Abstract: The present invention provides a door panel that comprises an outer panel and an inner panel joined together at adhering portions and, regardless of whether rib portions are formed on the adhering portions in order to prevent deformation of the adhering portions or for other purpose, can be modified to withstand severe heat by means of formation of large ventilation openings in the adhering portions without significantly impairing the shape or the strength of the door panel.

Abstract: Double paneled door assembly providing RF shielding and soundproofing through the use of two door panels, i.e., back door panel and front door panel, as well as respective back door frame and front door frame. The door panels and door frames are joined together by door pins and door pin bushing as well as frame pins and frame pin bushings, and the double door panels are mounted on the double frames by heavy duty hinges. The use of two door panels and frame panels with a volume of sealed air or other inert gas between the panels aids the RF shielding and soundproofing properties of the door. The bushings act as damping mechanisms to reduce transmission of vibration from the front side of the door assembly to the back side of the door assembly that will ultimately reduce waves permeating into an enclosed room or area.

Abstract: A hollow metal door using hollow structural sections with closed cross section, along with the method for making same, is described herein.

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 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 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 a frame having a hinge stile, a lock stile, a top rail, and a bottom rail defining an internal cavity, an interlayer secured within the internal cavity, a front skin further defining the internal cavity, and a rear skin opposite the front skin and further defining the internal cavity. A method of manufacturing a door including the steps of securing a hinge stile, a strike stile, a top rail, a bottom rail, and a first skin defining a frame and an internal cavity within the frame, inserting an interlayer within the internal cavity, securing the interlayer within the internal cavity to an inner surface of the frame with a plurality of fasteners, and securing a second skin opposite the first skin and further defining the internal cavity.

Abstract: A storm reinforcing brace for a corrugated polycarbonate plastic hurricane shutter panel, and the combination thereof. The brace includes an elongated bar member extrusion-formed as a single one-piece unit and having a continuous, uniform generally hat-shaped section defining a central portion, leg or side portions, and mounting flange portions thereof. The central portion is preferably flat with an inwardly extending C-shaped channel sized to entrappingly slidably receive a head of a separate threaded fastener from either end of the channel, the threaded fastener being held in the channel in an outwardly extending adjustably slidable orientation along the length of the brace. Each of the mounting flange portions lie in a plane inwardly offset from the central portion and laterally extending from each corresponding leg portion, each of the mounting flange portions for receiving fasteners therethrough anchoring the brace against the upright side members of a window frame.

Abstract: The present invention is directed to a method of forming a molded core component. A mat formed from cellulosic fiber and resin is provided. The mat is consolidated in a first press until the resin is substantially fully cured, and then removed from the first press. The consolidated mat is then placed in a second press having a mold cavity shaped to form at least one depression in at least one of the major surfaces. The consolidated mat is reformed in the second press to form a molded core component having at least one depression in at least one of the major surfaces. The molded core component has a variable density, preferably of between about 10 lbs/ft3 and 80 lbs/ft3.

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: A door panel that is capable of maintaining the adhering strength of the adhesive is provided. An outer panel and an inner panel are joined together by an adhesive. Adhesive retaining portions, each of which includes an adhesive retaining channel for retaining the adhesive, are provided in adhering portions of the inner panel. Each adhering portion includes vertically extending portions, and the adhesive retaining portions of the inner panel are formed in the shape of an extended raised portion and extend vertically in the respective vertically extending portions of the adhering portions, along ventilation openings, which are formed at locations corresponding to groups of ventilation holes of the outer panel. Each adhesive retaining portion is provided at the middle of each vertically extending portion of the adhering portions so as to be flanked by adhesion margins of identical width.

Abstract: A composite mixture for making a thin-layer composite product, such as a door skin, which includes cellulosic fibers, at least 1% by weight noncellulosic fibers, such as glass fibers, and at least 1% by weight of an isocyanate resin, and methods for making them. The noncellulosic fibers may be individualized before they come in contact with the resin.

Abstract: A method of manufacturing a plastic molded shutter assembly that can be customized in size. A shutter of a standard length, or series of shutters of standard lengths are manufactured. A plurality of cuts are made in the shutter, removing a predetermined amount of material from the shutter. The end cap is replaced and fixedly secured to the remaining shutter, resulting in a single shutter of a desired length.

Abstract: A hollow metal door using hollow structural sections with closed cross section, along with the method for making same, is described herein.

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: Using integrally formed stiles on skins of sheet molded plastics (thermosetting) employed to form the exterior surfaces of a synthetic door having sheets of reinforcing materials adhered to the inner surface of each of the skins, the skins can be connected through the integral stiles and slats of a fire proof materials can be affixed to these stiles and rails closing the top and bottom opening between the skins to increase the fire resistance of the resulting door when the core is filled with a phenolic foam. The structure described reduces the weight of the resulting door and places the fire resistant materials around the door edges which are the most susceptible to failure during a fire while structurally tying the slats together through the sheets of carbon fiber or fiberglass disposed on the inner surfaces of the skins whereby failure (disintegration) of the skins during a fire will not lead to a collapse of the door as with some prior art door structures.

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 panel that is light in weight and has sufficient strength is provided. A door panel has an outer panel, an inner panel, and a foamed material filling a space between the outer panel and the inner panel. The inner panel is formed by means of press molding so as to have an uneven surface with adhering portions and a raised portion. The adhering portions are affixed to the inner surface of the outer panel, and the space is formed between the raised portion and the outer panel. The outer panel has a thickness ranging from 1.2 to 5.0 times that of the inner panel. A hemmed portion is formed by folding the peripheral edge of the outer panel so as to curl over the peripheral edge of the inner panel and then pressing down the folded part.

Abstract: An integrally molded window spacer bar connector for joining opposed spacer bar end passages in the form of a hollow tube with a longitudinal axis of symmetry and a transverse axis of symmetry includes inclined leading edge ramps, a medial rib to control the insertion of the connector into spacer bars, and external channels to receive a sealant material for sealing the connector to the spacer bar at the seam of the joint of the spacer bar.

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, 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 provides a door panel that comprises an outer panel and an inner panel joined together at adhering portions and, regardless of whether rib portions are formed on the adhering portions in order to prevent deformation of the adhering portions or for other purpose, can be modified to withstand severe heat by means of formation of large ventilation openings in the adhering portions without significantly impairing the shape or the strength of the door panel.

Abstract: A door is constructed with a separate member joined to the door edge by a tongue-and-groove coupling and screws so as to be readily removable and replaceable. The separate member sustains the impacts imparted to the door by carts or wagons pushed past the door and can be readily replaced when damaged, thus avoiding replacement of the entire door. A flexible cover snaps over the outer surface of the separate member to add impact resistance and aesthetic appeal. Intumescent strips may be inserted inside or outside of the cover to enhance sealing between the door, and as adjacent door or door frame, thereby improving the fire resistance rating of the door. Accent strips or reveals of contrasting or complementary colors may be incorporated to add to the aesthetic appeal of the door. The door construction is of particular utility in schools, health care facilities and other institutions.

Abstract: An improved refrigerator door is provided with a metal outer panel and upper and lower plastic end caps installed on top and bottom edges of the door. The caps include grooves to receive flanges on the edges of the panel, thereby mounting the caps to the panel. The caps include ratcheting members to provide a mating fit with the panel. A bushing is snap fit into the upper cap without the use of hardware fasteners. Electric wires and a water line extend downwardly through the bushing to an ice and water dispenser in the door.

Abstract: A method of making a stainless steel composite door is accomplished by forming an oversized composite core by gluing a sheet of lightweight plywood to a sheet of brushed metallic laminate formed of a layer of metal and phenolic plastic. The thus formed core is cut to form an undercut step through only a portion of the plywood section, leaving the laminate intact. A pan is then laid down on a flat table with flanges pointing up. One-quarter inch thick spacer pads are placed in each of the four corners of the pan. The oversized metallic laminated core, with an undercut step, is placed on top of the pan and centered. Overhead clamps are tightened to hold the core in place in the pan. The metallic laminated core is routed by a trim router having a rotatable bearing and a cutting bit, with the bearing having a lesser radius than the router bit. The difference in radii between the bearing and the router bit is equal to the thickness of the flanges of the pan.

Abstract: Synthetic doors composed a rectangular frame with of skins of compression molded sheets secured to opposite sides of the frame and a core of foamed plastics with a window light therein are improved with a novel glazing cleat for securing a window light in an aperture in such a door that includes plate that rests against edges the skins about the aperture, the plate having an upright rim engaging a face of a window light and downwardly directed flanges which, with tangs on a retainer member having a upright tab engaging the opposite face the window light when nesting with the plate sandwiches the skins between the flanges and tangs to take advantage of the mechanical strength of the skins. Further if a fire resistant plate is married to internal face of each skin, the cleat will take advantage of the mechanical strength of such plates in supporting the window light in the case of fires, even if the outer or exterior skin or skins are turned to ash by a fire.

Abstract: A storm door assembly for a doorway to a building comprises a frame configured for hinged mounting at a doorway of a building. The frame comprises an opening through the frame, the opening comprising a depth and at least two channels disposed in parallel around an inner surface of the depth. At least two removable frame inserts are provided, each comprising a front surface, a rear surface, and an insert perimeter comprising a plurality of recesses positioned about the perimeter. A plurality of twisting cams are each disposed within one of the plurality of recesses and not extending beyond the front and rear surfaces, and the at least two frame inserts are each held in a fixed position with respect to the frame via placement of the twisting cams within the at least two channels.

Abstract: The present invention is a twinsheet door which includes a first door portion and a second door portion connected to the first door portion. The twinsheet door of the present invention is manufactured using a thermoforming process, during which a vacuum shapes the first door portion and the second door portion such that one or more closed sections are created when the first door portion is thermally bonded to the second door portion and simultaneously a vacuum is applied to form the first door portion and said second door portion. The closed section formed between the first door portion and second door portion provides additional strength and rigidity to the twinsheet door. Additionally, the forming of the closed section between the first door portion and the second door portion and the bonding between the first door portion and second door portion is achieved during a single manufacturing process.

Abstract: A construction panel including at least first, second, and third oriented stranded board (OSB) materials in sheet form adhesively glued together in a back to back arrangement. The construction panel can be used as a wood door core. A wood veneer covering or other exterior covering can be placed over the core as desired. The door construction may include rails along the top and the bottom of the core, and stiles along the side of the core. A method of assembling a construction panel wherein three panels of oriented stranded board (OSB) material in sheet form are glued together in a back to back arrangement. In one method, the two outermost faces of the panel are sanded or otherwise processed to smooth out imperfections on the front and rear faces.

Abstract: An improved panel (10) for lift doors, made of metal or another suitable material, including a plate (12) in a basically rectangular shape, whose longer sides extend in height and are folded back with a “C”-shaped profile in the longitudinal direction to form opposed edges or rims (14) turned towards the longitudinal axis of the plate itself, the lower base of the latter being equipped with a basically “S”-shaped back fold including a horizontal flat portion (22) along which a plurality of fissures (24) are made which receive a portion of the lower edge of one or more stiffening members (36).

Abstract: The present invention is a door with a modular frame which can be installed and removed easily. In several embodiments the door is constructed to fit in a standard interior doorway without modifications to the existing door frame. In several embodiments the opening is constructed in the upper half of the door. In several embodiments the screen is constructed in a modular frame for easy replacement of the screen if damaged or if other material such a glass or acrylic glass is desired in the opening. In several embodiments the modular frame can be replaced without tools. In several embodiments the modular frame could hold a number a different inserts. In several embodiments the door has a regular door panel on one side and an opening with a modular frame on the other side. In several embodiments the door has a self supporting screen.

Abstract: The present invention is a hollow core screen door with the screen opening in the upper half of the door. In several embodiments the door is constructed to fit in a standard interior doorway without modifying the existing doorway frame. In several embodiments the screen is constructed in a modular frame for easy replacement of the screen if damaged or if other material such a glass or plexiglass is desired in the screen opening. In several embodiments the modular screen frame can be replaced without tools.

Abstract: A door structure, comprising a metallic door frame, having opposite sides, plastic paneling received on the frame in covering relation with at least one of the sides, the plastic paneling including paneling sections having abutting edges.

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 is directed to a door skin having an exterior surface with an woodgrain pattern formed therein, and an etched plate for use as an embossing plate or with a molded die set, for forming the woodgrain pattern in the door skin. The exterior surface has outer portions lying on a first plane, spaced grooves recessed from the plane of the outer portions, and halftone portions. The halftone portions have spaced protrusions defined by channels, wherein the channels are recessed from the plane of the outer portions.

Abstract: Universal master boards and methods of making flush door skins and doors from the universal master boards are disclosed. The universal master boards each have an expansive surface with a graphic design of at least first depressions and second depressions in at least first and second surface regions, respectively. The first depressions simulate a first wood grain pattern, and the second depressions simulate a second wood grain pattern aligned in a different direction than the simulated first wood grain pattern. The universal master boards may be cut and demarcated selectively to establish different assortments of simulated wood patterns and different ornamental features, such as stiles and rails.

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 of forming a composite door is disclosed. The method comprises: mixing together a thermoplastic polymer with an organic fibrous material in a ratio such that the organic fibrous material constitutes 40 to 60 percent by weight of the mixture; extruding the mixture under heat and pressure to create a thin sheet form; cutting the sheet to a predetermined size; removing material from at least one surface of the sheet to create a homogeneous appearance devoid of obvious fibrous particles; thermoforming the sheet to impart to the at least one surface an exterior three dimensional door surface to create a thin door facing; and assembling two of the thermoformed thin door facings, a peripheral frame and a core material into a door.

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: A method for fabricating a door having a window, the door having a first door skin and a second door skin, the method including the following steps in the order named: forming a first door light opening perimeter having a first plurality of tabs arranged about the first door light opening perimeter, wherein the first door light opening perimeter defines a first door light portion; forming a second door light opening perimeter having a second plurality of tabs arranged about the second door light opening perimeter, wherein the second door light opening perimeter defines a second door light portion; positioning the first door skin on a first press; positioning an insert in aligned registration with the first plurality of tabs; positioning the second door skin over the insert, wherein the second plurality of tabs are in aligned registration with the insert, and the first door light opening perimeter is aligned with the second door light opening perimeter; applying pressure with the first press to secure the firs

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: A door assembly for use in a building includes a glass door panel having an outer surface and an inner surface and a perimeter region. The door assembly includes at least one metallic hardware element bonded via a layer of cured adhesive to the inner surface of the door panel and at least partially along the perimeter region of the door panel. The layer of cured adhesive bonds the at least one metallic hardware element to the inner surface of the door panel without exposure of the metallic hardware element on the outer surface of the door panel. The door assembly may include a perimeter frame portion bonded to the inner surface of the door panel via another layer of cured adhesive. At least a portion of a door handle assembly may protrude through an aperture formed in the glass door panel.

Abstract: A door panel that is light in weight and has sufficient strength is provided. A door panel has an outer panel, an inner panel, and a foamed material filling a space between the outer panel and the inner panel. The inner panel is formed by means of press molding so as to have an uneven surface with adhering portions and a raised portion. The adhering portions are affixed to the inner surface of the outer panel, and the space is formed between the raised portion and the outer panel. The outer panel has a thickness ranging from 1.2 to 5.0 times that of the inner panel. A hemmed portion is formed by folding the peripheral edge of the outer panel so as to curl over the peripheral edge of the inner panel and then pressing down the folded part.

Abstract: A door member comprising a frame having a first side and a second side, opposite the first side, a core positioned within the frame, and a molded skin attached to the first side of the frame. The skin is prepared from a molding compound which, when molded, has a shrinkage of between about ?0.0003 to about +0.0015. The molding compound comprises a resin system comprising a curable polyester resin, a co-curable unsaturated monomer, and at least two low profile additives. The molding compound also comprises at least about 30 percent by weight, based on the weight of the molding compound, of filler material, and fibrous reinforcement in an amount of less than about 35 weight percent, based on the weight of the molding compound.

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: A shutter and fastener system comprising a shutter and two or more fastener mechanisms each comprising cooperating latching and anchor devices, one device mounted on an edge portion of the shutter and the other on an adjacent trim portion. The latching device engages the anchor device and exerts a strong pulling force substantially parallel with the surface of the shutter. The anchor device converts a portion of this force to a perpendicular force resulting in firm engagement between the shutter and the trim portion. An installation method comprises the steps of proving a shutter with a t least one latching device mounted thereon and a small opening in the shutter aligned with operating means for the device. An anchor device is provided on an adjacent trim portion and the operating means is actuated from inside the shutter though the small opening to secure the shutter in place.

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 door panel that permits formation of small ventilation holes therein while ensuring adequate rigidity is provided. The door panel includes an outer panel, an inner panel, and a perforated ridge-and-furrow plate. The outer panel has openings, and the inner panel has openings. The inner panel is formed by means of press molding so as to have an uneven surface with recessed portions and a raised portion, with the raised portion protruding away from the outer panel and the recessed portions recessed towards and fixed to the inner surface of the outer panel. The perforated ridge-and-furrow plate is attached to the reverse side of the inner panel. The perforated ridge-and-furrow plate is a punching plate that is already provided with numerous small, circular ventilation holes, or with ventilation holes arranged in a mesh or a honeycomb shape. The perforated ridge-and-furrow plate includes alternating furrow portions and ridge portions formed in the region that corresponds to the openings of the inner panel.