Abstract: Disclosed is a thermoforming mold that defines a surface of a thermoformed part, a cavity recess that defines part of the interior space of the thermoformed part, a bond flange ridge, a vent recess and a chamber recess in an offal region outside of the surface of the thermoformed part, where the chamber recess, the vent recess and the cavity recess collectively define a continuous recess and where the part does not extend substantially beyond the bond flange ridge. Also disclosed is a manufacturing method including molding a first and second plastic sheet to thermoforming molds, impressing the first and second plastic sheets together between the thermoforming molds to define the part, a seam, a vent and a chamber then inserting a blow needle into the chamber and using that blow needle to move a fluid through the interior space of the part through the vent and then removing the offal and the chamber from the part. Also disclosed is a thermoformed part manufactured using the mold and method described above.

Abstract: Disclosed is a panel section intended for assembly with other equivalent panel sections as a section door. The panel section includes two sheets thermoformed together to define a panel, an attachment tab, a living hinge unitarily formed between the panel and the attachment tab, a receiver portion configured to receive the attachment tab of an equivalent panel section when assembled as a sectional door, a first bearing surface and a second bearing surface, where the second bearing surface is configured to bear against the first bearing surface on the equivalent panel section when assembled as a sectional door. Also disclosed are a method of thermoforming the disclosed panel section and a method of assembling the disclosed sectional door.

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: 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.