# US 9,752,378 B2 · Stackable molded articles, and related assemblies and methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,752,378 B2 - Document ID: US9752378B2 - Status: Granted - Kind: B2 - Application number: 15/397,119 - Filed: 2017-01-03 - Published: 2017-04-27 - Granted: 2017-09-05 - Earliest claimed: 2014-08-07 - Assignees: Masonite Corporation - Applicants: Masonite Corporation - Inventors: Timothy D. Gouge; Robert C. Allen; Allen R. Hill - Web page: https://patentgrep.com/patent/US9752378B2 ## CPC - E06B 3/78: with panels of plastics {(E06B3/721 - E06B3/725 take precedence)} - B27N 3/04: from fibres - B27N 3/20: characterised by using platen-presses - B27N 7/005: {Coating boards, e.g. with a finishing or decorating layer} - 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} - B27N 3/00: Manufacture of substantially flat articles, e.g. boards, from particles or fibres - B27N 7/00: After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity - E06B 2003/7049: {Specific panel characteristics} - 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) ## Abstract Molded articles are provided. An exemplary molded article includes an inner panel portion, a main body portion, and a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion. The contoured portion includes contoured corner segments and contoured intermediate segments extending between respective pairs of the contoured corner segments. The contoured intermediate segments have a first maximum thickness. The contoured corner segments have a second maximum thickness. The first maximum thickness of the contoured intermediate segments is greater than the second maximum thickness of the contoured corner segments. Related methods, assemblies, and apparatus are also provided. ## Claims ### Claim 1 A molded article, comprising: an inner panel portion having a plurality of inner panel corners; a main body portion; and a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion, the contoured portion comprising contoured corner segments adjacent to the inner panel corners of the inner panel portion and contoured intermediate segments extending lengthwise between respective pairs of the contoured corner segments, the contoured intermediate segments having an exterior surface, an interior surface, and a first maximum thickness measured from the exterior surface of the contoured intermediate segments to a closest point on the interior surface of the contoured intermediate segments, the contoured corner segments having an exterior surface, an interior surface, and a second maximum thickness measured from the exterior surface of the contoured corner segments to a closest point on the interior surface of the contoured corner segments, wherein the first maximum thickness is greater than the second maximum thickness. ### Claim 2 (depends on 1) The molded article of claim 1, wherein the molded article is a door skin. ### Claim 3 (depends on 1) The molded article of claim 1, wherein the molded article is stackable with an identical molded article, one on another, in a stacked relationship in which the contoured intermediate segments of the stacked molded articles abut against one another to establish contact zones, and wherein the contoured corner segments of the stacked molded articles are spaced from one another to establish corner relief areas. ### Claim 4 (depends on 1) The molded article of claim 1, wherein the molded article is stackable with an identical molded article, one on another, in a stacked relationship in which the difference in thickness between the first and second maximum thicknesses displaces a load of the upper stacked molded article on the lower stacked molded article from the contoured corner segments to the contoured intermediate segments so that the contoured intermediate segments bear a majority of the load. ### Claim 5 (depends on 1) The molded article of claim 1, wherein the first maximum thickness is uniform along the entire lengths of the contoured intermediate segments, and wherein the second maximum thickness is uniform along the entire lengths of the contoured corner segments. ### Claim 6 (depends on 1) The molded article of claim 1, wherein the contoured corner segments comprise two legs that are perpendicular to one another, and wherein the contoured intermediate segments extend linearly lengthwise between the respective pairs of the contoured corner segments. ### Claim 7 (depends on 1) A door comprising: a frame having first and second sides; and a door skin secured to the first side of the frame, the door skin comprising the molded article of claim 1. ### Claim 8 A molded article, comprising: an inner panel portion having a plurality of inner panel corners; a main body portion; and a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion, the contoured portion comprising contoured corner segments adjacent to the inner panel corners of the inner panel portion and contoured intermediate segments extending lengthwise between and interconnecting respective pairs of the contoured corner segments, the contoured intermediate segments having a first maximum thickness, the contoured corner segments having a second maximum thickness, wherein the first maximum thickness is greater than the second maximum thickness, and wherein the molded article is stackable with an identical molded article, one on another, in a stacked relationship in which the difference in thickness between the first and second maximum thicknesses displaces a load of the upper stacked molded article on the lower stacked molded article from the contoured corner segments to the contoured intermediate segments so that the contoured intermediate segments bear a majority of the load. ### Claim 9 (depends on 8) The molded article of claim 8, wherein the molded article is a door skin. ### Claim 10 (depends on 8) The molded article of claim 8, wherein the molded article is stackable with the identical molded article, one on another, in a stacked relationship in which the contoured intermediate segments of the stacked molded articles abut against one another to establish contact zones, and wherein the contoured corner segments of the stacked molded articles are spaced from one another to establish corner relief areas. ### Claim 11 (depends on 8) The molded article of claim 8, wherein the first maximum thickness is uniform along the entire lengths of the contoured intermediate segments, and wherein the second maximum thickness is uniform along the entire lengths of the contoured corner segments. ### Claim 12 (depends on 8) The molded article of claim 8, wherein the contoured corner segments comprise two legs that are perpendicular to one another, and wherein the contoured intermediate segments extend linearly lengthwise between the respective pairs of the contoured corner segments. ### Claim 13 (depends on 8) A door comprising: a frame having first and second sides; and a door skin secured to the first side of the frame, the door skin comprising the molded article of claim 8. ### Claim 14 A molded article, comprising: an inner panel portion having a plurality of inner panel corners; a main body portion; and a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion, the contoured portion comprising contoured corner segments adjacent to the inner panel corners of the inner panel portion and contoured intermediate segments extending in a lengthwise direction between and interconnecting respective pairs of the contoured corner segments, the contoured intermediate segments having a first maximum thickness, the contoured corner segments having a second maximum thickness, wherein the first maximum thickness is greater than the second maximum thickness, and wherein the first maximum thickness is uniform along the entire lengths of the contoured intermediate segments, and the second maximum thickness is uniform along the entire lengths of the contoured corner segments. ### Claim 15 (depends on 14) The molded article of claim 14, wherein: the contoured intermediate segments have an exterior surface, an interior surface, and the first maximum thickness measured from the exterior surface of the contoured intermediate segments to a closest point on the interior surface of the contoured intermediate segments; and the contoured corner segments have an exterior surface, an interior surface, and the second maximum thickness measured from the exterior surface of the contoured corner segments to a closest point on the interior surface of the contoured corner segments. ### Claim 16 (depends on 14) The molded article of claim 14, wherein the molded article is a door skin. ### Claim 17 (depends on 14) The molded article of claim 14, wherein the molded article is stackable with an identical molded article, one on another, in a stacked relationship in which the contoured intermediate segments of the stacked molded articles abut against one another to establish contact zones, and wherein the contoured corner segments of the stacked molded articles are spaced from one another to establish corner relief areas. ### Claim 18 (depends on 14) The molded article of claim 14, wherein the molded article is stackable with an identical molded article, one on another, in a stacked relationship in which the difference in thickness between the first and second maximum thicknesses displaces a load of the upper stacked molded article on the lower stacked molded article from the contoured corner segments to the contoured intermediate segments so that the contoured intermediate segments bear a majority of the load. ### Claim 19 (depends on 14) The molded article of claim 14, wherein the contoured corner segments comprise two legs that are perpendicular to one another, and wherein the contoured intermediate segments extend linearly lengthwise between the respective pairs of the contoured corner segments. ### Claim 20 (depends on 14) A door comprising: a frame having first and second sides; and a door skin secured to the first side of the frame, the door skin comprising the molded article of claim 14.