# US 8,539,729 B2 · Door, method of making door, and stack of doors

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- Number: US 8,539,729 B2
- Document ID: US8539729B2
- Status: Granted
- Kind: B2
- Application number: 13/312,125
- Filed: 2011-12-06
- Published: 2012-03-29
- Granted: 2013-09-24
- Earliest claimed: 2005-11-22
- Assignees: Masonite Corporation
- Applicants: Steven K. Lynch; Robert C. Allen; Greg Wysock
- Inventors: Steven K. Lynch; Robert C. Allen; Greg Wysock
- Web page: https://patentgrep.com/patent/US8539729B2

## CPC

- E06B 5/00: Doors, windows, or like closures for special purposes {(insulated compound frames specially adapted for sliding doors or windows E06B3/26347)}; Border constructions therefor
- B27N 3/08: Moulding or pressing (presses in general B30B)
- Y10T 428/24802: Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- E06B: FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES (shades or blinds for greenhouses A01G9/22; curtains A47H; lids for car boots or bonnets B62D25/10; skylights E04B7/18; sunshades, awnings E04F10/00)
- B27N: MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL (containing cementitious material B28B; shaping of substances in a plastic state B29C; fibreboards made from fibrous suspensions D21J; drying F26B17/00)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A door, method of making a door, and stack of doors includes providing a door having front and back skins that have differing, but complementary profiles, one for the front side of the door and one for the back side of the door where each allows and fits onto the other, while still providing direct contact in the stile and rail zones of the door permitting conventional door layup practices.

## Claims

### Claim 1

A door, comprising:
a front door skin, a rear door skin, and a perimeter frame comprising a bottom edge;
said front door skin comprising a first planar area and a first pattern, wherein a first portion of the first pattern is disposed at a first distance from said bottom edge and extends above the first planar area of the front door skin and a second portion of the first pattern is disposed at a second distance from said bottom edge and extends below the first planar area of the front door skin;
said rear door skin comprising a second planar area and a second pattern, wherein a first portion of the second pattern is disposed at a third distance from said bottom edge and extends below the second planar area of the rear door skin and a second portion of the second pattern is disposed at a fourth distance from said bottom edge and extends above the planar area of the rear door skin;
wherein said first and third distances are substantially equal and said second and fourth distances are substantially equal, and
wherein said first pattern of said front door skin is configured to allow said second pattern of said rear door skin of an identical second door to be nested therein.

### Claim 2 (depends on 1)

The door of claim 1, wherein said front door skin and said rear door skin each possess substantially uniform thicknesses.

### Claim 3 (depends on 1)

The door of claim 1, wherein the door is a first door and when in the adjacent, nesting relationship said planar area of said first door is in flush contact with said planar area of the identical second door.

### Claim 4 (depends on 3)

The door of claim 3, wherein said first and second patterns surround respective panels.

### Claim 5

A door, comprising:
a perimeter frame comprising opposite first and second frame sides and a top edge;
a first molded wood composite door skin having a first periphery secured to said first frame side, said first door skin comprising a first planar area and a first contoured pattern, said first contoured pattern comprising a first convex portion extending relative to said first planar area, said first convex portion being located a first distance from said top edge, and a first concave portion extending relative to said first planar area, said first concave portion being located a second distance from said top edge; and
a second molded wood composite door skin having a second periphery secured to said second frame side, said second door skin comprising a second planar area and a second contoured pattern, said second contoured pattern comprising a second convex portion extending relative to said second planar area, said second convex portion being located a third distance from said top edge, and a second concave portion extending relative to said second planar area, said second concave portion being located a fourth distance from said top edge;
wherein said first and fourth distances are substantially equal and said second and third distances are substantially equal, and
wherein said door is a first door positionable into adjacent, nesting relationship with a substantially identical second door so that when in the nesting relationship said first convex portion of said first door nests with said second concave portion of the identical second door.

### Claim 6 (depends on 5)

The door of claim 5, wherein said perimeter frame comprises a pair of stiles and a pair of rails.

### Claim 7 (depends on 5)

The door of claim 5, wherein said first contoured pattern is non-identical to said second contoured pattern.

### Claim 8 (depends on 7)

The door of claim 7, wherein said second contoured pattern is a mirror reverse image of said first contoured pattern.

### Claim 9

A stack of doors, comprising:
a first door comprising;
a perimeter frame having opposite first and second frame sides;
a front door skin having a periphery secured to said first frame side, said front door skin comprising a first planar portion and a first contoured pattern, said first contoured pattern comprising a convex portion extending outward relative to said first planar portion and a first concave portion extending inward relative to said first planar portion; and
a first rear door skin having a periphery secured to said second frame side, said first rear door skin comprising a second planar portion and a second contoured pattern; and
a second door comprising;
a second rear door skin comprising a third planar portion and a third contoured pattern having a second concave portion configured to nest with the first convex portion of said front door skin when placed in a stacked relationship therewith.

### Claim 10 (depends on 9)

The stack of doors of claim 9, wherein said first and second doors are substantially identical in shape.

### Claim 11 (depends on 9)

The stack of doors of claim 9, wherein said first door and said second door are different in shape.

### Claim 12 (depends on 9)

The stack of doors of claim 9, wherein said first and second contoured patterns are non-identical.

### Claim 13 (depends on 9)

The stack of doors of claim 9, wherein said first and second contoured patterns are identical to one another and wherein said third contoured pattern of said second door is non-identical to said first and second contoured patterns of said first door.

### Claim 14 (depends on 9)

The stack of doors of claim 9, wherein:
said front door skin comprises a molded wood composite; and
said first and second rear door skins comprise a molded wood composite.

### Claim 15

A door, comprising:
a perimeter frame having opposite first and second frame sides;
a molded wood composite front door skin secured to said first frame side, said front door skin comprising a first planar portion and a first pattern said first pattern comprising:
a first front bead and cove configuration wherein the first front bead portion is convex relative to said first planar portion and the first front cove portion is concave relative to said first planar portion; and
a second front bead and cove configuration wherein the second front bead portion is convex relative to said first planar portion and the second front cove portion is concave relative to said first planar portion; and
a molded wood composite rear door skin having a periphery secured to said second frame side, said rear door skin comprising a second planar portion and a second pattern comprising:
a first rear bead and cove configuration wherein the first rear bead portion is convex relative to said second planar portion and the first rear cove portion is concave relative to said second planar portion; and
a second rear bead and cove configuration wherein the second rear bead portion is convex relative to second planar portion and the second rear cove portion is concave relative to said second planar portion,
wherein said door is a first door positionable into adjacent, nesting relationship with an identical second door so that when in the nesting relationship the convex first front bead portion of said first door nests with the concave second rear cove portion of the identical second door.