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AssigneeMasonite Corporation
InventorsGeoffrey B. HARDWICK, Henry M. Coghlan, John Peter Walsh, Allen Ray Hill
Estimating the term…
The present invention is directed to a method of forming a molded core component. A mat formed from cellulosic fiber and resin is provided. The mat is consolidated in a first press until the resin is substantially fully cured, and then removed from the first press. The consolidated mat is then placed in a second press having a mold cavity shaped to form at least one depression in at least one of the major surfaces. The consolidated mat is reformed in the second press to form a molded core component having at least one depression in at least one of the major surfaces. The molded core component has a variable density, preferably of between about 10 lbs/ft3 and 80 lbs/ft3.
1-20. (canceled)
A variable-density, molded core component reformed from a pre-consolidated mat comprising substantially fully-cured cellulosic material and resin to have opposed major surfaces, at least one of the major surfaces of the variable-density core component having at least one depression.
The variable-density core component of claim 1, wherein the variable-density molded core component varies in density within a range between about 10 lbs/ft3 and 80 lbs/ft3.
The variable-density core component of claim 1, wherein the depressed area has a density between about 60 lbs/ft3 and 80 lbs/ft3.
The variable-density core component of claim 1, wherein areas adjacent the depression have a density between about 10 lbs/ft3 and 30 lbs/ft3.
The variable-density core component of claim 1, wherein the opposed major surfaces are mirror images of each other.
The variable-density core component of claim 1, wherein the depression is defined by a bottom surface and sidewalls.
A door comprising
The door of claim 1, wherein the opposed major surfaces of the variable-density molded core component are mirror images of each other.
The door of claim 1, wherein the depression of the variable-density molded core component is defined by a bottom surface and sidewalls.
A door comprising
Dependencies are inferred from the claim text.