such openings with panels disposed on the door;
- the door As indicated in FlG. l, the door, generally designated 10, is comprised of a frame structure 12 which may be mass produced ofa size generally utilized for particular applications, such as the front door of residences.
- the frame 12 has extending from one side thereof to the other a thin panel structure 22 which may be of plywood, pressed fiberboard or a resin material with the panel 22 being inserted into grooves formed in the frame 12 on both sides thereof.
- a thin panel structure 22 which may be of plywood, pressed fiberboard or a resin material with the panel 22 being inserted into grooves formed in the frame 12 on both sides thereof.
- This construction serves to provide carved pane] receiving insert areas 24 for the subsequent application of the polyurethane molded, carved panels..
- the panels are formed of the desired configuration, in accordance with the procedure noted above, to provide a particular design configuration such as 18 in FIG. 1.
- a method for producing laminated doors having carved panels disposed on the surface thereof the steps which comprise preselecting a wooden door frame having a first predetermined woodgrain and at least one opening disposed therein with a thin member extending over said opening to provide at least one carved panel insert area on one or both sides of said frame, injecting polyurethane into a mold having a configuration conforming to the desired design of said carved panels, and having a second predetermined grain, expanding said foam in said mold to form said carved panel, adhering at least one of said carved panels to the surface of said thin member in said panel insert area, applying amolding around the circumference of said adhered carved panel adjacent the junction of the edge of said carved panel with said door frame, and treating the surface of said frame and said carved panel to produce an integrally appearing door having at least one decoratively carved panel disposed on the surface thereof.
- a door having a wooden frame with at least one opening disposed therein
- the combination which comprises a thin-walled panel disposed in each of said openings and having a thickness less than said wooden frame, at least one injection molded, decorative structural foam panel adhered to a side of said thin-walled panel, a wooden molding disposed around the circumference of said structural foam panel at the intersection of each side of said foam panel with said frame, and said molding being connected to said foam panel and said frame along the entire length of said molding.
Landscapes
- Engineering & Computer Science (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Securing Of Glass Panes Or The Like (AREA)
Abstract
Methods are provided for economically producing doors having decorative carvings thereon. After selecting a prefabricated wooden door frame with one or more openings therein for receiving decorative carved panels, which openings have disposed therein thin plywood panels providing decorative panel insert areas, ''''carved'''' panels of polyurethane structural foam are formed by injection molding expandable plastic into a mold of a configuration of the final ''''carved'''' design. The formed foamed panels are subsequently adhered to one or both sides of the surfaces of the plywood panels. Subsequently, the combined woodpolyurethane doors are specially treated to provide an integrated, ''''all wood'''' appearing door having appropriately configured carvings disposed on the surface thereof. Also, disclosed herein are the new doors produced by the new methods.
Description
iJnited Etates Patent 1 Zaroor 51 May 8, 1973 54 CARVED DOORS [75] Inventor: Fred E. Zaroor, Muskogee, Okla.
[73] Assignee: Indian Capitol Plastics, Inc.,
Muskogee, Okla.
[22] Filed: Dec. 29, 1971 [21] Appl. No.: 213,356
[52] US. Cl. ..52/309, 52/455, 52/615, 156/245, 156/249 [51] Int. Cl. ..E06b 3/70 [58] Field of Search ..52/455, 456, 315, 52/316, 615, 309; 156/245, 299; 161/39, 41, 42
[56] References Cited UNITED STATES PATENTS 848,661 4/1907 Kostelaitz ..52/455 Primary Examiner.lohn E. Murtagh Attorney-Hubert T. Mandeville et a],
[ 1 ABSTRACT Methods are provided for economically producing doors having decorative carvings thereon. After selecting a prefabricated wooden door frame with one or more openings therein for receiving decorative carved panels, which openings have disposed therein thin plywood panels providing decorative panel insert areas, carved panels of polyurethane structural foam are formed by injection molding expandable plastic into a mold of a configuration of the final carved design. The formed foamed panels are subsequently adhered to one or both sides of the surfaces of the plywood panels. Subsequently, the combined wood-polyurethane doors are specially treated to provide an integrated, all wood appearing door having appropriately configured carvings disposed on the surface thereof. Also, disclosed herein are the new doors produced by the new methods.
10 Claims, 2 Drawing Figures Patented May 8, 1973 3,731,443
FIG. I
CARVED DOORS BACKGROUND AND SUMMARY OF INVENTION Generally speaking, the present invention relates to methods for producing doors and the doors produced by those methods. More particularly, this invention relates to methods for producing doors having intricately designed woodlike" carvings in the panels thereof and in a manner which makes the final product produced by the methods herein highly attractive commercially.
As is well known, the architectural and decorative tastes of the general public, both with respect to private residences and commercial establishments, have become more varied and selective in recent years. As a consequence, it has become necessary to provide a wide variety of design configurations in the appurtenances, which provide the particular style of the building being constructed and designed. As a result, it becomes necessary to provide a wider selection of different designs, such as Mediterrean, Early American, French Provincial and so forth, in order to conform to the particular taste of the individual requiring that a structure be built or redecorated or redesigned.
However, with ever increasing costs oflabor, it is difficult to produce or provide a wide variety of these designs to conform to the different tastes of the individuals involved on a mass production basis, particularly with respect to intricately formed or carved furniture, door panels, balustrades and other decorations which serve to give a structure its particular desired characteristics.
Thus, the problem arises that, although there is an increasingly sophisticated market for a wide variety of different designs, the cost of producing these different designs on a mass production basis makes production of the desired designs economically prohibitive except for a select few.
Certain suggestions have been made in the past for overcoming these difficulties, particularly with the development of structural foam moldings for producing simulated wood carvings for a variety of applications. In addition, certain developments havebeen made for producing door-shaving the appropriately designed and configured decorative panels thereon from such resin materials as polyurethane foam. However, such arrangements include utilizing extremely large molds for producing the entire door or whatever structural object such as wooden beams for a room which are to be produced. With such arrangements, the actual construction of the mold for producing such large objects becomes important with such applications only being appropriate for producing substantial numbers of such objects. If it is desired to produce only a comparatively small number of a particular design for a selective market, then the use of such large molds and the cost of making the molds in the first place makes such selective marketing, again, economically prohibitive.
By contrast, it has now been found in accordance herewith, that a wide variety of appropriately designed doors can be produced for a selective market providing a considerable variety of designs for the discriminating purchaser and in a manner which makes the doors produced thereby economically attractive on a somewhat selective mass production basis.
The above is achieved by first preselecting a prefabricated wooden door frame which has one or more openings in it depending upon the number of decorative foam panels to be applied to the door. Disposed in these openings are plywood pieces of approximately one-fourth inch thick, which plywood pieces serve as the support surfaces against which the decorative panels are subsequently adhered. Obviously, other materials can be substituted for plywood such as pressed fiberboard and a variety of structurally equivalent resin products which are on the market. The foam panels are then produced by molds such as silicone rubber molds which are made from actual wood carvings which have been wire brushed to bring out and emphasize the grain pattern and which are therefore configured to produce the final polyurethane panels of the design required or desired, i.e., wood-grained carvings. Prior to injection of the polyurethane into the mold cavity, a release agent is applied to the internal surfaces of the mold, all in well known manner. Thereafter, the polyurethane is injected into the mold for expansion therein to form the carved panels of a particular configuration. The general molding procedure may be, for example, more or less in accordance with Angel U.S. Pat. No. 3,268,636 or 3,436,446.
The polyurethane foams are generally formed from compositions which include polymers containing three hydroxy groups, such as hydroxyl terminated polyester or polyether, an organic diisocyanate, and a small amount of water. For the best results, a catalyst, preferably an amine catalyst, a tin catalyst and an em ulsifier are also included. Such compositions may be formed or otherwise treated in a manner known in the art to produce the desired cellular product.
As purely illustrative of a rigid urethane foam formulation which may be used in accordance herewith for making the molded part, one may note the following composition:
A. Polyfunctional Polyoxypropylene Polymer based on Methyl Glucoside [00.0 grams B. Polymethylene, PolyphenyI-isocyanate 109.0 grams C. Dimethylethanolamine 1.0 grams D. Dibutylindilaurate 1.0 grams E. Dimethylsiloxy-siloxane type surfactant 1.5 grams F. Trichlorofluoromethane (as an auxiliary blowing agent) 37.0 grams The amount of the above composition injected into the mold cavity varies depending upon the size of the panel being produced, in accordance herewith.
After the carved panel is produced in the mold, it is subsequently adhered to the surface of the plywood in the openings of the door either on one or both sides, as desired, by the use of any well known adhesive such as a mastic. Subsequent to this adherence of the carved panels to the surface of the plywood, thin wood moldings are placed around the periphery of the carved polyurethane panels, and these moldings are connected both to the door frame proper as well as the polyurethane panels so as to hold the panels firmly in place, these thin moldings may be adhered to the door by the use of pins, brads, and adhesives, all in well known manner. Advantageously, these thin moldings provide an attractive framing for the carved polyurethane panels applied to the doors.
Accordingly, with the foregoing and other objects in view, this invention will be more particularly described,
and other objects and advantages hereof will be apparent from the following description, the accompanying drawings, and the appended claims.
DESCRIPTION OF DRAWINGS FIG. 1 is a front elevational view of a door having decorative foam panels disposed in the openings thereof and showing a plurality of such openings with panels disposed on the door; and
FIG. 2 is a cross section along the line 2-2 of FIG. 1.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT Referring to the drawings, in which like reference characters refer to like parts throughout the several views thereof, one construction or arrangement embodying this invention is indicated as including a door with a top and bottom decoratively carved panel having disposed therein a centrally located planar panel.
As indicated in FlG. l, the door, generally designated 10, is comprised of a frame structure 12 which may be mass produced ofa size generally utilized for particular applications, such as the front door of residences. The door 10, as is shown in FIG. I, has three openings 14 therein with the top and bottom openings 14 being of the same size, whereas the central opening 14 is ofa smaller size.
As can be seen in FIG. 2, the frame 12 has extending from one side thereof to the other a thin panel structure 22 which may be of plywood, pressed fiberboard or a resin material with the panel 22 being inserted into grooves formed in the frame 12 on both sides thereof. Obviously, there will be grooves at the top and bottom of opening 14, as viewed in FIG. 1, as well as the sides for holding the panel 22 firmly in the frame opening 14. This construction serves to provide carved pane] receiving insert areas 24 for the subsequent application of the polyurethane molded, carved panels..The panels are formed of the desired configuration, in accordance with the procedure noted above, to provide a particular design configuration such as 18 in FIG. 1. The formed carved panels 16 areapplied to one or both surfaces of panel 22 with the arrangement shown here being the application of carved panels 16 on both sides of the panel 22. As noted above, panels 16 are adhered to the surface of panel 22' by an appropriate mastic type adhesive, all in well known manner, for support and reinforcement. Subsequent to adhesion ofpanel 16 to panel 22, the framing structures or moldings are applied around the four sides of the panel 16, as shown in FIG. 1 and these molding frameS 20 are adhered both to the surfaces of frames 12 and the molded panel 16, as shown in FIG. 2.
After formation of door 10, the entire surface thereof may be treated in order to give both the surfaces of polyurethane carved molding panels and the wood frame the appearance of a uniformly constructed carved door. For example, one or more vinyl stains may be sprayed on and wiped off to give the entire surface of the door a uniform tone. If desired, prior to the application of'the stain, the wooden door itself may be wire brushed to bring out the grain to generally match the same with the grain of the carved woodgrain panels 16. Subsequent to the application of the stain, which is usually applied by spraying in two coatings and manually wiped off, a vinyl barrier coating will be applied to the surfaces of the door in order to provide weather resistance for the door particularly if it is to be exposed to the elements. Subsequent to this treatment, two sealing coats will be applied individually to give the various parts of the door a final integrated and enhanced all wood appearance. Usually, the wood utilized for the frame 12 will be fir, whereas the molding 20 will be comprised of oak.
Thus, there is provided in accordance herewith interior designer-type doors having appropriate and intricately carved panels disposed thereon which appear to have been formed after long hours of work by wood craftsmen, and with the doors actually being comprised of mass produced frames with plywood opening inserts disposed therein and with relatively inexpensive individual panels formulated of a configuration, as desired in order to produce a wide variety of attractive doors of different carving configurations. With such an arrangement, the methods herein produce door products of enhanced designs for a discerning public and in a variety which is appropriate for a large number of tastes and in a manner which makes the doors economically feasible for production on a substantially mass produced basis.
While the methods and products herein described constitute preferred embodiments of this invention, it is to be understood that the invention is not limited to these precise methods and products, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.
What is claimed is:
1. In a method for producing laminated doors having carved panels disposed on the surface thereof, the steps which comprise preselecting a wooden door frame having a first predetermined woodgrain and at least one opening disposed therein with a thin member extending over said opening to provide at least one carved panel insert area on one or both sides of said frame, injecting polyurethane into a mold having a configuration conforming to the desired design of said carved panels, and having a second predetermined grain, expanding said foam in said mold to form said carved panel, adhering at least one of said carved panels to the surface of said thin member in said panel insert area, applying amolding around the circumference of said adhered carved panel adjacent the junction of the edge of said carved panel with said door frame, and treating the surface of said frame and said carved panel to produce an integrally appearing door having at least one decoratively carved panel disposed on the surface thereof.
2. A method as recited in claim 1, in which said thin member is comprised of one-fourth inch plywood.
3. A method as recited in claim 1, in which said adhering step is carried out with mastic.
4. A method as recited in claim 1, in which said frame, said molding, and said foam panel have generally similar grain patterns herein.
5. A method as recited in claim 1, in which said treating step includes wire brushing said surfaces, spraying said surfaces with vinyl stain, applying a vinyl barrier coating, and applying a sealing coat.
6. In a door having a wooden frame with at least one opening disposed therein, the combination which comprises a thin-walled panel disposed in each of said openings and having a thickness less than said wooden frame, at least one injection molded, decorative structural foam panel adhered to a side of said thin-walled panel, a wooden molding disposed around the circumference of said structural foam panel at the intersection of each side of said foam panel with said frame, and said molding being connected to said foam panel and said frame along the entire length of said molding.
7. A door as described in claim 6, in which the width and length of said thin-walled panel is slightly larger than said opening, and in which grooves are formed in said frame for insertion of the edges of said thin-walled
Claims (10)
1. In a method for producing laminated doors having carved panels disposed on the surface thereof, the steps which comprise preselecting a wooden door frame having a first predetermined woodgrain and at least one opening disposed therein with a thin member extending over said opening to provide at least one carved panel insert area on one or both sides of said frame, injecting polyurethane into a mold having a configuration conforming to the desired design of said carved panels, and having a second predetermined grain, expanding said foam in said mold to form said carved panel, adhering at least one of said carved panels to the surface of said thin member in said panel insert area, applying a molding around the circumference of said adhered carved panel adjacent the junction of the edge of said carved panel with said door frame, and treating the surface of said frame and said carved panel to produce an integrally appearing door having at least one decoratively carved panel disposed on the surface thereof.
2. A method as recited in claim 1, in which said thin member is comprised of one-fourth inch plywood.
3. A method as recited in claim 1, in which said adhering step is carried out with mastic.
4. A method as recited in claim 1, in which said frame, said molding, and said foam panel have generally similar grain patterns herein.
5. A method as recited in claim 1, in which said treating step includes wire brushing said surfaces, spraying said surfaces with vinyl stain, applying a vinyl barrier coating, and applying a sealing coat.
6. In a door having a wooden frame with at least one opening disposed therein, the combination which comprises a thin-walled panel disposed in each of said openings and having a thickness less than said wooden frame, at least one injection molded, decorative structural foam panel adhered to a side of said thin-walled panel, a wooden molding disposed around the circumference of said structural foam panel at the intersection of each side of said foam panel with said frame, and said molding being connected to said foam panel and said frame along the entire length of said molding.
7. A door as described in claim 6, in which the width and length of said thin-walled panel is slightly larger than said opening, and in which grooves are formed in said frame for insertion of the edges of said thin-walled panel.
8. A door as recited in claim 6, in which said thin-walled member is one-fourth inch thick and is comprised of a member selected from the group consisting of plywood, pressed fiberboard and a non-flexible resin.
9. A door as recited in claim 6, in which said structural foam material is rigid polyurethane.
10. A door as recited in claim 6, in which said frame, said molding, and said foam panels have generally similar grain patterns therein.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US21335671A | 1971-12-29 | 1971-12-29 |
Publications (1)
Publication Number | Publication Date |
---|---|
US3731443A true US3731443A (en) | 1973-05-08 |
Family
ID=22794813
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US3731443D Expired - Lifetime US3731443A (en) | 1971-12-29 | 1971-12-29 | Carved doors |
Country Status (1)
Country | Link |
---|---|
US (1) | US3731443A (en) |
Cited By (16)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4265068A (en) * | 1979-03-23 | 1981-05-05 | Combustion Engineering, Inc. | Security panel door |
US4327788A (en) * | 1980-04-11 | 1982-05-04 | Turner Dana L | Panel door and method of construction |
US4567074A (en) * | 1985-03-21 | 1986-01-28 | Litaker Stephen H | Insulating trap door cover |
US4583342A (en) * | 1981-12-11 | 1986-04-22 | Lier Clifford S | Securement of glass in fire doors and the like |
US5120485A (en) * | 1986-06-25 | 1992-06-09 | Johnson Terry S | Method of forming glazed enclosure |
US5560168A (en) * | 1995-03-10 | 1996-10-01 | The Stanley Works | Swinging door with mirror insert on one face and method of making same |
GB2318142A (en) * | 1996-09-02 | 1998-04-15 | Richard Hagan | An article having a decorative element secured in a surface recess |
FR2755724A1 (en) * | 1996-11-14 | 1998-05-15 | Cappello Lucio | Doors made of interchangeable, decorative panels made of moulded composite materials |
US20030168760A1 (en) * | 2002-03-08 | 2003-09-11 | Salvatore Badalamenti | Method of making and assembling foam crown molding |
US20070094956A1 (en) * | 2005-10-05 | 2007-05-03 | Fimbel Iii Edward | Carved solid face door and method of fabrication |
WO2008116383A1 (en) * | 2007-03-28 | 2008-10-02 | Hongwei Diao | A mimic panel door and a method thereof |
WO2008116384A1 (en) * | 2007-03-28 | 2008-10-02 | Hongwei Diao | A mimic panel door and a method thereof |
US20090205277A1 (en) * | 2008-02-19 | 2009-08-20 | Gibson A David | Construction Panel System And Method Of Manufacture Thereof |
US20090260296A1 (en) * | 2008-04-21 | 2009-10-22 | Edward Fimbel, Iii | Carved solid face doors having a raised panel design and methods of fabrication |
US20100199572A1 (en) * | 2005-10-05 | 2010-08-12 | Edward Fimbel, Iii | Carved solid face door having a window formed therein and methods of fabrication |
US20110225917A1 (en) * | 2010-03-16 | 2011-09-22 | Jennifer Golden | Decorative architectural element and method for making |
Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US848661A (en) * | 1906-03-15 | 1907-04-02 | Israel Kostelanitz | Door. |
-
1971
- 1971-12-29 US US3731443D patent/US3731443A/en not_active Expired - Lifetime
Patent Citations (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US848661A (en) * | 1906-03-15 | 1907-04-02 | Israel Kostelanitz | Door. |
Cited By (22)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4265068A (en) * | 1979-03-23 | 1981-05-05 | Combustion Engineering, Inc. | Security panel door |
US4327788A (en) * | 1980-04-11 | 1982-05-04 | Turner Dana L | Panel door and method of construction |
US4583342A (en) * | 1981-12-11 | 1986-04-22 | Lier Clifford S | Securement of glass in fire doors and the like |
US4567074A (en) * | 1985-03-21 | 1986-01-28 | Litaker Stephen H | Insulating trap door cover |
US5120485A (en) * | 1986-06-25 | 1992-06-09 | Johnson Terry S | Method of forming glazed enclosure |
US5560168A (en) * | 1995-03-10 | 1996-10-01 | The Stanley Works | Swinging door with mirror insert on one face and method of making same |
GB2318142A (en) * | 1996-09-02 | 1998-04-15 | Richard Hagan | An article having a decorative element secured in a surface recess |
GB2318142B (en) * | 1996-09-02 | 2000-10-11 | Richard Hagan | An article |
FR2755724A1 (en) * | 1996-11-14 | 1998-05-15 | Cappello Lucio | Doors made of interchangeable, decorative panels made of moulded composite materials |
US20030168760A1 (en) * | 2002-03-08 | 2003-09-11 | Salvatore Badalamenti | Method of making and assembling foam crown molding |
US20070094956A1 (en) * | 2005-10-05 | 2007-05-03 | Fimbel Iii Edward | Carved solid face door and method of fabrication |
US20100199572A1 (en) * | 2005-10-05 | 2010-08-12 | Edward Fimbel, Iii | Carved solid face door having a window formed therein and methods of fabrication |
US8561368B2 (en) * | 2005-10-05 | 2013-10-22 | Edward Fimbel, Iii | Carved solid face door and method of fabrication |
US8646233B2 (en) | 2005-10-05 | 2014-02-11 | Edward Fimbel, Iii | Carved solid face door having a window formed therein and methods of fabrication |
WO2008116383A1 (en) * | 2007-03-28 | 2008-10-02 | Hongwei Diao | A mimic panel door and a method thereof |
WO2008116384A1 (en) * | 2007-03-28 | 2008-10-02 | Hongwei Diao | A mimic panel door and a method thereof |
US20090205277A1 (en) * | 2008-02-19 | 2009-08-20 | Gibson A David | Construction Panel System And Method Of Manufacture Thereof |
US20090260296A1 (en) * | 2008-04-21 | 2009-10-22 | Edward Fimbel, Iii | Carved solid face doors having a raised panel design and methods of fabrication |
US20090260308A1 (en) * | 2008-04-21 | 2009-10-22 | Edward Fimbel, Iii | Carved solid face doors having inlaid overlays and methods of fabrication |
US8225579B2 (en) * | 2008-04-21 | 2012-07-24 | Edward Fimbel, Iii | Carved solid face doors having inlaid overlays and methods of fabrication |
US8468773B2 (en) | 2008-04-21 | 2013-06-25 | Edward Fimbel, Iii | Carved solid face doors having a raised panel design and methods of fabrication |
US20110225917A1 (en) * | 2010-03-16 | 2011-09-22 | Jennifer Golden | Decorative architectural element and method for making |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US3731443A (en) | Carved doors | |
US7337543B2 (en) | Articles of composite structure having appearance of wood | |
EP0770007B1 (en) | Compression molded door assembly | |
US4579613A (en) | Method for manufacturing of a molded door | |
WO2006007269A2 (en) | Composite structures having the appearance of knotty wood and methods of making such structures | |
US5783264A (en) | Decorative windows with contoured plastic resin laminated to glass | |
US3801072A (en) | Fence panel | |
US5306535A (en) | Decorative corner insert for window or door openings with contoured plastic resin laminated to glass forming the insert | |
US5354396A (en) | Methods of making tile designs | |
US3561181A (en) | Replica wooden beams | |
US20070187864A1 (en) | System and method for manufacturing and constructing a mold for use in generating cast polymer products resembling natural stonework | |
US3961118A (en) | Simulated wood panel | |
US6397541B1 (en) | Decorative panel | |
WO1994025254A1 (en) | Door and door frames | |
EP1862632A1 (en) | Trimmable Door Product with Pigmented Compression Molded Skins | |
US8561368B2 (en) | Carved solid face door and method of fabrication | |
US20090308008A1 (en) | Patterned Panel System with Integrated Decorative Surfaces | |
US20070048468A1 (en) | Decorative glazing panels and methods of manufacturing the same | |
CA2474224C (en) | Articles of composite structure having appearance of wood | |
ATE216655T1 (en) | NATURAL STONE IMITATION FOR ORNAMENTAL BUILDINGS AND PROCESS FOR THEIR PRODUCTION | |
GB2412894A (en) | Decorative glazing panels and method of manufacturing same | |
WO2024017550A1 (en) | A wall covering element | |
JPH10180776A (en) | Highly weatherable synthetic timber | |
RU1460U1 (en) | PANEL WITH DECORATIVE COATING FROM POLYMERIC COMPOSITE MATERIAL | |
KR100740535B1 (en) | Manufacturing method of wardrobe door |