Back to results
US 8,133,340 B2Granted
Method of manufacturing a universal door skin blank
AssigneeMasonite Corporation
InventorsSteven K. Lynch, Bei-Hong Liang, Mark A. Ruggie, Jason Walsh, Henry Coghlan
Life of this patent
Estimating the term…
Abstract
A universal door skin blank comprises an exterior side and an interior side for securing to a frame member, first and second molded, spaced stiles, and a flat planar portion disposed between the stiles and lying on a plane spaced from the plane of the stiles. An interface portion is disposed between and contiguous with the stiles and the flat planar portion. The invention also relates to a door having at least one universal door skin blank, with at least two separately formed rails secured to the planar portion of the blank at opposite ends thereof.
Claims17
A method of producing a plurality of doors, comprising the steps of:
- molding first and second flat wood composite substrates to form first and second universal door blanks, respectively, the first and second universal door blanks comprising first and second stiles spaced apart from one another with each stile having an exterior surface lying in a first plane, first and second interface portions integral and contiguous with the first and second stiles, respectively, and a flat planar portion extending in width from the first interface portion to the second interface portion and coextensive in length with the stiles, the flat planar portion being integral and contiguous with the first and second interface portions, the flat planar portion having substantially an entire exterior surface lying in a second plane spaced from the first plane;
- securing a first rail member and a second rail member to the first universal door blank to form a first door skin having a first design;
- securing a third rail member and a fourth rail member to the second universal door blank;
- and
- securing a raised panel to at least one of the first and second universal door blanks.
2 more elements
A method of producing a door, comprising;
- molding a flat wood composite substrate to form a universal door blank comprising first and second stiles spaced apart from one another and each having an exterior surface lying in a first plane, first and second interface portions integral and contiguous with the first and second stiles, respectively, and a flat planar portion extending in width from the first interface portion to the second interface portion and coextensive in length with the stiles, the flat planar portion being integral and contiguous with the first and second interface portions, the flat planar portion having substantially an entire exterior surface lying in a second plane spaced from the first plane with no major exterior surface portion of the flat planar portion protruding from the second plane;
- securing an interior side of the molded universal door blank to a first side of a door frame;
- providing at least two rails, each of the rails respectively having an exterior surface and an interior surface, the interior surface of each of the rails being securable to the flat planar portion at any position along the length of the flat planar portion;
- and
- securing the interior surface of the rails on the flat planar portion anywhere along the length thereof;
- and
- securing a raised panel to the flat planar portion.
4 more elements
A method of producing a door, comprising;
- molding a flat wood composite substrate to form a molded universal door blank comprising first and second stiles spaced apart from one another and each having an exterior surface lying in a first plane, first and second interface portions integral and contiguous with the first and second stiles, respectively, and a flat planar portion extending in width from the first interface portion to the second interface portion and coextensive in length with the stiles, the flat planar portion being integral and contiguous with the first and second interface portions, the flat planar portion having substantially an entire exterior surface lying in a second plane spaced from the first plane with no major exterior surface portion of the flat planar portion protruding from the second plane;
- securing an interior side of the molded universal door blank to a first side of a door frame;
- securing a first rail having an interior surface and an exterior surface on the flat planar portion anywhere along the length thereof;
- and
- securing a second rail having an interior surface and an exterior surface on the flat planar portion;
- and
- securing a raised panel to the flat planar portion.
4 more elements
Dependencies are inferred from the claim text.