Abstract: A method of forming a cushioning element. The method including placing a first sheet adjacent to an outer surface of a first mold portion, the first mold portion including a first mold cavity. The method including pressing a portion of the first sheet into the first mold portion and into the first mold cavity with a forming tool, wherein at least a portion of the forming tool is extended into the first mold cavity. The method including applying negative pressure to the first mold cavity to draw the portion of the first sheet into the first mold cavity, and joining a second sheet to the first sheet to form the cushioning element.

Abstract: The present invention relates to a capped stile for an entry door having an interior backer element and an exterior cap element secured thereto. The exterior cap element is formed from a moisture resistant, foamed polymer composite and has a specific gravity of about 0.9 or less. A door having the disclosed capped stile, and a method of forming a door, are also disclosed.

Abstract: The present invention relates to a capped stile for an entry door having an interior backer element and an exterior cap element secured thereto. The exterior cap element is formed from a moisture resistant, foamed polymer composite and has a specific gravity of about 0.9 or less. A door having the disclosed capped stile, and a method of forming a door, are also disclosed.

Abstract: A sill assembly includes an integral sill assembly having a sill base and an inclined threshold. The sill base is overmolded in an injection molding process onto the inclined threshold. A rail assembly is adjustably secured to the sill base.

Abstract: A sill assembly includes an integral sill assembly having a sill base and an inclined threshold. The sill base is overmolded in an injection molding process onto the inclined threshold. A rail assembly is adjustably secured to the sill base.

Abstract: A sill assembly includes an integral sill assembly having a sill base and an inclined threshold. The sill base is overmolded in an injection molding process onto the inclined threshold. A rail assembly is adjustably secured to the sill base.

Abstract: The present invention relates to a capped stile for an entry door having an interior backer element and an exterior cap element secured thereto. The exterior cap element is formed from a moisture resistant, foamed polymer composite and has a specific gravity of about 0.9 or less. A door having the disclosed capped stile, and a method of forming a door, are also disclosed.

Abstract: A sill assembly includes an integral sill assembly having a sill base and an inclined threshold. The sill base is overmolded in an injection molding process onto the inclined threshold. A rail assembly is adjustably secured to the sill base.

Abstract: A modular exterior threshold and door sill assembly is provided for an entryway. The threshold and sill assembly includes an elongated sill assembly having at least one elongated channel. An elongated rail assembly is provided that extends at least a portion of the length of the elongated sill assembly. A portion of the elongated rail assembly is received within the elongated channel. The threshold and sill assembly includes at least one sill component connected to one of the elongated rail assembly and the elongated channel, wherein the at least one sill component includes at least one of a cover assembly, an astragal bolt receiver assembly, a mullion boot assembly, a side panel spacer assembly and an outswing rail assembly. The elongated rail assembly may be fixed or adjustable. The adjustable rail assembly may be adjusted using adjustors that are fixedly secured to the sill assembly.