Universal door skin blank, method of manufacturing a door produced therewith, and door produced therefrom
AssigneeMasonite Corporation
InventorsSteven K. Lynch, Bei-Hong Liang, Mark A. Ruggie, Jason Walsh, Henry Coghlan
Life of this patent
Estimating the term…
Abstract
A universal door skin blank comprises an exterior side and an interior side for securing to a frame member, first and second molded, spaced stiles, and a flat planar portion disposed between the stiles and lying on a plane spaced from the plane of the stiles. An interface portion is disposed between and contiguous with the stiles and the flat planar portion. The invention also relates to a door having at least one universal door skin blank, with at least two separately formed rails secured to the planar portion of the blank at opposite ends thereof.
Claims40
A universal door skin blank, comprising:
- an exterior side and an interior side for being secured to a frame member;
- first and second molded, spaced stiles;
- a flat planar portion disposed between said stiles and lying on a plane spaced from the plane of said stiles;
- and
- an interface portion disposed between and contiguous with said stiles and said flat planar portion.
A door, comprising:
- a peripheral frame having oppositely disposed sides;
- first and second door skins, each one of said skins having an exterior side and an interior side secured to one of said frame sides, and at least one of said skins formed to have spaced stiles lying on a first plane and a planar portion disposed between said stiles and lying on a plane spaced from the plane of said stiles;
- and
- at least two separately formed rails secured to said planar portion at opposite ends thereof.
A method of producing a door, comprising the steps of:
- providing a peripheral door frame having oppositely disposed sides;
- providing first and second wood composite blanks having an exterior side and an interior side;
- forming at least one of the blanks to have spaced stiles, a planar portion disposed between the stiles and lying on a plane spaced from the plane of the stiles, and an interface portion disposed between and contiguous with the stiles and the planar portion;
- securing the interior sides of the formed blanks to one of the frame sides;
- forming at least two rails, each one of the rails having an exterior surface and an interior surface;
- and
- securing the interior surface of the rails onto the planar portion.
A method of producing a universal door skin blank, comprising the steps of:
- providing a die set having an upper die spaced from a lower die, the dies creating a forming chamber defining first and second spaced stiles lying on a first plane, and a planar portion lying on a second plane spaced from the first plane and the planar portion being integral with and disposed between the stiles;
- disposing a substrate between the upper and lower dies;
- and
- compressing the substrate using heat and pressure to form a blank having first and second molded, spaced stiles, and a flat planar portion disposed between the stiles and lying on a plane spaced from the plane of the stiles.
Dependencies are inferred from the claim text.