Method of molding a thermostat polymer door skin, shelf stable thermostat molding composition, and door assembly using the door skins so formed
OwnerKenneth J. Koncelikinventor
Life of this patent
Estimating the term…
Abstract
A method of forming polymer door skins using a low viscosity, shelf stable homogeneous thermosetting reinforced polymer material. The polymer material includes a thermosetting curable polymer, a particulate filler, mica platelets, staple fibers, and hollow microspheres. The reinforced resin door skins of the present invention are formed at relatively low pressures which decreases costs by allowing the use of aluminum rather than steel tooling. The door skins, when assembled on a frame with an insulative core provides a molded, reinforced plastic door having a superior wood grain surface appearance, superior thermal characteristics and lower manufacturing costs.
Claims15
A method of molding a thermoset polymer door skin comprising
- admixing a curable thermosetting polymer, a catalyst, a particulate filler and staple fibers to form a homogeneous composition having shelf stability,
- introducing said homogeneous composition into a mold defining a cavity for a door skin, and
- molding the homogeneous composition in the mold cavity pressure up to about 500 psi and a temperature up to about 320.degree. F. to cure the thermosetting polymer and form the thermoset polymer door skin.
The method of molding a thermoset polymer door skin comprising
- admixing about 25 to about 80 wt % thermosetting curable polymer,
- about 5 to about 40 wt % calcium carbonate,
- about 5 to about 15 wt % mica,
- up to about 3 wt % hollow microspheres,
- about 0.5 to about 10 wt % staple fibers, and
- an effective amount of a catalyst and mold release agent to form a homogeneous composition,
- introducing said homogeneous composition into a mold defining a cavity for a door skin, and
- molding the homogeneous composition in the mold cavity at a pressure up to about 500 psi to cure the thermosetting polymer and form the thermoset polymer door skin.
Dependencies are inferred from the claim text.