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 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 composite building component includes a non-planar molded composite web having two outer zones and two angled zones wherein the caliper of the angled zones differs from the caliper of at least one of the outer zones, and a flange disposed on an outer surface of an outer zone. A method of providing a composite building component also is disclosed.

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 composite building component includes a non-planar molded composite web having two outer zones and two angled zones wherein the caliper of the angled zones differs from the caliper of at least one of the outer zones, and a flange disposed on an outer surface of an outer zone. A method of providing a composite building component also is disclosed.

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: A composite building component, including a non-planar molded composite web having two outer zones and two angled zones wherein the caliper of the angled zones differs from the caliper of at least one of the outer zones, and a flange disposed on an outer surface of an outer zone.

Abstract: A composite building component, including a non-planar molded composite web having two outer zones and two angled zones wherein the caliper of the angled zones differs from the caliper of at least one of the outer zones, and a flange disposed on an outer surface of an outer zone.

Abstract: A core component is shaped to compensate for varying widths and depths of the shell or framing of a building or structural member. The component includes two major surfaces defining respective front and rear sides of the component, and the rear side of the component is preferably the mirror image of the front side. The core component is preferably pre-formed and provided in a space or void on the interior of building or structural members, e.g., two prefabricated molded doorskins. The core component is preferably made from a composite soft board material. Processes for the production of a core component and a building member such as a composite door product are also disclosed.

Abstract: A molded core component includes a center plane piece and at least one wall extending from the center plane piece. The wall preferably includes contours which form a multiplicity of pods, cells, or protrusions integral with the center plane piece. The core component is preferably inserted into the space or void formed by two prefabricated molded fiberboard doorskins, wherein the center plane piece lies substantially in the central plane of the door product. Processes for the production of a molded core component and a composite door product are also disclosed.

Abstract: A molded wood composite article man-made from wood fibers or wood particles on at least an upper, molded surface of the article, and a method of manufacturing the article to include a relatively uniform density, detailed design contours and textured aesthetics on one or more molded depression-interior inclined surfaces, while preventing embrittlement, softness and blistering of the article along the depression-interior inclined surfaces. These attributes are achieved by molding one or more depressions into an initially planar layer of cellulosic material, wherein the molded depressions have one or more inclined walls that have upper surfaces, along essentially an entire inclined span, that include detailed design contours, including adjacent curved and planar portions, e.g., bead and cove.

Abstract: A process of pre-finishing wood composite panels and/or structures having flat and contoured surfaces to result in a structure exhibiting the appearance of natural hard wood includes the steps of (1) providing a textured substrate; (2) applying a ground coat to the substrate; (3) applying a buffing glaze to the substrate; (4) selectively removing a portion of the buffing glaze from the substrate; and (5) applying a sealer to retain the remaining buffing glaze in textured ticks of the substrate.