Abstract: A method of venting a rear facer sheet for lamination is accomplished by continuously drawing the rear facer sheet through a perforating device which creates conical apertures in the rear facer. Two metal rails affixed to opposing edges of a front facer are continuously drawn into a laminator after first having an expanding foam material continuously deposited onto the upper surface of the front facer. The perforated rear facer is continuously drawn into the laminator and affixed to the two metal rails, creating an enclosed volume in which the expanding foam is located. The apertures in the rear facer allow for the escape of gasses and air during lamination, promoting even flow and uniform density of the foam material. The perforating device has an upper and a lower rotating cylinder, the lower cylinder being equipped with piercing elements and the upper cylinder being equipped with grooves corresponding to the piercing elements.

Abstract: A method of forming a door panel is accomplished by providing a plurality of spaced rollers. A first plastic facer is drawn beneath the rollers wherein the first facer is in the form of a continuous sheet having an upwardly facing surface. A second plastic facer is drawn beneath the rollers, and is in the form of a continuous sheet and at least a portion of the second facer is spaced above the first spacer. A pair of rails are positioned on opposed sides of the first facer and drawn beneath the rollers. A foam material is deposited on the upwardly facing surface prior to drawing the first facer beneath the rollers. The foam material expands and hardens to adhere together the first facer, second facer and rails into a continuous length of assembled panel.