Abstract: The present relates to a sidelite assembly having first and second panels and a window. Each of the panels has an inner edge extending outwardly from a major planar portion and surrounding an opening. The inner edge includes a first portion having a ridge extending outwardly from a distal end thereof and a second portion having a channel extending inwardly from the distal end. An outer edge extends outwardly from the major planar portion and adjacent a periphery thereof, and includes a first portion having a ridge extending outwardly from a distal end thereof and a second portion having a channel extending inwardly from the distal end. The ridges of the first panel are aligned with and received in the channels of the second panel. The window is disposed within the opening.

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.

Abstract: A man-made, molded article is provided. The article includes a profile including a planar wall, and an adjacent integral molded depression having a contoured wall extending downwardly from the planar wall. The contoured wall includes a bead portion, a cove portion, and a ledge between the bead and cove portions. The articles are stackable, one above another for transport, in a nestable relationship in which multiple contact zones are present between the contoured walls of an adjacently stacked pair of the molded articles. The contact zones include an arcuately extending contact interface zone between the bead exterior and interior surfaces. The depression has a substantially uniform thickness varying by no more than about +1 percent to about ?11 percent in relation to a thickness of the planar wall. Related methods and assemblies are also provided.

Abstract: A universal door skin blank comprises an exterior side and an interior side for securing to a frame member, first and second molded, spaced stiles, and a flat planar portion disposed between the stiles and lying on a plane spaced from the plane of the stiles. An interface portion is disposed between and contiguous with the stiles and the flat planar portion. The invention also relates to a door having at least one universal door skin blank, with at least two separately formed rails secured to the planar portion of the blank at opposite ends thereof.

Abstract: An impact resistant door skin, a door including the same, and a method of manufacturing an impact resistant door skin from a pre-formed door skin are provided. The method includes the steps of providing at least one preformed door skin and applying adhesive to a rear side of the at least one preformed door skin. A fiberglass mesh mat is pressed onto the rear side of the at least one preformed door skin. Then, chopped glass fibers coated with adhesive are sprayed onto the rear side of the at least one preformed door skin using a chopper gun to form a layer of chopped glass fibers on the fiberglass mesh mat. The performed door skin may be a molded door skin having at least one recessed panel formed therein.

Abstract: A protecting wall board assembly for houses, including two “?” shaped column and a plurality of hollow flat plates. The “?” shaped column has a guiding slot and corresponding first arm and second arm. The first arm is connected with a bent section. The second arm is connected with a protruding rib. Corresponding first engaging portion and second engaging portion are provided on an upper end portion and a lower end portion of the hollow flat plate. A plurality of hollow flat plates are accommodated in the guiding slot of the two “?” shaped column, and are fixedly joined together with the first and second engaging portions. The hollow flat plates are fixed between the bent section and the protrusion tube. The parts are of simple structure, can be easily manufactured, assembled, and disassembled, and can be used for the windows and doors having different widths and heights.

Abstract: A method of molding an inexpensive door skin with stylized panels using machined wooden strips which extend around the panel areas to simulate the appearance of a solid wood door. Wood veneer sections are placed on the mold around the wood strips and in between the panel areas and the laid up assembly is compressed by molding to form a door skin having the appearance of a solid wood door surface with raised panels. A backing of fiberboard such as MDF or similar material is placed against the back of the laid up assembly prior to compression. In another embodiment a door blank is shaped and veneer and strips are laid up on a mold. The door blank and mold are compressed to form a door with a finished surface. The shaped door blank serves as a mold component and as the interior of the finished door.

Abstract: Carved solid face doors having inlaid overlays and methods of manufacture thereof are provided herein. In some embodiments, a carved, solid face door may include a solid base having a face and an opposing rear surface, wherein the face has a design carved into at least one section of the face; one or more channels carved into the face adjacent to the design, each channel having a depth that is below a depth of the design carved into face of the door adjacent to the channel; and one or more inlay panels disposed in the one or more channels.

Abstract: The present invention provides a system, method and apparatus for producing fire rated doors having added strength, better finishing and low cost manufacturing flexibility. The fire rated doors are made from two panels “sandwiched” together. An optional interior layer (e.g., fire resistant material, lead sheeting, steel or Kevlar) can be added between the door panels for various purposes. Splines, stiles or sticks are inserted in longitudinal channels in the door panels to provide assistance in aligning the door panels and greater hardware holding strength. An intumescent banding material concealed by a banding material around the perimeter of the door seals the door within its frame during a fire. The door design and the automated manufacturing process provide greater design choice, reduced cost and faster fabrication.

Abstract: The present relates to a sidelite assembly having first and second panels and a window. Each of the panels has an inner edge extending outwardly from a major planar portion and surrounding an opening. The inner edge includes a first portion having a ridge extending outwardly from a distal end thereof and a second portion having a channel extending inwardly from the distal end. An outer edge extends outwardly from the major planar portion and adjacent a periphery thereof, and includes a first portion having a ridge extending outwardly from a distal end thereof and a second portion having a channel extending inwardly from the distal end. The ridges of the first panel are aligned with and received in the channels of the second panel. The window is disposed within the opening.

Abstract: Disclosed is a raised profile panel having various patterns for a door, which allows a user to repair a profile of the door or change a design of the door according to the demand of the user without exchanging the door with a new one when the profile formed on a surface of the door for decoration is damaged or the user wants to change the design of the door. The raised profile panel includes a profile section manufactured separately from the door and having a bonding surface forming an inner wall of the profile section and an exposed surface forming an outer wall of the profile section; and an adhesive layer provided on the bonding surface of the profile section to bond the bonding surface of the profile section with the surface of the door.

Abstract: A window frame assembly for installation within a garage door having front and rear exposed surfaces and one or more window openings. The assembly includes front and rear window frame members which are installed within the door opening on the front and rear exposed surfaces. The front and rear members are brought toward each other to sandwich the borders of the door panel defining the window opening and while also capturing an associated transparent pane. The rear frame member has a rib formed about an inner peripheral edge which is received in locking engagement within a cooperating peripheral groove provided on an inner side of the transparent panel. The rib and groove locking arrangement transfers impact forces on the pane to deformation forces on the front and rear frame members. A series of fastening members are used to hold the front and rear frame members securely against each other.

Abstract: A door assembly has a first door panel and a second door panel. The first door panel is made from a composite wood material and includes an exterior surface and an interior surface. The interior surface has a first door lite receiving region with a thickness less than at least one other region of the door panel. The second door panel is made from a composite wood material having an exterior surface and an interior surface. The interior surface has a second door lite receiving region with a thickness less than at least one other region of the door panel. The second door panel is attached to the first door panel to form a door and the first and second door lite receiving regions are aligned with one another.

Abstract: The invention relates to a method for producing window or door elements that have a profile frame made up of profile pieces, and that have at least one glass pane attached thereto. The profile pieces are pre-affixed to each other in order to form corner joints, and subsequently, the at least one glass pane is glued to the pre-affixed profile frame, so that the corner joints attain their stability from the glued-in glass pane.

Abstract: A composite wood-metal structural member comprises a web and a pair of flanges. The web is at least partially made of metal and the flanges are at least partially made of wood. The web includes a pair of metal panels and each panel includes a central section and a pair of end sections. The end sections wrap around a part of the flanges and are attached thereto.

Abstract: A garage door or garage door segment is provided, and includes a base structure and a cementitious layer on the exterior face of the base structure.

Abstract: A man-made, molded article is provided. The article includes a profile including a planar wall, and an adjacent integral molded depression having a contoured wall extending downwardly from the planar wall. The contoured wall includes a bead portion, a cove portion, and a ledge between the bead and cove portions. The articles are stackable, one above another for transport, in a nestable relationship in which multiple contact zones are present between the contoured walls of an adjacently stacked pair of the molded articles. The contact zones include an arcuately extending contact interface zone between the bead exterior and interior surfaces. The depression has a substantially uniform thickness varying by no more than about +1 percent to about ?11 percent in relation to a thickness of the planar wall. Related methods and assemblies are also provided.

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.

Abstract: A door adapted for automated assembly includes a door frame, a first door sheet and a second door sheet. The door frame preferably includes a hinge rail, a strike rail, a top rail, a bottom rail and four corner keys. The hinge rail preferably includes a pair of snap slots formed on opposing sides. The strike rail preferably includes a pair of hook slots formed adjacent opposing sides. The door frame is assembled by inserting corner keys into ends of the hinge rail, strike rail, top rail and bottom rail. Each door sheet includes a J-shaped end formed on one end and a hook end formed on the other end thereof. The hook end is inserted into one of the hook slots and the J-shaped end is pushed into one of the snap slots. The door may then be filled with a foam material.

Abstract: A sidelite assembly including first and second panels with an opening for receiving a window or glazing is provided. The first and second panels include inner and out edge portions with ridges and/or channels that allow for the alignment and attachment of the first and second panels to one another.

Abstract: A reverse molded fiberboard panel; a wainscot kit comprising a plurality of differently sized reverse molded panels, and a planar finishing or spacer panel, adapted to completely cover any size wall between a wall base board and a wall chair rail; and a method of reverse molding a loose cellulosic mat, in a single pressing step, to provide one or more relatively high density, raised panels without requiring preliminary pressing, or other pre-shaping step, such as scalping. The reverse-molded panels are molded in a conventional, multi-opening fiberboard press, in a single pressing step process, while achieving excellent transfer of mold detail (embossing fidelity) without visually noticeable fiber fracture.

Abstract: The present invention concerns a method of forming a multi-ply core component. A mold press is provided having an upper die and a lower die defining a mold cavity. At least one of the upper die and the lower die has a plurality of protrusions. A first wood composite board and a second wood composite board are disposed within the mold cavity. The first and second boards are fused proximate the plurality of protrusions by compressing the boards in the mold cavity through application of heat and pressure.

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.

Abstract: The present invention relates to a fireproof door, which comprises a fire-protection glass and a support means for supporting the fire-protection glass, and the support means comprising an elastic member in contact with both surfaces of an edge portion of the fire-protection glass, a reinforcing frame for supporting the elastic member, and a fixing plate fixed to a support and corresponding to both surfaces of the reinforcing frame. The fireproof door of the present invention has a grade A fireproof performance.

Abstract: A door comprising first and second door skins secured to each other to form a cavity therebetween filled with expended foam. Each of the door skins has an opening therethrough for receiving a glass insert and a flange portion. Distal ends of the flange portions of the first and second door skins engage each other in an overlapping relationship by the expansion pressure of the expanded foam. The door further comprises a glazing rim member having a leg portion snap-locked between the flange portions of the first and second door skins. The method for assembling the door comprises the steps of filling the cavity between the door skins with foam material, then inserting the glass insert through the openings in the door skins and mounting the glazing rim member to the first door skin by snap-locking between the flange portions of the first and second door skins.

Abstract: A window frame assembly for installation within a garage door having front and rear exposed surfaces and one or more window openings. The assembly includes front and rear window frame members of injection molded plastic which are installed within the door opening on the front and rear exposed surfaces. The window frame members have alignment elements to assist in assemble and have engagement elements located about their peripheries which snap together in mating fashion to mount the frame members within the window opening. The engagement elements are adjustable to accommodate garage door panels of varying thicknesses and window panes of varying thicknesses. The engagement elements are also disengageable with a hand tool to separate the frame members and remove the members from the window opening.

Abstract: A man-made, molded article is provided. The article includes a profile including a planar wall, and an adjacent integral molded depression having a contoured wall extending downwardly from the planar wall. The contoured wall includes a bead portion, a cove portion, and a ledge between the bead and cove portions. The articles are stackable, one above another for transport, in a nestable relationship in which multiple contact zones are present between the contoured walls of an adjacently stacked pair of the molded articles. The contact zones include an arcuately extending contact interface zone between the bead exterior and interior surfaces. The depression has a substantially uniform thickness varying by no more than about +1 percent to about ?11 percent in relation to a thickness of the planar wall. Related methods and assemblies are also provided.

Abstract: A door including a frame having a plurality of slots on opposing sides, a pair of skins having a plurality of protrusions extending from a back surface, wherein the skin is secured to the frame with an adhesive between the skin and the frame as well as between the protrusions and slots. A method of manufacturing a door including the steps of forming a plurality of slots in a frame, forming a plurality of protrusions on a back side of a first skin, applying a layer of adhesive on at least one of the frame and the skin, and inserting the plurality of protrusions into the plurality of slots.

Abstract: The present invention concerns a method of forming a multi-ply core component. A mold press is provided having an upper die and a lower die defining a mold cavity. At least one of the upper die and the lower die has a plurality of protrusions. A first wood composite board and a second wood composite board are disposed within the mold cavity. The first and second boards are fused proximate the plurality of protrusions by compressing the boards in the mold cavity through application of heat and pressure.

Abstract: A garage door window has an outside frame member which has an inside frame member connection. The inside frame member has a protrusion connecting with the inside frame member connection. There is also an outside retainer channel, an inside retainer channel and an outside retainer fitting within the outside retainer channel, with an inside retainer fitting with the inside retainer channel. The inside retainer is nondestructively removable relative the inside retainer channel by a snap fit. An outside track is formed on the outside frame member, between a central inside face of the outside frame member and the outside retainer. An inside track is formed on the outside frame member, between the outside retainer and the inside retainer. A screen is mounted on the outside track, a fixed window mounted on the outside track; and an active window is mounted on the inside track.

Abstract: The present relates to a sidelite assembly having first and second panels and a window. Each of the panels has an inner edge extending outwardly from a major planar portion and surrounding an opening. The inner edge includes a first portion having a ridge extending outwardly from a distal end thereof and a second portion having a channel extending inwardly from the distal end. An outer edge extends outwardly from the major planar portion and adjacent a periphery thereof, and includes a first portion having a ridge extending outwardly from a distal end thereof and a second portion having a channel extending inwardly from the distal end. The ridges of the first panel are aligned with and received in the channels of the second panel. The window is disposed within the opening.

Abstract: A man-made, molded article is provided. The article includes a profile including a planar wall, and an adjacent integral molded depression having a contoured wall extending downwardly from the planar wall. The contoured wall includes a bead portion, a cove portion, and a ledge between the bead and cove portions. The articles are stackable, one above another for transport, in a nestable relationship in which multiple contact zones are present between the contoured walls of an adjacently stacked pair of the molded articles. The contact zones include an arcuately extending contact interface zone between the bead exterior and interior surfaces. The depression has a substantially uniform thickness varying by no more than about +1 percent to about ?11 percent in relation to a thickness of the planar wall. Related methods and assemblies are also provided.

Abstract: A door facing is provided. The door facing includes a body portion, and male and female alignment members protruding from a main surface area of the body portion. Also provided are door assemblies including the door facing and methods of making the door facing and the door assembly.

Abstract: The present invention concerns a method of forming a multi-ply core component. A mold press is provided having an upper die and a lower die defining a mold cavity. At least one of the upper die and the lower die has a plurality of protrusions. A first wood composite board and a second wood composite board are disposed within the mold cavity. The first and second boards are fused proximate the plurality of protrusions by compressing the boards in the mold cavity through application of heat and pressure.

Abstract: Techniques are provided for mounting simulated muntin bars, preassembled muntin grids and the like between parallel glazing sheets in an integrated multipane window sash. Among the mounting techniques disclosed are clips for holding simulated muntin components to a spacing and mounting structure of an integrated multipane window sash. All or portions of the clips can be desiccated.

Abstract: A door and window system comprising a door, a window, a bracket, and a retainer. The door has a portal, and the window is adapted to fit within the portal. The window having a first face and a second face. The bracket has a first window support, and the retainer has a second window support. The first window support includes a surface upon which the first face of the window is supported, and the second window support includes a surface upon which the second face of the window is supported. The door includes first and second outer skins.

Abstract: The present invention provides a system, method and apparatus for producing fire rated doors having added strength, better finishing and low cost manufacturing flexibility. The fire rated doors are made from two panels “sandwiched” together. An optional interior layer (e.g., fire resistant material, lead sheeting, steel or Kevlar) can be added between the door panels for various purposes. Splines, stiles or sticks are inserted in longitudinal channels in the door panels to provide assistance in aligning the door panels and greater hardware holding strength. An intumescent banding material concealed by a banding material around the perimeter of the door seals the door within its frame during a fire. The door design and the automated manufacturing process provide greater design choice, reduced cost and faster fabrication.

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.

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.

Abstract: A method for fabricating muntin grid pieces includes steps that attach an outer muntin grid element to an inner muntin grid element to form a two piece muntin grid piece. The outer muntin grid element surrounds at least three sides of the inner muntin grid element and may be held to the outer muntin grid element without connectors such as adhesive. The outer muntin grid element may be a slit tube that is spread open to be positioned over the inner muntin grid element.

Abstract: A reverse molded fiberboard panel; a wainscot kit comprising a plurality of differently sized reverse molded panels, and a planar finishing or spacer panel, adapted to completely cover any size wall between a wall base board and a wall chair rail; and a method of reverse molding a loose cellulosic mat, in a single pressing step, to provide one or more relatively high density, raised panels without requiring preliminary pressing, or other pre-shaping step, such as scalping. The reverse-molded panels are molded in a conventional, multi-opening fiberboard press, in a single pressing step process, while achieving excellent transfer of mold detail (embossing fidelity) without visually noticeable fiber fracture.

Abstract: A door has a core that includes a porous layer having a thickness and two opposing major surfaces. In one construction, the core also includes three fire-retardant layers, and two of the fire-retardant layers are separated by the porous layer. The porous layer and the fire-retardant layers are coupled together. Other constructions include one or more fire-retardant layers in balanced or unbalanced placement around the porous layer.

Abstract: A reverse molded fiberboard panel; a wainscot kit comprising a plurality of differently sized reverse molded panels, and a planar finishing or spacer panel, adapted to completely cover any size wall between a wall base board and a wall chair rail; and a method of reverse molding a loose cellulosic mat, in a single pressing step, to provide one or more relatively high density, raised panels without requiring preliminary pressing, or other pre-shaping step, such as scalping. The reverse-molded panels are molded in a conventional, multi-opening fiberboard press, in a single pressing step process, while achieving excellent transfer of mold detail (embossing fidelity) without visually noticeable fiber fracture.

Abstract: A door comprising first and second door skins secured to each other to form a cavity therebetween filled with expended foam. Each of the door skins has an opening therethrough for receiving a glass insert and a flange portion. Distal ends of the flange portions of the first and second door skins engage each other in an overlapping relationship by the expansion pressure of the expanded foam. The door further comprises a glazing rim member having a leg portion snap-locked between the flange portions of the first and second door skins. The method for assembling the door comprises the steps of filling the cavity between the door skins with foam material, then inserting the glass insert through the openings in the door skins and mounting the glazing rim member to the first door skin by snap-locking between the flange portions of the first and second door skins.

Abstract: The present invention is directed to a door facing formed from a polymeric composite material. The door facing has a first major surface intended to be interiorly disposed and a second major surface intended to be exteriorly disposed. At least a portion of the first major surface is to be subjected to thermal and mechanical stresses during door assembly. The first major surface has a textured pattern in the portion to be subjected to thermal and mechanical stresses. The textured pattern includes a plurality of spaced grooves extending into the first major surface and minimizing thermal and mechanical stresses. A door formed with the disclosed polymeric door facing and a method of forming a door facing are also disclosed.

Abstract: An impact resistant door including a frame (24) presenting an inner wall (36) and defining a pane slot (58) and a flap slot (60) and a groove (62) along each side of the pane slot (58). The door includes a pane of laminated glass (46) having an inside sheet of glass (48) and an outside sheet of glass (50) sandwiched together and having oppositely facing outside surfaces (56) to define a pane width (Wt) therebetween. An interlayer (52) is adhesively sandwiched between the sheets of glass and presents an edge flap (54) extending along the periphery of the pane of laminated glass (46). The pane width (Wt) is disposed in the pane slot (58) and the edge flap (54) is disposed in the flap slot (60) of the frame (24). A plurality of inserts (64) engage the outside surfaces (56) of the glass, and each insert (64) includes a projection (68) extending into the groove (62) of the frame (24) along the adjacent outside surface (56) of glass.

Abstract: A hollow core door comprises a perimeter frame, and first and second molded skins. Each skin has an exterior surface and an interior surface secured to opposing sides of the frame. At least one of the skins has an outer planar area, an inner planar area, and an asymmetric profile surrounding the inner planar area and interconnecting and integral with the outer planar area and the inner planar area. The asymmetric profile area has a convex portion extending outwardly from and relative to the plane of the outer planar area.

Abstract: A door comprises a frame, first and second outer skins, and first and second stiffeners. The first and second outer skins are respectively connected to first and second sides of the frame, and the first and second stiffeners are positioned between the first and second outer skins and are attached to the frame. The first stiffener is connected to the first side of the frame, and the second stiffener is connected to the second side of the frame. The first and second outer skins are respectively connected to the first and second stiffeners at positions adjacent the frame. The first and second stiffeners are joined together within an area defined by the frame, and the first and second stiffeners are joined together along a plane approximately equidistant from the first and second outer skins. The door also includes a window.

Abstract: A frame corner joint includes first and second frame rails having hollow interiors of predetermined contours and ends in mitered abutment. A corner key has legs inserted into the mitered ends of the frame rails. End portions of the legs substantially fill the hollow interiors of the frame rails forming a substantially closed cavity within the frame rails and between the end portions of the corner key legs. Solidified resin foam is disposed within this cavity rigidifying the corner joint, while the remainder of the interiors of the frame rails preferably is substantially free of solidified foam. At least one end portion of at least one leg of the corner key preferably has a flexible wall portion to permit escape of foam from within the cavity in the event of excess foam pressure. The hollow interiors of the frame rails preferably are mirror images of each other, and the legs of the corner key, including the end portions of the legs, preferably are mirror images of each other.

Abstract: The invention relates to a door comprising a door panel forming a front surface and a back surface of the door, and a grip integrated into the door panel and extending from the front surface up to the back surface of the door panel, the grip being shaped to enable users to open/close the door. The grip extends over substantially an entire dimension of the front and back surfaces and divides the door panel into separate door panel segments extending on opposite sides of the grip. The invention further relates to an assembly comprising a door and at least one interchangeable grip, the door comprising a door panel forming a front surface and a back surface of the door, and a fixing element integrated into the door panel and extending from the front surface up to the back surface of the door panel, the fixing element being provided for removably fixing the at least one interchangeable grip.