Abstract: Fiberboard doors and methods for constructing the same are shown. Doors are constructed by assembling fiberboard stiles and fiberboard rails to form door-halves and then by bringing the door-halves together. The doors may be constructed to have one or more panels, mullions and intermediate rails. The doors may also be of standard or decorative design, and include panels made of glass or other materials.

Abstract: A component shutter assembly and method of forming same. The assembly comprises a one-piece molded plastic, integrally formed shutter panel. The shutter panel may be molded in a small plurality of standard lengths and then one or both ends thereof cut to shorten the shutter panel to a specific, desired length once it is determined what-specific length of shutter is needed for a particular application. An independent, integrally formed end panel may then be secured to one or both ends of the cut shutter panel and ultrasonically welded thereto to form a finished component shutter assembly having a particular desired length and the appearance of a one-piece, integrally formed shutter. Embodiments directed to raised panel and louvered shutters are disclosed, as is a removable center panel section which may be used in connection with the louvered shutter panels if it is desired to provide a mid-panel section which is offset from the mid-point of the overall length of the shutter panel.

Abstract: A frame assembly for a door light is formed with inner and outer half-frames sandwiching a translucent panel. The half-frames have a plurality of side members defining a closed polygon. Each side member includes, in cross-section, a flat portion for supporting the frame in an opening in a support, a face portion extending from the flat portion towards the center of the polygon, a third portion extending inwardly from the face portion toward the other half-frame and to a position adjacent the translucent panel, and a fourth portion extending from the third portion parallel to the face portion and away from the center of the polygon. Fasteners extend through bores in the inner half-frame and engage clips slidably adjustable in the outer half-frame to couple and secure the half-frames in the support opening. Each clip has a base with an opening receiving a fastener, and legs with flanges engaging the fourth portion and a lip on the flat portion of the outer half-frame.

Abstract: A frame assembly of the knock-down type in which the component parts can be shipped or transported in a knock-down condition and readily constructed with a minimum of tools or no tools, and disassembled when desired. The frame assembly includes at least one pair of spaced vertical stiles and at least one pair of horizontal rails substantially orthogonal thereto, and associated connecting elements for connecting the stiles and rails, one of the connecting elements being joined with a stile at a corner connection thereof and another of the connecting elements being joined with a rail at a corner connection thereof so that a pair of the associated connecting elements joins one of the stiles to one of the rails, and all of the stiles and rails as appropriate are joined to each other.

Abstract: A process for cutting out decorative, artistic designs, and the three-dimensioned decorative and artistic products produced thereby which are incorporatable into articles of manufacture. The process creates relief designs by angle cutting, at predetermined and variable cut-angles and predetermined and variable cut-widths. The decorative cut-out piece, cut from a base piece, is one-directionally removable and one-directionally insertable into the aperture created when the piece is cut from the base piece. The cut-out piece inserts into the corresponding aperture a distance which is determined by a combination of cut-angle and cut-width. The maximum cut-angle and the maximum cut-width is limited by the thickness of the base piece. The cut width is substantially equal to the saw blade cut width or the width of the cut produced by any appropiate cutting device.

Abstract: A wood door system (10) provides enhanced weather durability for use on outdoor wooden storage buildings. The door system includes trim (30) and one or more movable doors (40). Wood trim members (32, 34) cover a gap between the exterior wall of the wooden storage building. Movable door members (40) are operably attached to the wooden storage building. Bracing members (42, 44, 46) are attached to movable door members (40) to strengthen said movable door members. Wood trim members (32, 34) and bracing members (42, 44, 46) also provide a decorative feature for the wood doors system (10). The wood trim member (32) and the bracing members (42, 44, 46) have an upper surface tapered outwardly and downwardly from the wooden storage building wall to prevent precipitation and contamination from collection on said upper surfaces. Such shedding of precipitation serves to wash any airborne contaminants from said surfaces.

Abstract: A modular plastic shutter assembly that includes an injection molded panel that has been cut to length to accommodate the particular shutter assembly. A die cutter having an appropriately shaped cutting blade cuts an end of the panel to the desirable length. A separate injection molded panel end piece is secured to the cut end of the panel to form a complete panel.

Abstract: This relates to a workpiece particularly a simulated raised panel door as used on furniture and kitchen cabinets. Such doors are fabricated from a single sheet of core material and have a panel section machined into its face. In certain specific instances it is desired that the corners of the machined panel section be square and at best of very low radii. Because of this corner design it is virtually impossible and definitely time consuming to machine such corners in volume. The problem is solved by using preformed corner plugs inconjunction with a machined core. The core is composed of standard fiberboard material with a panel section machined into its face and plug housings machined into the face of the core at the panel section's proposed square corners. The corner plug is composed of a plastic material formed in part to that of a typical woodworking plug of cylindrical shape and a square inside corner section formed into the face and edge of the plug.

Abstract: A frame assembly for a door light is formed with inner and outer half-frames sandwiching a translucent panel. The half-frames are separately and similarly formed of sheet material, each with a plurality of substantially similar side members defining a closed polygon. Each side member includes, in cross-section, a flat portion for supporting the frame in an opening in a support, a face portion extending from the flat portion towards the center of the polygon, a third portion extending inwardly from the face portion toward the other half-frame and to a position adjacent the translucent panel, a fourth portion extending from the third portion parallel to the face portion and away from the center of the polygon, and a fifth portion extending inwardly from the fourth portion toward the other half-frame and about a peripheral edge of the translucent panel. Fasteners couple the half-frames and secure the half-frames in the support opening.

Abstract: A window assembly having a pair of window frame halves each including a plurality of screw bosses. The screw bosses are arranged to align in male/female pairs when the frame halves are brought together in proper alignment. The mating male and female screw bosses are frictionally interfitted to releasably intersecure the frame halves during storage, transportation, and installation.

Abstract: A window frame comprises first and second window pane mounting frame pieces generated from a single extrusion with a bridge between the two frame pieces. The frame pieces are separated from one another at the bridge producing a bridge part on each of the frame pieces. The first frame piece has a side recess aligned with its bridge part to receive a fastener for mechanically securing the frame pieces back together with one another from opposite sides of the window pane through the bridge parts of the respective frame pieces.

Abstract: A hollow core door has a perimeter frame with stiles and top and bottom rails, and a pair of skins secured to the perimeter frame. One skin has an aperture therein with its side margins spaced inwardly of the perimeter frame, and inner frame elements are disposed between the margins of the aperture and the stiles, secured to at least one skin. A mirror with dimensions smaller than those of the aperture is secured in a molding which extends about its periphery of the mirror, and the molding has a peripheral portion overlying the skin about the side margins of the aperture and a body portion which extends inwardly of the door. The molding is secured against the skin.

Abstract: A modular anti-warping door panel for use in the construction of a door or door panels. The door panel comprises a rigid reinforcing frame constructed of material resistant to warping. The reinforcing frame is defined by two spaced apart elongated rigid members and one or more transverse spaced members. The reinforcing frame is retained in an elongated butte stile and a lock stile and a top and bottom rail. The stiles and rails are formed as hollow members of rectangular cross-section forming a peripheral panel frame. The two elongated rigid members are retained along an inner peripheral channel of the rectangular door frame. Panels are retained in an opening defined by the inner peripheral channel. A rigid post is secured in the butte and lock stiles along an outer edge portion thereof and concealed within the hollow stiles.

Abstract: A glazing seal is used in combination with a rectangular door frame and a rectangular window frame. The door frame includes a window opening and the window frame is fitted within the window opening. The window frame surrounds a sheet of glass having a perimetric edge. The sealing member has a first portion extending around the perimetric edge of the glass and sealingly engaging the edge of the glass and the window frame. The sealing member also has a second portion thereof fitted between the window frame and the door frame to provide a substantially airtight seal there between.

Abstract: A panel (1) comprising a front surface (2) shaped to simulate a framed-up panel is manufactured by forming a main panel member (4) from a main substrate (7) laminated with a main veneer sheet (10). A front surface (5) of the main panel member (4) is formed and shaped to simulate a pair of stiles (12) and an infill panel (14) and to define rail receiving surfaces (15) at opposite ends of the infill panel (14). Rails (16) each formed from a secondary substrate (20) laminated with a secondary veneer sheet (24) are bonded to the rail receiving surfaces (15) and join the stiles (12).

Abstract: Floor structures that are erected on a temporary basis on ground so that they can be removed and not do permanent damage to the environment. In one embodiment a frame is mounted on poles that are staked into the ground. The floor has sections that extend between sides of the frame and are connected together to move in unison to be extended for use and retracted for storage. Such extension and retraction may be motorized. In another embodiment a glass floor structure bridges a pool and steps provide access for people.

Abstract: An energy-efficient, wood-skinned fire door having a laminate construction. There is a core panel formed of a fire-resistant material, preferably mineral fiber board. The perimeter frame around this has a channel formed in its inner edge for receiving the core panel in a close interfit therewith. This supports the panel in the channel, and also eliminates any direct path for a fire to proceed past the edge of the fire-resistant panel. Foil-covered thermal insulation panels are positioned on opposite sides of the core panel, and these are covered with wooden door skins. This provides a structure which is highly fire resistant and exhibits excellent insulation qualities, yet which is also aesthetically pleasing so as to be suitable for residential use.

Abstract: A method of simulating a solid wood multipanel door is disclosed. Predetermined portions of the thin sheets of wood which are typically used to construct hollow core doors are cut away. The portions are used to construct artificial door panels, which are replaced into the openings in the hollow core door from which they were cut. Molding is then placed around the artificial door panels. In an alternative embodiment, Wainscott panels may be constructed utilizing the inventive technique.

Abstract: Disclosed is a composite wood structure including (a) first and second spaced layers, and (b) a core interposed between the layers. A sheet-like vapor barrier is between the layers and limits migration of moisture through the barrier to less than about 6 grams per square meter of barrier area per hour. The wood structure is thereby made warp-resistant. In another embodiment, the structure has a vapor barrier on an outer surface and may have one or more additional vapor barriers between structure layers. Preferred vapor barrier materials include melamine formaldehyde impregnated paper, phenol formaldehyde impregnated paper, thermoset materials, thermoplastic materials and aluminum foil.

Abstract: A fire resistant panel door is constructed from panels, stiles, mullion and rails having a core of fire resistant material. The door components are joined together so that the fire resistant material extends substantially continuously from side to side and from top to bottom of the finished door. The fire resistant core of each door panel is recessed within the fire resistant core of the associated rails and stiles to reduce air infiltration through the door which can compromise the door's fire resistance.

Abstract: Door assembly and method of manufacture thereof having a wooden composite subframe assembly and an insulative foam core that are encapsulated within an exterior veneer or solid wood stile and/or rail of finish wood material. Wooden door jamb assembly having a wooden composite subframe, an insulative foam door jamb core, and an exterior veneer or solid wood laminate of finish wood material.

Abstract: A simulated solid wood multi panel door is disclosed. Predetermined portions of thin sheets of wood which form the front and back of the door are cut away. The portions are replaced with artificial panels, which panels are mounted within the openings left by the cut away portions. Molding is then preferably placed around the artificial panels.

Abstract: A true divided look is provided in an insulated two-pane window assembly through use of a resilient silicone foam internal muntin bar grid which is low in thermal conductivity to limit heat transfer between panes and is high in flexibility to allow for bending when forming curved shapes. The grid is secured by adhesive on one side to one pane of glass, thereby allowing natural expansion and contraction of the glass panes. The resilient muntin bar includes the resilient muntin bar being U-shaped with a base from which legs extend which are compressible and adapted to move laterally in response to pressure from the panes due to changing thermal conditions or bonding of external wooden muntin bars to the panes. Movement of the panes toward each other would be limited by bottoming out against the base of the resilient muntin bar.

Abstract: A composite exterior door structure comprising an inner frame of transversely connected elongated structural members formed of synthetic low thermally conductive material. The structural members have opposed parallel flat side walls and edge walls, the latter being formed with connecting channels. The structural members are interconnected to form a rectangular frame. Connectors of low thermally conductive material are connected to the connecting channels of inner ones of the edge walls of the structural members. An outer metal door covering is connected over an outer one of at least some of the opposed parallel flat side walls of the structural members and the connectors by displaceable connections to permit the outer door covering to shift due to expansion and contraction independently of the structural members. An inner door covering is immovably secured to an inner one of the opposed parallel flat walls and thermally insulated from the outer door covering.

Abstract: A panel light assembly used in panels. The panel light assembly has a retainer clip for a mounting glazing between two opposing frames that are mounted in apertures in the skins of the panel located on either side of the core of the panel. The retaining clip, preferably made of a springy material, includes longitudinally extending legs depending from opposite longitudinal sides of the clip and which are operable to slide over and securingly engage the panel skins. Oppositely spaced and oppositely directed trim retainer prongs project up from said clip body and generally towards a longitudinal center-line of said clip body for engaging the frames and securing the glazing between the frames in the panels light apertures. The present invention provides at least two skin spacer tabs depending from the clip wherein each of the skin spacer tabs is spaced sufficiently apart from legs so as to be able to receive the skins therebetween.

Abstract: An angulated door assembly affording reduced entry and exit time and motion therethrough. Each door is angulated relative to the adjacent walls and/or the conventional path of ingress/egress therethrough. Such an assembly configuration affords increased sealing capacity as well as convenience for the user. The door opens and closes faster by swinging less than a conventional door, which presents itself orthogonally to the path of ingress/egress. By utilizing a pair of angulated doorways, the doors self-seal against each other while providing the advantages of angulated disposition relative to the path of ingress/egress.

Abstract: Fire-resistant structures are provided having at least a 20 minute ASTM E-152 fire test rating. The structures include a core having a gypsum-containing composition and a density of at least about 60 lbs/ft, a flexural strength of at least 30 lbs (1/2 inch thick material), and a screw-holding capacity of at least about 400 lbs. The gypsum-containing composition further contains a substantially uniform distribution of solids including about 65 wt. % to about 90 wt. % set gypsum dihydrate, about 7 wt. % to about 30 wt. % paper fiber, and about 1.5 wt. % to about 35 wt. % of one or more performance boosters selected from inorganic fiber, clay, vermiculate, and binder polymer.

Abstract: A hollow composite interior door assembly includes a pair of sheet molding compound skins mounted on a rectangular frame. No spacer is used to provide the necessary rigidity to the structure. Rather, the skins are adhered to each other along opposed recesses crating a lattice structure framework that supports the assembly.

Abstract: A door having a door core construction having a front face and a rear face which are both planar, and at least one window opening formed in said front and rear faces, both the front face and the rear face being entirely covered by a transparent covering layer.In an alternative embodiment the door construction may comprise a door core having at least one aperture extending between a front and rear surface of the door core, the aperture being closed by a pair of panes, one pane being mounted so as to have an outer surface contiguous with the front surface of the door core and the other pane being mounted so as to have an outer surface contiguous with the rear surface of the door core, a front and rear surface covering layer covering the front and rear surfaces respectively of the core and having an aperture of smaller dimensions than the pane mounted in the surface covered thereby so that the peripheral margin of said pane is also covered by said covering layer.

Abstract: Modular shutter constructed of modular components including side rails, end rails, and a central generally planar panel member, and including a stabilizing member disposed between the edge of said central panel member and adjacent end rails and connectable therebetween for maintaining the relative positioning therebetween and including a portion for covering any gap between the edge of said central panel member and the adjacent end rail.

Abstract: A movable barrier capable of disassembly comprises a plurality of rails having at least one hollow at each edges thereof, a pair of stiles having holes formed at the positions of facing to the hollows of the plurality of rails, and means for combining the plurality of rails and the pair of stiles. Since the movable barrier according to the present invention can be disassembled and reassembled, transportation to a desired place is convenient. Further, broken or otherwise damaged portions of the movable barrier can be easily replaced or repaired.

Abstract: A window frame connector having a generally tubular body to fit over aligned screw bosses of opposite window frame halves to align and releasably intersecure the frame halves for transportation. The connector includes a pair of diametrically opposed longitudinal slots in each of its opposite ends. The slots in the two ends are longitudinally aligned. Either connector end may be pinched to open the opposite end, and the connector slots receive ribs supporting the interconnected screw bosses.

Abstract: A file cabinet door is disclosed whose front carries a contrasting design or pattern. Decorative openings are provided through a front panel in the door in the form of a pattern. A decorative interior panel of contrasting appearance to the front panel is provided rearward of the front panel. A person on viewing the front panel sees a contrasting design by reason of the openings rendering the interior panel visible therethrough.

Abstract: A frame for a door or the like has a multiplicity of cross members formed with outer surfaces as supports for finishing panels and having their ends matingly engaged with joints formed by longitudinal sections forming the opposite longitudinal edges of the door and having seats engaging the panels.

Abstract: A front panel assembly for barbecue grill carts is disclosed, the panel having a pair of mounting brackets pivotally attached to the front legs of the grill cart. Rectangular slats are arranged between the mounting brackets, and are held rigidly in place thereby, to form a substantially solid panel in the front of the barbecue grill cart.

Abstract: A compression formed panel of a wood fiber board and a plastic resin means impregnated into the wood fiber board for maintaining the shape of said door core or panel after compression, and a method for making same requiring either a catalyst that causes the plastic resin to set at a temperature in excess of 100.degree. Celsius, or a catalyst that causes the plastic resin to set or polymerize at a temperature lower than 100.degree. Celsius.

Abstract: Wooden door assembly and method of manufacture thereof having a wooden composite subframe stile and rail assembly and an insulative foam core that are encapsulated within an exterior veneer or solid wood stile, rail, and raised panel assembly of finish wood material. Wooden door jamb assembly having a wooden composite subframe, an insulative foam door jamb core, and an exterior veneer or solid wood laminate of finish wood material.

Abstract: A method is disclosed for forming an alcove in a rough opening for a standard door. The alcove is formed with a pair of converging side walls, disposed at an angle relative to the plane of the rough opening, which define a recessed door opening that is closed by an access door. The walls and the access door may be covered with mirrors forming a three-way mirror arrangement. In an alternative embodiment of the invention, the alcove is formed with a recessed wall relative to the plane of the door opening and one or more side wall doors. In order to facilitate construction of the alcove, a construction guide is disclosed which locates the positions of the side walls used to form the alcove. The guide as well as preformed structural members allow for relatively quick and easy construction of the mirrored alcove. Mirror panels are removably mounted for allowing relatively easy replacement of damaged mirrors.

Abstract: A front enclosure for a bathtub including a top rail, a bottom rail, and vertical supports arranged to contain panels which fit in the grooves in the rails and vertical supports. The enclosure may be readily assembled and adjusted to fit and be installed on the front of a bathtub to provide an enhanced appearance. The enclosure attaches to the front of the bathtub without requiring any structural modification of the bathroom or significant disruption of the household.

Abstract: An improved hollow paneled door construction using an improved void filler that is expandable and which has components of a specific thickness except for relieved sections of reduced thickness to overlie the panels between the doorskins.

Abstract: A file cabinet door is disclosed whose front carries a contrasting design or pattern. Decorative openings are provided through a front panel in the door in the form of a pattern. A decorative interior panel of contrasting appearance to the front panel is provided rearward of the front panel. A person on viewing the front panel sees a contrasting design by reason of the openings rendering the interior panel visible therethrough.

Abstract: Firedoor constructions manufactured from board compositions containing calcium sulfate in hemi-hydrate or anhydrous form and fibrous additives, including pulped paper fibers preferably derived from waste newspaper, capable of being formed into firedoor members having superior mechanical properties and/or fire resistance.

Abstract: A window frame connector having a generally tubular body to fit over aligned screw bosses of opposite window frame halves to align and releasably intersecure the frame halves for transportation. The connector includes a pair of diametrically opposed longitudinal slots in each of its opposite ends. The slots in the two ends are longitudinally aligned. Either connector end may be pinched to open the opposite end, and the connector slots receive ribs supporting the interconnected screw bosses.

Abstract: A method and a kit is disclosed for forming an alcove in a rough opening for a standard door. The alcove is formed with a pair of converging side walls, disposed at an angle relative to the plane of the rough opening, which define a recessed door opening that is closed by an access door. The walls and the access door may be covered with mirrors forming a three-way mirror arrangement. In an alternative embodiment of the invention, the alcove is formed with a recessed wall relative to the plane of the door opening and one or more side wall doors. In order to facilitate construction of the alcove, a construction guide is disclosed which locates the positions of the side walls used to form the alcove. The guide as well as preformed structural members allow for relatively quick and easy construction of the mirrored alcove. Mirror panels are removably mounted for allowing relatively easy replacement of damaged mirrors.

Abstract: A door construction is disclosed having a peripheral frame, a glazing panel, and front and rear unitary facings, each facing having an upper door light casing portion and a lower door plant panel portion. The facings are placed back-to-back over a single, central opening in the frame, clamping the frame and glazing panel between the edges of the facings. The door thus constructed has the appearance of traditional woodwork and avoids the alignment and parts inventory problems of the prior art.

Abstract: A building panel, such as a door, wall panel, etc., is formed of a solid, planar body, having first and second opposed, major surfaces. A groove of a predetermined shape, such as a square or rectangle, is formed in at least one of the first and second major surfaces of the body. The groove has an open end and extends partially into the body. A decorative molding having a base portion complementary to the shape of the groove is fixedly mounted in the groove. In one embodiment, the molding includes opposed, outwardly extending flanges which are located to overlay the edges of the major surfaces of the body when the molding is mounted in the groove on the body. The groove and the molding may be mounted on both of the major surfaces of the body and in multiple numbers or patterns on one or both of the major surfaces of the body.

Abstract: A framework of a wooden building has a pair of vertically extending pillars formed on opposite sides thereof with longitudinal grooves and a wall panel mounted between the pillars, having its side edges inserted in the grooves in the pillars. A diagonal pillar formed in the opposite sides thereof with grooves may be provided between the vertical pillars to support two triangular wall panels. A fitting such as a window sash may be mounted between the pillars so as to be sandwiched between upper and lower wall panels.

Abstract: The invention is a laminated wood product having superior appearance and dimensional stability. It has a core member of common lumber. This core member has been relieved in one of a number of ways to reduce or eliminate warping induced by internal stresses. Preferably this is accomplished by making kerfs in the edges or in the faces which extend almost completely through the product. Sheets of patched or otherwise relatively defect-free veneer are then laminated to each face of the core member. These prevent telegraphing of core defects and kerfs. A piece of clear or otherwise acceptable appearance grade lumber is then laminated to each edge of the product. Ultimately, appearance grade veneer is laminated to each face to create an assembly giving the appearance and utility of clear, solid sawn wood.

Abstract: A panel door of composite construction includes a pair of stiles and top and bottom rails which cooperate to define a rectangular frame, a plastic foam core bordered by the frame and an opposed pair of molded fiberglass skins which sandwich the frame and core. Each skin has an edge located rim portion which overhangs the outer corner edges of the stiles and rails, and each of the stiles and rails has an outer corner edge with a profile complementary to and mating with the inside of the adjacent rim portion. Along the side edges, the skins have innermost and outermost rim portions, and the stiles have complementary profiled outer corner edges.

Abstract: A fire retardant composition and method wherein the composition includes 30 to 75% of an inert mineral filler selected from perlite and vermiculite, 10 to 40% by weight of glass fibers having a diameter in the range of about 10 to about 15 microns and lengths under 1" and from 3 to 15% by weight of binder which is a mixture of an alkali metal silicate and a curable phenolic resin, at least one of which is present in dry form.