Foamed plastic core door
AssigneeMasonite Corporation
InventorFred I. Palmer
Life of this patent
Estimating the term…
Abstract
A foamed plastic core door, structural panel or closure member comprises an inner core of light weight, cellular, foamed plastic material having opposite outwardly facing side surfaces, each formed with a base portion having a plurality of relatively small, integrally formed, outwardly projecting, compressible bosses arranged at spaced apart intervals thereon. At least one outer skin or decorative door face member is provided having an inside surface confronting said core surface in facing spaced apart relation with the base portion and in adhesive contact against the outer faces of a plurality of the projecting bosses, thus, providing a thin, dead air, insulating space between a major area portion of the side face of the core and the adjacent confronting inside surface of the outer skin.
Claims18
A closure member comprising:
- an inner core of light weight, resinous plastic, relatively rigid type, cellular foam material having an outwardly facing surface formed with a planar base portion having a plurality of small, outwardly projecting compressible bosses arranged in spaced apart intervals in a matrix pattern thereon;
- said projecting bosses being formed to be substantially frusto-conical in shape and including a substantially planar outer face of circular shape;
- an outer skin for said closure member having an inside surface confronting said core surface in facing spaced apart relation with said planar base portion and in direct contact against outer faces of said projecting bosses;
- said skin formed of thin sheet material comprising compressed wood fibres and having smooth planar outer surface portions and an inner surface compressing some of said bosses;
- said core including a plurality of said planar base portions at spaced apart locations on said outwardly facing core surface and an intermediate surface portion separating said planar portions without any projecting bosses formed thereon;
- said intermediate surface portion being non-planar and said outer skin including a generally matching non-planar inside surface portion in spaced apart relation therewith;
- and
- adhesive means for securing said outer skin to said projecting bosses.
A door comprising:
- an inner core of light weight, resinous plastic, relatively rigid type, cellular foam material having opposite faces and a peripheral edge,
- a plurality of outwardly projecting, relatively compressible bosses integrally formed on said faces at spaced apart positions in a matrix pattern thereon;
- a pair of opposite door faces formed of thin sheet material compressed wood fibres having a smooth outer surface and an inner surface adhesively secured to compressed faces of said bosses on opposite side faces of said core, a major portion of the total area of said inner surfaces maintained in spaced apart relation from adjacent side faces of said core by the thickness of said compressible bosses,
- a peripheral frame of structural members extended around the periphery of said core and adhesively sandwiched between facing marginal edge portions of said door face, and
- said core including an elongated rib formed around the periphery thereof for contact with said members of said frame.
Dependencies are inferred from the claim text.