Abstract: The present invention relates to shaker doors with solid cores and methods for making the same. The shaker doors contain different core materials at the recessed panel than the raise peripheral region to provide dimensional stability and reduced distortion when the doors are exposed to high humidity. The devices and methods also provide for easy assembly of solid core shaker doors, including fire rated doors.

Abstract: A composite sandwich structure comprises a core sandwiched between composite laminate facesheets. The core includes a plurality of core sections spliced together at joints that incorporate integral features for arresting the propagation of irregularities in the facesheets.

Abstract: A core for a fire rated door includes an extruded fire resistant material, a filler material and a panel. The extruded fire resistant material has a first raised portion, a second raised portion and a lower portion that extends from a first end to a second end. The first raised portion has a first thickness and a first width that extends from the first side to the lower portion. The lower portion has a second thickness. The second raised portion has the first thickness and a second width that extends from the second side to the lower portion. The filler material is disposed above the lower portion of the extruded fire resistant material between the first raised portion and the second portion. The panel is attached to the first raised portion and the second raised portion of the extruded fire resistant material and covers the filler material.

Abstract: A self supporting panel system used to fabricate ceilings, floors, walls, or roofs. The panel system is assembled from a plurality of panels, each having a core that is sandwiched between opposing plate members. In a preferred embodiment, the core of each panel includes a unifying material to enhance the load bearing capacity of the panel.

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: The invention relates to an aircraft side fairing, with a component (9) in the form of individual hollow chambers (12, 13, 14) which are arranged essentially in a preferably curved plane and are arranged between two cover layers (1, 2), wherein a gastight film which completely encases the component (9) with the hollow chambers (12, 13, 14) is provided and, after application of a vacuum to evacuate the hollow chambers (12, 13, 14), surrounds the component (9) with the hollow chambers in a gastight manner.

Abstract: An improved cellular building block including a middle beam and two legs. The cellular building block having the first leg coupled to the middle beam such that the leg is perpendicular to the middle beam and a second leg coupled to the middle beam such that the leg is perpendicular to the middle beam and spaced apart from the first leg, the first leg and the second leg having an inside edge and an outside edge. Having at least one barb located on the inside edge of the first leg and on the inside edge of the second leg and further configured to lock into a recess. The cellular building blocks connect in a two dimensional or three dimensional pattern and a produce a structured material that holds itself together and exhibits beneficial characteristics.

Abstract: A self supporting panel system used to fabricate ceilings, floors, walls, or roofs. The panel system is assembled from a plurality of panels, each having a core that is sandwiched between opposing plate members. In a preferred embodiment, the core of each panel includes a unifying material to enhance the load bearing capacity of the panel.

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 skin comprises an exterior side and an interior side for being secured to a frame member. First and second molded, spaced stiles lie on a first plane. A flat planar portion is disposed between the stiles and lies on a second plane spaced from the first plane. A first interface portion is disposed between and contiguous with the stiles and the flat planar portion. First and second integrally molded, spaced rails lie on a third plane, wherein the third plane is intermediate the first and second planes.

Abstract: A double walled reinforcement structure and method for making a double walled reinforcement structure having a plurality of longitudinally extending and nested structural members. Each structural member comprises a first cell having a first cross-section and a second cell having a second cross-section. The second cell is positioned within the first cell and the second cell contacts the first cell in a plurality of locations to provide mutual support of the cells in a manner increasing the tensile and compressive strength of the structure.

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: 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: 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 self supporting panel system used to fabricate ceilings, floors, walls, or roofs. The panel system is assembled from a plurality of panels, each having a core that is sandwiched between opposing plate members. In a preferred embodiment, the core of each panel includes a unifying material to enhance the load bearing capacity of the panel.

Abstract: Disclosed herein are multiwall sheeting and articles comprising multiwall sheeting. In one embodiment, a multiwall sheet comprises: greater than or equal to three polymer walls (e.g., comprising a first outer layer, a second outer layer, and an inner layer), a transverse layer, and a liquid. The liquid is located in cells formed by the transverse layer and the walls. The multiwall sheet has a first visible light transmission and a first direct solar transmission. A second multiwall sheet has the same materials and the same design as the multiwall sheet but with no liquid, and has a second visible light transmission and a second direct solar transmission. The first visible light transmission is greater than the second visible light transmission and the first direct solar transmission is about 63% to about 70% as determined in accordance with ISO 9050.

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 core material having a structure in which three paulownia plates are laminated, the thickness of the inner paulownia plate being larger than the thickness of each of the outer paulownia plates; a core material for a wooden door which applies the above core material as a core material for a wooden door; and a wooden door having surface materials joined to both surfaces of the core material for a wooden door.

Abstract: A self supporting panel system used to fabricate ceilings, floors, walls, or roofs. The panel system is assembled from a plurality of panels, each having a core that is sandwiched between opposing plate members. In a preferred embodiment, the core of each panel includes a unifying material to enhance the load bearing capacity of the panel.

Abstract: A construction element 1 consists of multiple individual layers 2, 3, 4 whereas the medium layer 3 is in turn composed of a multitude of additional individual layers 23, 24, 25. The individual layers 2, 4, 23, 24, 25 are configured in such a way that they interlock and clamp into each other thereby producing or defining surfaces that allow the elements or individual layers 2, 4, 23, 24, 25 that are integrated in the construction of the construction element to evenly absorb the forces that are being applied. At the same time, not only pressure or lateral forces but also tensile and transverse forces can be absorbed so that altogether a construction element 1 with a low weight but high stability has been created. This construction element 1 can be shaped or deformed appropriately and can also be extended three-dimensionally so that an adaptation to the individual conditions in any plane or direction is possible.

Abstract: A light construction panel having excellent outer appearance and high persistent against deformation is disclosed. The light construction panel is formed with an outer frame and a core, the frame and the core having the same material thickness, and also with an upper and a lower cover sheet which cover the frame and the core. The core consists of an inner part made from light construction material and an upper and lower sealing layer. Such a panel is distinguished by a particular rigidity. Moreover the transition between frame and core no longer shows on the surface of the panel.

Abstract: The present invention provides a vacuum heat-insulating block including a honeycomb core, wherein the block structure prevents the honeycomb core having a low bulk specific gravity from collapsing by atmospheric pressure, the block attaining flexibility and sound absorption property. The vacuum heat-insulating block 100 according to the present invention is basically composed of a core utilizing a plurality of layered honeycomb members 50 (formed by bonding a honeycomb core member 51 to a support plate 55) and covering the core with a cover member 70. Moreover, a woven or non-woven fabric 60 having air permeability is disposed between the layers of honeycomb core members 51.

Abstract: A laminated wood piece is disclosed comprising a solid hardwood component having an upper surface and a lower surface that are substantially parallel to each other and a wood composite component having layers oriented substantially parallel to the lower surface of the solid hardwood component. The ratio of a thickness of the solid hardwood component to a thickness of the wood composite component being from about 1:1 to about 1:10. The laminated wood piece is suitable for use a door stile.

Abstract: A door assembly includes a plurality of spacers. The spacers have a first side and a second side. A first sheet of fire-resistant insulating material is coupled to the first side. A second sheet of fire-resistant insulating material is coupled to the second side. A first outer skin is coupled to the first sheet opposite said plurality of spacers. A second outer skin is coupled to the second sheet opposite the plurality of spacers.

Abstract: A press-molded door including a reinforcing structure having a plurality of hollow vertical stiffeners joined by a horizontal web, two of the stiffeners arranged on opposite edges of the reinforcing structure with a groove formed in an edge face thereof, a T-shaped stile arranged in each edge stiffener with a tongue that fits into the groove, and front and back panels arranged on opposite sides of the reinforcing structure.

Abstract: A wall panel structure for controlling humidity within a building having a panel assembly attachable to an inner wall surface of the building including: a first panel having a surface with a first predetermined porosity to moisture; and a second panel secured to said first panel with a space for accomodating airflow between the first and second panels, the second panel having a surface with a second predetermined porosity to moisture, the first perdetermined panel porosity being greater than the second predetermined porosity to thereby absorb moisture from air being circulated between the first and second panels; whereby humidity of an environment within the building is controllable.

Abstract: A panel system includes a first skin, a second skin, a web core constructed from sheet material for securing the skins together in a spaced, sandwich relationship, and a connecting means for affixing the web core within the skins. The web core includes a plurality of spaced apart longitudinal members having longitudinally spaced projections extending therefrom and further having transversely aligned, longitudinally spaced slots therein. The web core further includes a plurality of spaced-apart, transverse cross members each having spaced slots therein receiving the longitudinal members at corresponding transversely aligned slots thereof to provide an interlocked grid between the first and second skins. The grid is connected to the skins utilizing the projections, which extend through slits in the skins to facilitate welding or otherwise bonding the components.

Abstract: A wall panel including a rectangular frame, a pair of wall members and a thin decorative sheet covering the wall members. The frame includes two spaced apart, generally parallel vertical frame members. The horizontal frame members are connected to the vertical frame members at opposite ends thereof to form the rectangular frame. In one embodiment, each of the frame members includes a core member and a pair of sidewall member attached to opposite sides of the core member. The wall member are attached to the sidewalls on opposing sides of the frame members. In another embodiment, inner wall members are attached to the opposing sides of the frame members, and outer wall members are thereafter attached to the inner wall member. A decorative sheet covers the outer surface of each outer wall member. The wall panels are connected to each other with a connector member.

Abstract: The present invention provides contoured crushable composite structural members and methods for making the same. The contoured structural members comprise composite materials sandwiching a support or stabilizing structure. The contoured structure can be provided by tube rolling (or roll wrapping) the composite materials and the support structure together and then, if necessary, bonding them or connecting them. The structural members are made crushable by incorporating an initiator into the structures of the members. With a contoured, crushable, and generally non-flat structure, applications for the structural members of the present invention are nearly limitless.

Abstract: A wall panel including a rectangular frame, a pair of wall members and a thin decorative sheet covering the wall members. The frame includes two spaced apart, generally parallel vertical frame members and spaced apart, generally parallel horizontal lower and upper frame members. The horizontal frame members are connected to the vertical frame members at opposite ends thereof to form the rectangular frame. Each of the frame members includes a core member and a pair of sidewall members attached to opposite sides of the core member. The wall members are attached to the sidewalls on opposing sides of the frame members. A decorative sheet covers the outer surface of each wall member. A method for manufacturing the frame members includes providing a fixture with spaced apart first, second and third surfaces. A hanger bracket is mounted to the vertical frame core member and is positioned in the fixture such that the hanger bracket engages the first surface.

Abstract: A modular construction system that utilizes an extruded wall panel formed from rigid PVC to form either a door system, a wall system, or a storage building. The construction system includes an extruded wall panel defined by planar front and back surfaces that define a hollow interior. The wall panel can be configured to act as a door panel for a modular door system. A plurality of wall panels can be joined by a panel adapter to define a wall having a user selected configuration. Further, the wall panels can be joined to define the sidewalls of a storage building. An eave connector formed from extruded plastic supports a series of wall panels on the sidewalls and cooperates with a roof connector to form the roof of the storage building from the extruded wall panels.

Abstract: A door having a core made from a composite panel material such as medium density fiberboard or particleboard is provided with a plurality of dowels which are secured, such as by an adhesive, within openings extending into the core. The dowels and openings are positioned in alignment with the screw holes in the hinges which mount the door to a jamb or cabinet. Screws or other fasteners extend through the screw openings in the hinges and are secured within the dowels. The dowels permit conventional wood screws to be used to mount the hinges to the door and improve the screw holding capability of the door. The dowels also eliminate the need to use edge banding for screw holding purposes and thereby eliminate the problems associated with the joint formed between the edge banding and the core material.

Abstract: A wall panel including a rectangular frame, a pair of wall members and a thin decorative sheet covering the wall members. The frame includes two spaced apart, generally parallel vertical frame members and spaced apart, generally parallel horizontal lower and upper frame members. The horizontal frame members are connected to the vertical frame members at opposite ends thereof to form the rectangular frame. In one embodiment, each of the frame members includes a core member and a pair of sidewall members attached to opposite sides of the core member. The wall members are attached to the sidewalls on opposing sides of the frame members. In another embodiment, inner wall members are attached to the opposing sides of the frame members, and outer wall members are thereafter attached to the inner wall member. A decorative sheet covers the outer surface of each outer wall member. The wall panels are connected to each other with a connector member.

Abstract: A wall panel including a rectangular frame, a pair of wall members and a thin decorative sheet covering the wall members. The frame includes two spaced apart, generally parallel vertical frame members and spaced apart, generally parallel horizontal lower and upper frame members. The horizontal frame members are connected to the vertical frame members at opposite ends thereof to form the rectangular frame. Each of the frame members includes a core member and a pair of sidewall members attached to opposite sides of the core member. The wall members are attached to the sidewalls on opposing sides of the frame members. A decorative sheet covers the outer surface of each wall member. A method for manufacturing the frame members includes providing a fixture with spaced apart first, second and third surfaces. A hanger bracket is mounted to the vertical frame core member and is positioned in the fixture such that the hanger bracket engages the first surface.

Abstract: A multi-panel hollow door has a core made of corrugated paperboard. The core is formed from a stack of plies in which adjacent plies are adhered to one another in accordance with a predetermined pattern of adherence (e.g., a gluing pattern). The stack is expanded in a direction perpendicular to the plies to form an elongated series of cells disposed longitudinally between transversely spaced panel indentations of a door skin, at a central region of the door. Each cell has a pair of transversely spaced vertices, and juxtaposed end portions of vertex-forming plies form tabs. Each tab is preferably oriented to overlap an adjacent portion of a vertex-forming ply, the desired orientation being obtained by partial slitting of a single vertex-forming ply. Unexpanded end portions of a stack of plies may be broken off to form pads between corresponding portions of the skins.