Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: A metal door comprising exterior and interior panel members secured together so as to create a thermal insulating air gap between the back side of the exterior panel member and the front side of the interior panel member.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: A hollow metal door using hollow structural sections with closed cross section, along with the method for making same, is described herein.

Abstract: An integrally molded window spacer bar connector for joining opposed spacer bar end passages in the form of a hollow tube with a longitudinal axis of symmetry and a transverse axis of symmetry includes inclined leading edge ramps, a medial rib to control the insertion of the connector into spacer bars, and external channels to receive a sealant material for sealing the connector to the spacer bar at the seam of the joint of the spacer bar.

Abstract: A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

Abstract: A method for fabricating a door having a window, the door having a first door skin and a second door skin, the method including the following steps in the order named: forming a first door light opening perimeter having a first plurality of tabs arranged about the first door light opening perimeter, wherein the first door light opening perimeter defines a first door light portion; forming a second door light opening perimeter having a second plurality of tabs arranged about the second door light opening perimeter, wherein the second door light opening perimeter defines a second door light portion; positioning the first door skin on a first press; positioning an insert in aligned registration with the first plurality of tabs; positioning the second door skin over the insert, wherein the second plurality of tabs are in aligned registration with the insert, and the first door light opening perimeter is aligned with the second door light opening perimeter; applying pressure with the first press to secure the firs

Abstract: A construction module having a multi-layered top panel, a multi-layered intermediate panel and a multi-layered bottom panel which are bonded together and desired cavities are provided through one or more of the top panel, intermediate panel and bottom panel.

Abstract: A construction module having a multi-layered top panel, a multi-layered intermediate panel and a multi-layered bottom panel which are bonded together and desired cavities are provided through one or more of the top panel, intermediate panel and bottom panel.

Abstract: The present invention relates to vacuum insulated building panels. The insulating building panel of this invention uses suction pressure created by a vacuum as the sole means of attachments between two parallel steel (10) or glass (12) panel plates and a post frame (14). When vacuum is applied, the plates engage the post frame in an airtight manner and spheres (112) are used as spacers to maintain separation of the plates and they roll without resistance to accommodate any movement of one plate in relation to the other. These features of the building panel eliminate warping which is caused by expansion or contraction of weather exposed faces of the panel plates due to fluctuating outside temperatures and also eliminate stress upon support structures.

Abstract: A reinforcement is configured to be disposed between spaced apart panels of a hollow door, and includes an elongated body, a flange carried by the body, and a fastener passage extending through the elongated body and the flange.

Abstract: The present invention relates to a door frame system including a door frame having a vertical reference face and a horizontal reference face formed perpendicularly to each other on the opposite face to the inclined guide face, a guide groove formed below the horizontal reference face, and bridges formed below the guide groove and having screw holes cut facing each other and a plurality of bolt holes passed along the longitudinal direction of the door frame through the side portions distant from the vertical center portions thereof for inserting a socket bolt thereto; a pressure bench having a plate glass-compressing face formed facing the vertical reference face of the door frame for compressing a plate glass, a horizontal face formed perpendicular to the plate glass-compressing face, and a pressure generation face formed on the rear portion thereof; a compression rail having a generally triangular-shaped section for compressing the pressure bench; and a brush assembly having a brush formed of thick hairs for

Abstract: A door construction is illustrated with plural bumpers formed during the door manufacturing process. Respective sets of edges of the door body, such as trailing edges of door panel sections of the door body and top edges of the door panel sections, may be trimmed to establish the width and the height of the desired door. A closure or spacer member may be used to connect the trimmed edges. The door may be supported by a hinge assembly for pivoting about an upright pivot axis. The door body may be a monolithic one-piece construction, apart from any such closure members, and optional any window and window support. The door body may be formed by rotational molding.

Abstract: A storm door has first and second elongated, partly curved lock receiving openings formed in respective elongated edges. Each opening is filled in part with a molded hollow insert with an external periphery which matches a periphery of the respective opening. A lock mechanism has a housing with an external periphery that matches, at least in part, an internal periphery of a respective insert. An actuating port in the housing has a central axis, which extends parallel to the respective edge, through the door through which extends a rotatable actuating shaft. An external handle can be attached to the shaft. An unused insert can be closed with a slidably engaging cover.

Abstract: The present invention provides a door with an adjustable height and an adjustable width. The door of the invention comprises a central unit, a bottom unit overlapping with the central unit to define a bottom overlapping region, a side unit overlapping with the central unit to define a side overlapping region, and a corner unit overlapping with the side unit and with the bottom unit. The height of the door may be adjusted by changing the size of the bottom overlapping region. The width of the door may be adjusted by changing the size of the side overlapping region. The corner unit is attached to the bottom unit and to the side unit in a manner ensuring that the shape of the door as a whole is rectangular at any height and width to which the door is adjusted.

Abstract: An improved molded door having provisions for glass insert comprising at least 50% of said door's exterior surface includes a quadrilateral frame formed of a top rail, a bottom rail, a right stile and a left stile joined together, two sheets of molded door skins, each skin having a large central opening with an inwardly directed flange extending normal to its planer surface and around its respective opening, which flanges interlock when assembled on frame and form secondary frame for receiving a glass insert, means operable to join the skins to the quadrilateral frame, means operable to join the integral flanges of the skins in an interlocked relationship around their respective openings thereby forming an interlocked secondary frame for receiving a glass insert, a secondary left stile located between the joined flanges and the left stile with this stile joined to the skins and a secondary right stile located between the joined flanges and the right stile with this stile joined to said skins whereby the

Abstract: A joining strip is provided by which sheet metal may be formed into a hollow tubular panel. The joining strip provides a seam between panel edges that acts as a thermal break between inner and outer faces of the panel. The joining strip may also carry a resilient tubular cushion which extends into the joint between the side ends of two panels that are connected by a hinge. This cushion contributes to providing an air seal within the joint between the two panels. Applications include roll-up garage doors and roll-away, articulated walls.

Abstract: A structural building system including an improved, structural-load-bearing, building component, such as a building panel, having front and back sections, an insulating core, integral symmetrical joinery, a thermal break, and at least one shear resistance connector The panel is asymmetrical about one axis, and is designed to be directionally positioned with respect to the maximum anticipated force. A shear resistance connector array may be positioned between the front and back sections or may be integral to the front or back section. A face sheet may span one or more than one building panel, and provides structural support to the building system.

Abstract: A joining strip is provided by which sheet metal may be formed into a hollow tubular panel. The joining strip provides a seam between panel edges that acts as a thermal break between inner and outer faces of the panel. The joining strip may also carry a resilient tubular cushion which extends into the joint between the side ends of two panels that are connected by a hinge. This cushion contributes to providing an air seal within the joint between the two panels. Applications include roll-up garage doors and roll-away, articulated walls.

Abstract: A panel system includes a first skin, a second skin, a web core constructed from sheet material for securing the skins together in a spaced, sandwich relationship, and a connecting means for affixing the web core within the skins. The web core includes a plurality of spaced apart longitudinal members having longitudinally spaced projections extending therefrom and further having transversely aligned, longitudinally spaced slots therein. The web core further includes a plurality of spaced-apart, transverse cross members each having spaced slots therein receiving the longitudinal members at corresponding transversely aligned slots thereof to provide an interlocked grid between the first and second skins. The grid is connected to the skins utilizing the projections, which extend through slits in the skins to facilitate welding or otherwise bonding the components.

Abstract: Composite products comprising or incorporating compression moldings of waste or filler particles (16) encapsulated and bound together by a thermoplastic binder (15) into a compacted mass of a shape selected for its end use, the compression molding being prepared by intensely mixing together particles of thermoplastic and waste or filler material to raise their temperature to bring the thermoplastic particles to a molten state where they coat the waste or filler particles (16), then compression molding the hot coated waste or filler particles.