Molded door frame and method

A door having an outer panel and an inner panel, each panel having a central opening for a window, said panels defining a door frame having side edges, a top edge, and bottom edge, said central opening having side edges, a top edge, and a bottom edge, comprising:

• said edges surrounding the outer extremes of the door and the inner boundary of the central opening thereby forming a circumambient dam wall assembly,
• all of said dam walls assembly being formed by edge portions extending circumambient from each panel and integrally molded in said panels,
• each of said extending edge portion engaging an opposed overlapping foam blocking means forming an uninterrupted hollow interior between the opposed panels,
• the dam wall assembly and hollow interior characterized by the absence of secondary stiles, rails, or other independent elements inserted interiorly of the hollow interior,
• an uninterrupted pre-filling hollow interior surrounding the window edges and interior of the outer edges,
• and a foam filled uninterrupted interior essentially filling the pre-filling hollow interior from any opening in the otherwise dammed hollow area defined by the edges and adhesively securing the inner and outer panels to each other,
• whereby the finished door has a foam filled core to fill the hollow interior, add to structural integrity, enhance the monocoque effect of the overall door structure, and adhere the inner and outer panels to each other.

A molded door frame having two frame panels, an outer panel and an inner panel, which panels are secured to each other by a foamed in place filling between the outer panel and the inner panel, the improvement comprising,

• side wall edges, a top wall edge, and a bottom wall edge on the inner door panel and the outer door panel defining circumambient outer edges;
• each of said edges overlappingly engaging the opposite edge;
• a window opening surrounded by circumambient side edges, top, and bottom edges defining inner edges and an open window area;
• said inner edges overlapping each other and defining an essentially uninterrupted hollow space between the inner and outer edge;
• all of said edges being formed integrally in said panels and extending from the panels;
• and
• a continuous hollow void between the panels which is unblocked and open so that foam may flow freely in any direction in said hollow void,
• whereby a continuous foam fill can occupy the hollow void and move into the entire hollow area without blockage and is surrounded by edges to adhesively secure the two frames together and to add strength to the structure and insulate the door.

A door having an outer panel and an inner panel, comprising,

• circumambient side edges, a top edge and a bottom edge integral with each of said panels formed for interlockingly engaging the opposite side, top and bottom edges of said outer and inner panels;
• further edges forming a window opening having interlocking engagement means for engaging the opposite panel;
• all of said edges forming an uninterrupted pre-filling unblocked hollow interior between the panels, and
• a foam filled interior passing continuously without interruption through the pre-filling hollow interior between the panels in the absence of secondary independently formed securing means for securing the outer frame to the inner frame;
• whereby a door is formed with a foam filled interior, the foam for which is uninterrupted in its penetration of the entire hollow interior, and foam leakage is prevented by the interlocking engagement of the edges which prevent the seepage of blow-by experienced with a butt joint when foam is filled under pressure.