Patents by Inventor Randy Jon Clark
Randy Jon Clark has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 8679386Abstract: A method to produce thin-layer lignocellulosic composites, such as wood-based doorskins, that exhibit substantial resistance to moisture is disclosed. In an embodiment, the method includes the steps of forming a mixture including a refined lignocellulosic fiber, wax, and an organic isocyanate resin. The mixture is initially pressed to form a loose mat. Subsequently, the mat is pressed between two dies at an elevated temperature and pressure to further reduce the thickness of the mat and to promote the interaction of the resin with the lignocellulosic fibers. In an embodiment, a release agent is included as part of the fiber mixture, or sprayed onto the surface of the mat. The thin-layer lignocellulosic composites of the present invention exhibit strong surface strength, high adhesiveness, and a 50% reduction in linear expansion and thickness swelling upon exposure to a high moisture environment as compared to thin-layer composites that do not include the isocyanate resin.Type: GrantFiled: March 15, 2011Date of Patent: March 25, 2014Assignee: JELD-WEN, inc.Inventors: Randy Jon Clark, Walter B. Davis, Jonathan Phillip Alexander
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Publication number: 20120292805Abstract: In one aspect, the present invention is a thin-layer lignocellulose composite having increased resistance to moisture. The thin-layer lignocellulosic composite includes a mixture of no more than about 95% by weight of a lignocellulosic fiber and at least about 5% by weight of an organic isocyanate resin. The mixture further includes short fibers and a release agent that does not interfere with subsequent processing of the thin-layer lignocellulosic composite. The mixture is pressed between two dies at an elevated temperature and pressure and for a sufficient time to form a thin-layer composite of predetermined thickness, and to allow the isocyanate resin to interact with the lignocellulosic fiber and short fibers such that the resultant thin-layer composite has a predetermined resistance to moisture.Type: ApplicationFiled: November 14, 2011Publication date: November 22, 2012Applicant: JELD-WEN, INC.Inventors: Randy Jon Clark, Kenneth Dale Kiest
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Patent number: 8058193Abstract: In one aspect, the present invention is a thin-layer lignocellulose composite having increased resistance to moisture. The thin-layer lignocellulosic composite includes a mixture of no more than about 95% by weight of a lignocellulosic fiber and at least about 5% by weight of an organic isocyanate resin. The mixture further includes short fibers and a release agent that does not interfere with subsequent processing of the thin-layer lignocellulosic composite. The mixture is pressed between two dies at an elevated temperature and pressure and for a sufficient time to form a thin-layer composite of predetermined thickness, and to allow the isocyanate resin to interact with the lignocellulosic fiber and short fibers such that the resultant thin-layer composite has a predetermined resistance to moisture.Type: GrantFiled: December 11, 2008Date of Patent: November 15, 2011Assignee: JELD-WEN, inc.Inventors: Randy Jon Clark, Kenneth Dale Kiest
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Publication number: 20110165375Abstract: A method to produce thin-layer lignocellulosic composites, such as wood-based doorskins, that exhibit substantial resistance to moisture is disclosed. In an embodiment, the method includes the steps of forming a mixture including a refined lignocellulosic fiber, wax, and an organic isocyanate resin. The mixture is initially pressed to form a loose mat. Subsequently, the mat is pressed between two dies at an elevated temperature and pressure to further reduce the thickness of the mat and to promote the interaction of the resin with the lignocellulosic fibers. In an embodiment, a release agent is included as part of the fiber mixture, or sprayed onto the surface of the mat. The thin-layer lignocellulosic composites of the present invention exhibit strong surface strength, high adhesiveness, and a 50% reduction in linear expansion and thickness swelling upon exposure to a high moisture environment as compared to thin-layer composites that do not include the isocyanate resin.Type: ApplicationFiled: March 15, 2011Publication date: July 7, 2011Applicant: JELD-WEN, INC.Inventors: Randy Jon Clark, Walter B. Davis, Jonathan Phillip Alexander
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Patent number: 7943070Abstract: Thin-layer lignocellulose composites having reduced thickness and methods for the manufacture of such thin-layer composites are disclosed. Also described is a process for making wood-based composite door skins of reduced thickness. The door skins may be less than 0.115 inches (2.92 mm) thick.Type: GrantFiled: May 5, 2004Date of Patent: May 17, 2011Assignee: JELD-WEN, inc.Inventors: Randy Jon Clark, Michael Jay Henry
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Patent number: 7919186Abstract: A method to produce thin-layer lignocellulosic composites, such as wood-based doorskins, that exhibit substantial resistance to moisture is disclosed. In an embodiment, the method includes the steps of forming a mixture including a refined lignocellulosic fiber, wax, and an organic isocyanate resin. The mixture is initially pressed to form a loose mat. Subsequently, the mat is pressed between two dies at an elevated temperature and pressure to further reduce the thickness of the mat and to promote the interaction of the resin with the lignocellulosic fibers. In an embodiment, a release agent is included as part of the fiber mixture, or sprayed onto the surface of the mat. The thin-layer lignocellulosic composites of the present invention exhibit strong surface strength, high adhesiveness, and a 50% reduction in linear expansion and thickness swelling upon exposure to a high moisture environment as compared to thin-layer composites that do not include the isocyanate resin.Type: GrantFiled: May 16, 2008Date of Patent: April 5, 2011Assignee: JELD-WEN, inc.Inventors: Randy Jon Clark, Walter B. Davis, Jonathan Philip Alexander
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Publication number: 20100151229Abstract: In one aspect, the present invention is a thin-layer lignocellulose composite having increased resistance to moisture. The thin-layer lignocellulosic composite includes a mixture of no more than about 95% by weight of a lignocellulosic fiber and at least about 5% by weight of an organic isocyanate resin. The mixture further includes short fibers and a release agent that does not interfere with subsequent processing of the thin-layer lignocellulosic composite. The mixture is pressed between two dies at an elevated temperature and pressure and for a sufficient time to form a thin-layer composite of predetermined thickness, and to allow the isocyanate resin to interact with the lignocellulosic fiber and short fibers such that the resultant thin-layer composite has a predetermined resistance to moisture.Type: ApplicationFiled: December 11, 2008Publication date: June 17, 2010Applicant: JELD-WEN, inc.Inventors: Randy Jon Clark, Kenneth Dale Kiest
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Patent number: 7721500Abstract: A door has a core that includes a porous layer having a thickness and two opposing major surfaces. In one construction, the core also includes three fire-retardant layers, and two of the fire-retardant layers are separated by the porous layer. The porous layer and the fire-retardant layers are coupled together. Other constructions include one or more fire-retardant layers in balanced or unbalanced placement around the porous layer.Type: GrantFiled: January 23, 2007Date of Patent: May 25, 2010Assignee: JELD-WEN, inc.Inventors: Randy Jon Clark, Gary Lee Koepke, Keith Lynn Lewallen, Brent David Olson, William Robert Transue
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Publication number: 20100021706Abstract: Thin-layer lignocellulosic composites made using hybrid poplar and methods for the manufacture of such thin-layer composites are disclosed. Also described is a process for making thin-layer lignocellulosic composite door skins using hybrid poplar wood fiber.Type: ApplicationFiled: May 15, 2008Publication date: January 28, 2010Applicant: JELD-WEN, inc.Inventors: Randy Jon Clark, Kenneth Dale Kiest, Michael Jay Henry
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Publication number: 20090071609Abstract: Disclosed are automated processes and systems for the assembly of composite doors, and doors made using such processes and systems. The automated process may comprise a continuous series of steps allowing individual doors to be made in tandem, rather than in batch. The process may allow for the automation of individual steps such that the need for coordinating separate assembly steps may be substantially reduced.Type: ApplicationFiled: November 26, 2008Publication date: March 19, 2009Applicant: JELD-WEN, inc.Inventors: Jon Christopher Stroup, David Patrick Dailey, John Robert Walter, Thomas Scott Reich, Mark John Strocko, Randy Jon Clark, Brent David Olson
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Patent number: 7501037Abstract: Disclosed are automated processes and systems for the assembly of composite doors, and doors made using such processes and systems. The automated process may comprise a continuous series of steps allowing individual doors to be made in tandem, rather than in batch. The process may allow for the automation of individual steps such that the need for coordinating separate assembly steps may be substantially reduced.Type: GrantFiled: July 1, 2004Date of Patent: March 10, 2009Assignee: JELD-WEN, inc.Inventors: Jon Christopher Stroup, David Patrick Dailey, John Robert Walter, Thomas Scott Reich, Mark John Strocko, Randy Jon Clark, Brent David Olson
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Publication number: 20090001628Abstract: Systems and methods for making a material composition are disclosed. The method includes mixing a thermoset polymer, a petroleum distillate, a release agent, and a catalyst to form an admixture. A cellulosic material is mixed with the admixture to form a generally homogenous furnish. The system includes a mixing chamber, a feeding chamber, and a die. The die includes a pressing chamber, which has a volume formed by first and second platens. The platens are in facing opposition to one another and have a length extending continuously from an entrance to an exit of the die. The platens have a plurality of orifices and heating elements disposed along the length. The platens are disposed in first and second positions. The first position forms a first volume and the second position forms a second volume.Type: ApplicationFiled: August 26, 2008Publication date: January 1, 2009Applicant: JELD-WEN, inc.Inventors: Sean Robert Broker, Jonathan Philip Alexander, David J. Bleha, Randy Jon Clark, Walter B. Davis
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Publication number: 20090004315Abstract: Systems and methods for making a material composition are disclosed. The method includes mixing a thermoset polymer, a petroleum distillate, a release agent, and a catalyst to form an admixture. A cellulosic material is mixed with the admixture to form a generally homogenous furnish. The system includes a mixing chamber, a feeding chamber, and a die. The die includes a pressing chamber, which has a volume formed by first and second platens. The platens are in facing opposition to one another and have a length extending continuously from an entrance to an exit of the die. The platens have a plurality of orifices and heating elements disposed along the length. The platens are disposed in first and second positions. The first position forms a first volume and the second position forms a second volume.Type: ApplicationFiled: August 26, 2008Publication date: January 1, 2009Applicant: JELD-WEN, inc.Inventors: Sean Robert Broker, Jonathan Philip Alexander, David J. Bleha, Randy Jon Clark, Walter B. Davis
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Publication number: 20080286581Abstract: A method to produce thin-layer lignocellulosic composites, such as wood-based doorskins, that exhibit substantial resistance to moisture is disclosed. In an embodiment, the method includes the steps of forming a mixture including a refined lignocellulosic fiber, wax, and an organic isocyanate resin. The mixture is initially pressed to form a loose mat. Subsequently, the mat is pressed between two dies at an elevated temperature and pressure to further reduce the thickness of the mat and to promote the interaction of the resin with the lignocellulosic fibers. In an embodiment, a release agent is included as part of the fiber mixture, or sprayed onto the surface of the mat. The thin-layer lignocellulosic composites of the present invention exhibit strong surface strength, high adhesiveness, and a 50% reduction in linear expansion and thickness swelling upon exposure to a high moisture environment as compared to thin-layer composites that do not include the isocyanate resin.Type: ApplicationFiled: May 16, 2008Publication date: November 20, 2008Applicant: JELD-WEN, inc.Inventors: Randy Jon Clark, Walter B. Davis, Jonathan Philip Alexander
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Patent number: 7449229Abstract: Systems and methods for making a material composition are disclosed. The method includes mixing a thermoset polymer, a petroleum distillate, a release agent, and a catalyst to form an admixture. A cellulosic material is mixed with the admixture to form a generally homogenous furnish. The system includes a mixing chamber, a feeding chamber, and a die. The die includes a pressing chamber, which has a volume formed by first and second platens. The platens are in facing opposition to one another and have a length extending continuously from an entrance to an exit of the die. The platens have a plurality of orifices and heating elements disposed along the length. The platens are disposed in first and second positions. The first position forms a first volume and the second position forms a second volume.Type: GrantFiled: November 1, 2002Date of Patent: November 11, 2008Assignee: Jeld-Wen, inc.Inventors: Sean Robert Broker, Jonathan Philip Alexander, David J. Bleha, Randy Jon Clark, Walter B. Davis
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Patent number: 7399438Abstract: A method to produce thin-layer lignocellulosic composites, such as wood-based doorskins, that exhibit substantial resistance to moisture is disclosed. In an embodiment, the method includes the steps of forming a mixture including a refined lignocellulosic fiber, wax, and an organic isocyanate resin. The mixture is initially pressed to form a loose mat. Subsequently, the mat is pressed between two dies at an elevated temperature and pressure to further reduce the thickness of the mat and to promote the interaction of the resin with the lignocellulosic fibers. In an embodiment, a release agent is included as part of the fiber mixture, or sprayed onto the surface of the mat. The thin-layer lignocellulosic composites of the present invention exhibit strong surface strength, high adhesiveness, and a 50% reduction in linear expansion and thickness swelling upon exposure to a high moisture environment as compared to thin-layer composites that do not include the isocyanate resin.Type: GrantFiled: February 24, 2004Date of Patent: July 15, 2008Assignee: JELD-WEN, inc.Inventors: Randy Jon Clark, Walter B. Davis, Jonathan Philip Alexander
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Patent number: 7390447Abstract: Thin-layer lignocellulosic composites made using hybrid poplar and methods for the manufacture of such thin-layer composites are disclosed. Also described is a process for making thin-layer lignocellulosic composite door skins using hybrid poplar wood fiber.Type: GrantFiled: May 28, 2004Date of Patent: June 24, 2008Assignee: JELD-WEN, Inc.Inventors: Randy Jon Clark, Kenneth Dale Kiest, Michael Jay Henry
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Patent number: 7185468Abstract: A door has a core that includes a porous layer having a thickness and two opposing major surfaces. In one construction, the core also includes three fire-retardant layers, and two of the fire-retardant layers are separated by the porous layer. The porous layer and the fire-retardant layers are coupled together. Other constructions include one or more fire-retardant layers in balanced or unbalanced placement around the porous layer.Type: GrantFiled: October 31, 2002Date of Patent: March 6, 2007Assignee: Jeld-Wen, inc.Inventors: Randy Jon Clark, Gary Lee Koepke, Keith Lynn Lewallen, Brent David Olson, William Robert Transue
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Publication number: 20040229010Abstract: A method to produce thin-layer lignocellulosic composites, such as wood-based doorskins, that exhibit substantial resistance to moisture is disclosed. In an embodiment, the method includes the steps of forming a mixture including a refined lignocellulosic fiber, wax, and an organic isocyanate resin. The mixture is initially pressed to form a loose mat. Subsequently, the mat is pressed between two dies at an elevated temperature and pressure to further reduce the thickness of the mat and to promote the interaction of the resin with the lignocellulosic fibers. In an embodiment, a release agent is included as part of the fiber mixture, or sprayed onto the surface of the mat. The thin-layer lignocellulosic composites of the present invention exhibit strong surface strength, high adhesiveness, and a 50% reduction in linear expansion and thickness swelling upon exposure to a high moisture environment as compared to thin-layer composites that do not include the isocyanate resin.Type: ApplicationFiled: February 24, 2004Publication date: November 18, 2004Inventors: Randy Jon Clark, Walter B. Davis, Jonathan Philip Alexander
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Publication number: 20040226245Abstract: A door has a core that includes a porous layer having a thickness and two opposing major surfaces. In one construction, the core also includes three fire-retardant layers, and two of the fire-retardant layers are separated by the porous layer. The porous layer and the fire-retardant layers are coupled together. Other constructions include one or more fire-retardant layers in balanced or unbalanced placement around the porous layer.Type: ApplicationFiled: October 31, 2002Publication date: November 18, 2004Inventors: Randy Jon Clark, Gary Lee Koepke, Keith Lynn Lewallen, Brent David Olson, William Robert Transue