# US 8,771,581 B2 · Method of making annealed door skins and composite door assemblies, and related articles > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,771,581 B2 - Document ID: US8771581B2 - Status: Granted - Kind: B2 - Application number: 13/334,835 - Filed: 2011-12-22 - Published: 2012-06-28 - Granted: 2014-07-08 - Earliest claimed: 2010-12-22 - Assignees: Masonite Corporation - Applicants: James Pfau; James Bryant; Liqun Xu; Elizalde Exconde - Inventors: James Pfau; James Bryant; Liqun Xu; Elizalde Exconde - Web page: https://patentgrep.com/patent/US8771581B2 ## CPC - C08K 7/14: Glass - B29C 65/02: by heating, with or without pressure - B29C 71/02: Thermal after-treatment {(B29C71/0063 and B29C71/0072 take precedence)} - E06B 3/7001: {Coverings therefor; Door leaves imitating traditional raised panel doors, e.g. engraved or embossed surfaces, with trim strips applied to the surfaces} - E06B 3/72: consisting of frame and panels {, e.g. of raised panel type (E06B3/7001 - E06B3/7015 and E06B3/82 take precedence)} - B29C 2071/022: {Annealing} - B29L 2031/724: {Doors} - E06B 3/825: {with a wooden frame} - Y10T 29/49826: Assembling or joining - Y10T 29/49828: Progressively advancing of work assembly station or assembled portion of work - Y10T 156/10: Methods of surface bonding and/or assembly therefor - Y10T 428/24994: Fiber embedded in or on the surface of a polymeric matrix - C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - 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) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method is provided for making an annealed door skin or composite door assembly. At least the door skin is formed of a composition comprising a thermoset binder and fiberglass. The door skin, alone or in combination with other parts of a door assembly, is subjected to annealing to make the annealed door skin. The process of annealing comprises the step of heating the door skin, alone or in combination with other parts of the door assembly, above the glass transition temperature yet below the thermal degradation temperature of the thermoset binder for a sufficient amount of time to cause release internal stresses in the door skin, then the step of cooling the door skin. ## Claims ### Claim 1 A method for making an annealed door skin, comprising: annealing a door skin comprising a thermoset binder and fiberglass to make an annealed door skin, said annealing comprising heating the door skin above the glass transition temperature yet below the thermal degradation temperature of the thermoset binder for a sufficient amount of time to release of internal stresses in the door skin; and cooling the door skin. ### Claim 2 (depends on 1) The method as defined in claim 1, wherein said heating is conducted at or above about 200° F. ### Claim 3 (depends on 1) The method as defined in claim 1, wherein the sufficient amount of time is at least 24 hours. ### Claim 4 (depends on 1) The method as defined in claim 1, wherein the sufficient amount of time is at least 48 hours. ### Claim 5 (depends on 1) The method as defined in claim 1, wherein said cooling comprises cooling the door skin at a rate of about 50° F. or less per hour. ### Claim 6 (depends on 1) The method as defined in claim 1, wherein said cooling comprises cooling the door skin at a rate of about 25° F. or less per hour. ### Claim 7 (depends on 1) The method as defined in claim 1, wherein said cooling comprises cooling the door skin at a rate of about 15° F. per hour. ### Claim 8 (depends on 1) The method as defined in claim 1, wherein said cooling comprises cooling the door skin to about 125° F. at a rate of about 15° F. per hour. ### Claim 9 (depends on 1) The method as defined in claim 1, wherein said heating is conducted at or above about 180° F. for at least 48 hours, and wherein said cooling comprises cooling the door skin at a rate of about 50° F. or less per hour. ### Claim 10 A method for making an annealed composite door, comprising: annealing a composite door comprising a door frame and first and second door skins on opposite sides of the door frame to make an annealed composite door, at least the first door skin comprising a thermoset binder and fiberglass, said annealing comprising heating the composite door above the glass transition temperature yet below the thermal degradation temperature of the thermoset binder for a sufficient amount of time to cause release internal stresses in the door skin; and cooling the composite door. ### Claim 11 (depends on 10) The method as defined in claim 10, wherein said heating is conducted at or above about 200° F. ### Claim 12 (depends on 10) The method as defined in claim 10, wherein the sufficient amount of time is at least 24 hours. ### Claim 13 (depends on 10) The method as defined in claim 10, wherein the sufficient amount of time is at least 48 hours. ### Claim 14 (depends on 10) The method as defined in claim 10, wherein said cooling comprises cooling the door skin at a rate of about 50° F. or less per hour. ### Claim 15 (depends on 10) The method as defined in claim 10, wherein said cooling comprises cooling the door skin at a rate of about 15° F. per hour. ### Claim 16 (depends on 10) The method as defined in claim 10, wherein said heating is conducted at or above about 200° F. for at least 24 hours, and wherein said cooling comprises cooling the door skin at a rate of about 50° F. or less per hour. ### Claim 17 (depends on 10) The method as defined in claim 10, wherein said heating is conducted at or above about 180° F. for at least 48 hours, and wherein said cooling comprises cooling the door skin at a rate of about 50° F. or less per hour. ### Claim 18 (depends on 1) The method as defined in claim 1, wherein said heating is conducted at or above about 200° F. for at least 24 hours, and wherein said cooling comprises cooling the door skin at a rate of about 50° F. or less per hour. ### Claim 19 A method for making an annealed composite door, comprising: annealing a composite door comprising a door frame and first and second door skins on opposite sides of the door frame to make an annealed composite door, at least the first door skin comprising a thermoset binder and fiberglass, said annealing comprising heating the composite door in a range of 180-220° F. for at least 24 hours; and cooling the composite door at a rate of about 50° F. or less per hour. ### Claim 20 (depends on 19) The method as defined in claim 19, wherein said heating is maintained for at least 48 hours. ### Claim 21 (depends on 19) The method as defined in claim 19, wherein said cooling comprises cooling the first door skin at a rate of about 25° F. or less per hour. ### Claim 22 (depends on 19) The method as defined in claim 19, wherein said cooling comprises cooling the first door skin at a rate of about 15° F. or less per hour. ### Claim 23 (depends on 19) The method as defined in claim 19, wherein said cooling comprises cooling the first door skin to about 125° F. at a rate of about 15° F. per hour. ### Claim 24 (depends on 1) The method as defined in claim 1, wherein the door skin is a door skin of a residential or commercial building. ### Claim 25 (depends on 10) The method as defined in claim 10, wherein the door skin is a door skin of a residential or commercial building. ### Claim 26 (depends on 19) The method as defined in claim 19, wherein the door skin is a door skin of a residential or commercial building.