Molded core component
AssigneeMasonite Corporation
InventorsSteven K. Lynch, Mark A. Ruggie, William P. Hoel
Life of this patent
Estimating the term…
Abstract
A molded core component includes a center plane piece and at least one wall extending from the center plane piece. The wall preferably includes contours which form a multiplicity of pods, cells, or protrusions integral with the center plane piece. The core component is preferably inserted into the space or void formed by two prefabricated molded fiberboard doorskins, wherein the center plane piece lies substantially in the central plane of the door product. Processes for the production of a molded core component and a composite door product are also disclosed.
Claims33
A contoured, integrally-molded article useful as a core component for a structural member, comprising:
- (a) a substantially planar layer portion;
- and
- (b) a plurality of contoured portions integral with, and projecting outwardly from, said layer portion, said contoured portions defining a plurality of contoured pod members;
- wherein each of said pod members (1) defines a void on an open interior thereof and (2) is spaced apart from contours forming the other pod member(s) by a section of said planar layer portion.
A contoured, integrally-molded article useful as a core component for a structural member, comprising:
- a central planar layer surrounding a plurality of integral depressions, each of said depressions having within the depression (1) a lower planar wall substantially parallel to said central planar layer, and (2) an inclined wall integral with both the upper and lower planar walls at the ends of said inclined wall;
- said inclined wall having an upper surface integral with an upper surface of said upper and said lower planar walls, said inclined wall being contoured to have a circular cross section, said cross-section being horizontal and parallel to said central planar layer.
A molded article of manufacture capable of nesting, one article above another, for transport and/or storage without significant damage, said article comprising:
- a central planar layer surrounding an integral depression, said depression having within the depression (1) a lower planar wall substantially parallel to said central planar layer, and (2) an inclined wall integral with both the upper and lower planar walls at the ends of said inclined wall;
- said inclined wall having an upper surface integral with an upper surface of said upper and lower planar walls, said inclined upper surface being contoured to have a circular cross section, said cross-section being horizontal and parallel to said central planar layer;
- said inclined wall being inclined at an angle of 25.degree. to about 45.degree. from said lower planar wall, and having a thickness that varies 20% or less relative to a mean thickness of said inclined wall between said upper and lower planar walls.
A man-made composite wood door made from consolidated cellulosic material, comprising:
- (a) a doorskin face and a doorskin back, each of said doorskins having an inner surface and an outer surface, and wherein said doorskins form a door body and define an interior space therebetween;
- and
- (b) a core component located in said interior space and including consolidated cellulosic material and sufficient binder to adhere the cellulosic material together into a structurally sound member, said core component comprising:
- (1) a central planar layer disposed in said interior space;
- and
- (2) a plurality of contoured portions integral with, and projecting outwardly from, said central planar layer, said contoured portions defining a plurality of contoured pod members, each of said pod members being spaced apart from the other pod member(s) by a section of said central planar layer.
A method for the preparation of a man-made molded wood article useful as a core component for a structural member, comprising:
- (a) combining a cellulosic filler and a binder resin;
- (b) forming the product of step (a) into a mat;
- (c) placing said mat into a contoured mold cavity;
- (d) compressing said mat in said cavity, to subject the mat to sufficient heat and pressure in the mold cavity to contour upper and lower surfaces of the mat to correspond in shape to the contours of the mold cavity and to bind the composite layer together;
- and
- (e) molding said mat in said mold cavity to include (1) a central planar layer and (2) contoured portions defining a plurality of contoured pod members disposed outwardly from, and formed integrally with, said central planar layer, wherein each of said pod members is spaced apart from contours forming the other pod member(s) by a section of said central planar layer.
Dependencies are inferred from the claim text.