Reverse molded plant-on panel component, method of manufacture, and method of decorating a door therewith
AssigneeMasonite Corporation
InventorsSteven K. Lynch, Dale E. Schafernak, Karine Luetgert, Bei-Hong Liang, Lee Braddock
Life of this patent
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Abstract
A reverse molded, plant-on decorative panel component comprises a panel portion lying on a first plane, a skirt portion, and a contoured portion. The skirt portion has a first surface adapted to be exteriorly disposed and an opposite second surface adapted to be interiorly disposed in order to be adhesively secured to a planar surface. The contoured portion extends outwardly from and surrounds the panel portion and interconnects and is integral with the panel portion and the skirt portion. The skirt portion extends peripherally about the contoured portion.
Claims25
A reverse molded wood composite door skin having an exterior surface adapted to be exteriorly disposed and an opposite interior surface adapted to be interiorly disposed, comprising:
- at least one panel portion, said exterior surface of said at least one panel portion extending in a first plane;
- a skirt portion having a first thickness and a first specific gravity, said exterior surface of said skirt portion extending in a second plane, said interior surface of said skirt portion adapted to be adhesively secured to a planar support surface;
- and
- a contoured wall surrounding said panel portion and interconnecting and integral with said panel portion and said skirt portion, said skirt portion extending peripherally about said contoured wall, said contoured wall including first and second contoured portions, said first contoured portion being adjacent said skirt portion and being reverse molded so that said exterior surface thereof extends outwardly relative to said second plane to an outermost convex top having a rounded apex that is farther outward from the first and second planes than any other part of the contoured wall, said second contoured portion being positioned between said first contoured portion and said panel portion and having said exterior surface thereof extending inwardly relative to said first plane, said outermost convex top of said rounded apex having a second thickness that is less than said first thickness and a second specific gravity that is greater than said first specific gravity.
A reverse molded wood composite door skin having an exterior surface adapted to be exteriorly disposed and an opposite interior surface adapted to be interiorly disposed, said reverse molded wood composite door skin comprising:
- at least one planar panel portion, said exterior surface of said at least one planar panel portion extending in a first plane;
- a major planar portion having a first thickness and a first specific gravity, said exterior surface of said major planar portion extending in a second plane that is different than said first plane, said interior surface of said major planar portion adapted to be adhesively secured to a support surface;
- a contoured portion surrounding said planar panel portion and being surrounded by the major planar portion, said contoured portion interconnecting and integral with said planar panel portion and said major planar portion, said exterior surface of said contoured portion extending outwardly from and relative to said first plane and interconnecting and integral with said major planar portion and said planar panel portion, said contoured portion being reversed molded so that said exterior surface thereof extends outwardly relative to said second plane to an outermost convex top portion having a rounded apex that is farther outward from the first and second planes than any other part of the contoured portion, said rounded apex having a second thickness that is less than said first thickness and a second specific gravity that is greater than said first specific gravity.
A door comprising:
- a planar support structure;
- and
- a reverse molded wood composite door skin having an exterior surface adapted to be exteriorly disposed and an opposite interior surface adapted to be interiorly disposed, comprising
- at least one panel portion, said exterior surface of said at least one panel portion extending in a first plane;
- a skirt portion having a first thickness and a first specific gravity, said exterior surface of said skirt portion extending in a second plane, said interior surface of said skirt portion secured to the planar support structure;
- and
- a contoured wall surrounding said panel portion and interconnecting and integral with said panel portion and said skirt portion, said skirt portion extending peripherally about said contoured wall, said contoured wall including first and second contoured portions, said first contoured portion being adjacent said skirt portion and being reverse molded so that said exterior surface thereof extends outwardly relative to said second plane away from the planar support structure to an outermost convex top having a rounded apex that is farther outward from the first and second planes than any other part of the contoured wall, said second contoured portion being positioned between said first contoured portion and said panel portion and having said exterior surface thereof extending inwardly relative to said first plane, said rounded apex having a second thickness that is less than said first thickness and a second specific gravity that is greater than said first specific gravity.
Dependencies are inferred from the claim text.