Abstract: A skylight assembly is provided with a glazing unit which transmits light while limiting heat transfer. The glazing unit has spaced apart top and bottom layer defining an enclosed cavity at least partially filled with translucent insulating particles. A peripheral frame formed in situ from a polymeric material about the glazing unit forming a leak-tight joint.

Abstract: A method for manufacturing a fenestration article includes placing a light transmitting pane on a first conformable seal in a first mold portion. The pane has an overmold flange. The method also includes placing a second conformable seal is situated opposed to and positioned on the second side of the pane, the second seal positioned in cooperation with the first conformable seal and a second mold portion to form a center opening in the pane. The first and second portions of the mold are closed, defining a mold cavity therebetween, into which a plastic material is introduced encapsulating the overmold flange and forming in the mold cavity a frame about the light transmitting pane with the center opening situated further away from the wall than the frame, when the fenestration article is installed in the wall.

Abstract: An overmolded building product having a frame and a thin shell base. The frame has a periphery and a first aperture. The frame further has an overmolding adapted to receive a pane, which has an interior side and exterior side in contact with the overmolding. The pane covers the first aperture and transmits light. The thin shell base has an exterior side opposed to a portion of an interior side forming a first cavity. The first cavity selectably receiving a filler. The thin shell has a first distal end of the exterior side which may be selectably positionable adjacent to and securable to a roof member. The roof member defines a second aperture leading to a room in a building. The interior side of the thin shell defines a second cavity adjacent to the pane. The frame is securable to the thin shell base. The frame and thin shell base are molded using a process selected from thermoforming, rotomolding, compression molding, or injection molding.

Abstract: A fenestration product such as a skylight or a window assembly is provided having a frame with a peripheral wall with a light transmitting central region and a plastic dome formed of a light transmitting material mounted to the frame. The plastic dome has a central region which transmits light, a downwardly extending peripheral wall extending about and mounted to the peripheral frame, and an outwardly extending flashing flange for mounting the assembly to a building structure. Various embodiments of the part illustrated include a skylight assembly having a frame formed of a plastic layer formed into an inverted ‘U’ shape cross-section forming an annular channel filled with insulating foam. A sealed, vertically mounted window unit is also disclosed. Other embodiments have an insulating layer of transparent plastic material spaced from the dome forming an enclosed, gas filled insulating region. Methods of forming and installing a fenestration assembly are also described.

Abstract: A skylight assembly is provided with a glazing unit which transmits light while limiting heat transfer. The glazing unit has spaced apart top and bottom layer defining an enclosed cavity at least partially filled with translucent insulating particles. A peripheral frame formed in situ from a polymeric material about the glazing unit forming a leak-tight joint.

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: A fenestration product such as a skylight or a window assembly is provided having a frame with a peripheral wall with a light transmitting central region and a plastic dome formed of a light transmitting material mounted to the frame. The plastic dome has a central region which transmits light, a downwardly extending peripheral wall extending about and mounted to the peripheral frame, and an outwardly extending flashing flange for mounting the assembly to a building structure. Various embodiments of the part illustrated include a skylight assembly having a frame formed of a plastic layer formed into an inverted “U” shape cross-section forming an annular channel filled with insulating foam. A sealed, vertically mounted window unit is also disclosed. Other embodiments have an insulating layer of transparent plastic material spaced from the dome forming an enclosed, gas filled insulating region. Methods of forming and installing a fenestration assembly are also described.

Abstract: A fenestration is provided having a peripheral frame defining a frame opening, the frame being adapted to being installed upon an opening in a building panel. Cooperating with the peripheral frame is a laminated panel which is structurally mounted to and sealingly spans the peripheral frame opening to form a structural and leak proof interconnection. The laminated panel is formed of three structural layers; an outer and inner plastic sheet and a resin layer interposed therebetween which are collectively bonded together to form a structural laminate, the laminated panel being capable of transmitting visible light therethrough.

Abstract: An overmolded building product having a frame and a thin shell base. The frame has a periphery and a first aperture. The frame further has an overmolding adapted to receive a pane, which has an interior side and exterior side in contact with the overmolding. The pane covers the first aperture and transmits light. The thin shell base has an exterior side opposed to a portion of an interior side forming a first cavity. The first cavity selectably receiving a filler. The thin shell has a first distal end of the exterior side which may be selectably positionable adjacent to and securable to a roof member. The roof member defines a second aperture leading to a room in a building. The interior side of the thin shell defines a second cavity adjacent to the pane. The frame is securable to the thin shell base. The frame and thin shell base are molded using a process selected from thermoforming, rotomolding, compression molding, or injection molding.

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: Compression molded pigmented door skins fabricated by compression molding a pigmented, curable, unsaturated polyester sheet molding compound containing a co-curable unsaturated monomer, a low profile additive, and a microvoid-reducing thermoplastic polymer, exhibit uniform stainability while maintaining a low linear thermal coefficient of expansion. Such door skins are suitable for preparing wood grain textured exterior insulated doors which exhibit minimal thermal deflection when exposed to interior/exterior temperature differentials, even at eight foot door heights. The doors may be stained without first applying a seal coat.

Abstract: One aspect of the present invention is directed to a door, and more specifically, to a door that includes a web and a rigid foamed core. In one embodiment, a door is disclosed which comprises a door shell having a generally planar construction with marginal edges and first and second door skins helping to define an interior door cavity, a web disposed within the interior door cavity, and a rigid foamed cementitious core disposed within the interior door cavity and cooperating with the web.

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: A high performance door comprising a door shell having a generally planar construction with marginal edges and at least one door skin helping to define an interior door cavity and a door member disposed within the interior door cavity is disclosed. The door member is preferably constructed of a gas-entrained cementitious material and has a compressive strength of at least about 30 lbf/in2 when measured using ASTM C-39. A method for forming a door member for use in construction with the door generally comprising: providing a door shell, placing the door shell in a fixture, filling the interior door cavity with a gas-entrained cementitious material, green-strength curing the gas-entrained cementitious material, and removing the door shell from the fixture is disclosed. The cured gas-entrained cementitious material provides a gas-entrained cementitious core for use in conjunction with a door.

Abstract: Weatherable building materials particularly well suited for entry door skins and other exterior building components are prepared by compression molding lignocellulosic fibers digested under conditions such that partial breakdown of hemicellulosic and other components produces an in situ binder, together with a secondary phenol/formaldehyde binder resin, followed by impregnating the product with a non-fugitive tertiary binder.

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 relates to a weatherable building product comprising a wood member. The wood member has at least a portion which is coated with a coating composition comprising an interpenetrating polymer network of an acrylic latex and a vinylidene chloride polymer. The wood member comprises solid wood or fiber-based materials.

Abstract: Compression molded pigmented door skins fabricated by compression molding a pigmented, curable, unsaturated polyester sheet molding compound containing a co-curable unsaturated monomer, a low profile additive, and a microvoid-reducing thermoplastic polymer, exhibit uniform stainability while maintaining a low linear thermal coefficient of expansion. Such door skins are suitable for preparing wood grain textured exterior insulated doors which exhibit minimal thermal deflection when exposed to interior/exterior temperature differentials, even at eight foot door heights. The doors may be stained without first applying a seal coat.

Abstract: Compression molded pigmented door skins fabricated by compression molding a pigmented, curable, unsaturated polyester sheet molding compound containing a co-curable unsaturated monomer, a low profile additive, and a microvoid-reducing thermoplastic polymer, exhibit uniform stainability while maintaining a low linear thermal coefficient of expansion. Such door skins are suitable for preparing wood grain textured exterior insulated doors which exhibit minimal thermal deflection when exposed to interior/exterior temperature differentials, even at eight foot door heights. The doors may be stained without first applying a seal coat.

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.