Door, deep draw molded door facing and methods of forming door and facing
AssigneeMasonite Corporation
InventorsBei Hong Liang, Jason M. Walsh, Steven K. Lynch, Mark A. Ruggie, Richard D. Trubey, Henry M. Coghlan
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Abstract
The present invention relates to a wood composite panel having a major planar portion, at least one panel portion, and an inwardly extending contoured portion surrounding the panel portion and interconnecting the major planar portion and the panel portion. The contoured portion defines an inter-relationship between a vector angle and a deep draw depth that achieve a satisfactory stretch factor. The present invention also relates to a door having the disclosed wood composite door facings, and methods of forming the facing and door.
Claims20
A method of forming a wood composite door facing, comprising:
- disposing a mat in a mold having a lower die and an upper die collectively forming a die cavity when the mold is in a closed postion, wherein the lower die has a first flat portion and at least one first downwardly extending contoured design portion, and the upper die has a second flat portion and at least one second downwardly extending contoured design complementary to the at least one first downwardly extending contoured design portion;
- and
- compressing the mat between the lower and upper dies to form a door facing having a contoured portion and a planar portion, wherein the compression results in the contoured portion having a vector angle and a draw depth that achieve a satisfactory stretch factor as shown in FIG. 6.
A method of forming a door, comprising:
- securing a first door facing to a first side of a frame, the first door facing having a first contoured portion and a first planar portion, the first contoured portion having a first vector angle and a first draw depth that achieve a satisfactory stretch factor as shown in FIG. 6;
- and
- securing a second door facing to a second side of the frame, the second door facing having a second contoured portion and a second planar portion, the second contoured portion having a second vector angle and a second draw depth that achieve a satisfactory stretch factor as shown in FIG. 6.
A method of forming a door, comprising:
- disposing a mat comprising cellulosic material in a mold having a lower die and an upper die, wherein the lower die has a first flat portion and a first contoured portion, and the upper die has a second flat portion and a second contoured portion complementary to the first contoured portion;
- compressing the mat between the lower and upper dies to form a door facing having a contoured portion and a planar portion, wherein the compression results in the contoured portion having a vector angle and a draw depth that achieve a satisfactory stretch factor as shown in FIG. 6;
- removing the door facing from the mold;
- and
- securing the door facing to a first side of a frame.
Dependencies are inferred from the claim text.