This invention relates door skins, sometimes known as door facings, and in particularly preferred embodiments of the invention door skins made of cellulosic material and a binder resin. This invention also relates to doors including door skins and a doorframe, and to door skins that are configured to be nested or stacked to facilitate shipping and handling.
Traditional solid wood doors have become relatively expensive due to raw material costs. A commonplace alternative to traditional solid wood doors in residential and commercial buildings is a door assembly that includes a rectangular doorframe of stiles and rails, and door skins secured to the opposite sides of the doorframe to define a door cavity between the door skins and surrounded by the doorframe. The door skins can be made of, for example, steel, fiberglass composites, cellulosic (e.g., wood) composites such as high density fiberboard (HDF) and medium density fiberboard (MDF), and other materials. Wood grain can be molded or embossed into the exterior surfaces of the door skins. Further, paneling can be formed in the exterior surfaces of the door skins to give an appearance that simulates solid wood products. The door cavity between the door skins typically yet optionally includes one or more core components.
According to an embodiment of the invention, a door skin is provided that includes at least one inner panel, an outer body portion surrounding the at least one inner panel, and at least one contoured portion surrounding the at least one inner panel and interconnecting the at least one inner panel to the outer body portion. The at least one contoured portion is recessed from the at least one inner panel and the outer body portion and includes a center base portion that interconnects with the outer body portion via a first sloping portion and with the inner panel via a second sloping portion. The first sloping portion includes a first angled portion that is continuous with the outer body and a first bump having a first convex exterior surface that extends convexly continuously from the first angled portion to the center base portion. The second sloping portion includes second and third bumps. The second bump is continuous with the center base portion and has a second convex exterior surface that extends convexly continuously from the center base portion to the third bump. The third bump is continuous with the least one inner panel and has a third convex exterior surface that extends convexly continuously from the second bump to the at least one inner panel.
According to another embodiment of the invention, a door is provided that includes a door frame and at least one door skin secured to the door frame. The door skin includes at least one inner panel, an outer body portion surrounding the at least one inner panel, and at least one contoured portion surrounding the at least one inner panel and interconnecting the at least one inner panel to the outer body portion. The at least one contoured portion is recessed from the at least one inner panel and the outer body portion and includes a center base portion that interconnects with the outer body portion via a first sloping portion and with the inner panel via a second sloping portion. The first sloping portion includes a first angled portion that is continuous with the outer body and a first bump having a first convex exterior surface that extends convexly continuously from the first angled portion to the center base portion. The second sloping portion includes second and third bumps. The second bump is continuous with the center base portion and has a second convex exterior surface that extends convexly continuously from the center base portion to the third bump. The third bump is continuous with the least one inner panel and has a third convex exterior surface that extends convexly continuously from the second bump to the at least one inner panel.
Other aspects of the invention, including door skins, assembled doors, nested and/or stacked door skins, subassemblies, related methods, and the like which constitute part of the invention, will become more apparent upon reading the following detailed description of the exemplary embodiments.
The accompanying drawings are incorporated in and constitute a part of the specification. The drawings, together with the general description given above and the detailed description of the exemplary embodiments and methods given below, serve to explain the principles of the invention. In such drawings:
Reference will now be made in detail to exemplary embodiments and methods of the invention. It should be noted, however, that the invention in its broader aspects is not necessarily limited to the specific details, representative materials and methods, and illustrative examples shown and described in connection with the exemplary embodiments and methods. Like reference numerals designate like parts throughout the drawings.
Referring to
The door skins 11 and 14 may be made from wood composite materials such as medium density fiberboard (MDF) or high density fiberboard (HDF), fiberglass-reinforced polymer materials, metal (e.g., steel), or other materials. Preferably, the door skins 11 and 14 are molded wood composite articles made from a cellulosic mat containing a combination of cellulosic fibers and a natural or synthetic binder, such as a phenol formaldehyde or urea formaldehyde resin. The frame 18 may be made of wood, composite materials, metal, or other materials. A door cavity between the door skins 11 and 14 typically yet optionally includes one or more core components (not shown). The core component(s) can be a pre-formed structure or structures, or may be formed in situ, such as by injecting a foam precursor composition into the door cavity and allowing the precursor composition to expand and fill the door cavity with foam.
The making of door skins in general and assembling of doors is known in the art, as described for example in U.S. Pat. No. 5,543,234 to Lynch et al. and U.S. Pat. No. 9,657,512.
The first and second door skins 11 and 14 of the first illustrated embodiment of
As best shown in
The outer side (away from the inner panel 20) of the center base portion 30 is continuous and interconnects with the outer body portion 24 via a first contoured, sloping portion 34 rising from the center base portion 30 to the outer body portion 24. The first sloping portion 34 contains a first bump (or bead) 36 adjacent to the center base portion 30 and an angled portion 38 adjacent to the outer body portion 24. The first bump 36 and the angled portion 38 meet at a V-shaped intersection (or vertex) 40. When viewed from the exterior surface 12, the bump 36 of the first sloping portion 34 forms an upwardly convex protrusion or “bead” that extends convexly continuously from the angled portion 38 to the center base portion 30. The exterior surface 12 of the angled portion 38 is planar.
The inner side (towards the inner panel 20) of the center base portion 30 is continuous and interconnects with the inner panel 20 via a second sloping portion 32 rising from the center base portion 30 to the inner panel 20. The second sloping portion 32 contains a secondbump (or bead) 42 adjacent to the center base portion 30 and a third bump (or bead) 44 adjacent to the inner panel 20. The second bump 42 and the third bump 44 meet at a V-shaped intersection (or vertex) 46. When viewed from the exterior surface 12, the second and third bumps 42, 44 of the second sloping portion 32 form upwardly convex protrusions with the V-shaped intersection 46. The exterior surface 12 of the second bump 42 extends convexly continuously from the center base portion 30 to the third bump 44. The exterior surface 12 of the third bump 44 extends convexly continuously from the second bump 42 to the inner panel 20.
As best shown in
Referring now to
The first and second door skins 11 and 14 include first sloping portions 34a and 34b, respectively. An angled portion 38a of the first sloping portion 34a of the first door skin 11 is immediately adjacent to and within (or interior relative to) an outer body portion 24a. Likewise, an angled portion 38b of the first sloping portion 34b of the second door skin 14 is immediately adjacent to and within (or interior relative to) an outer body portion 24b. The interior surface 13 of the angled portion 38a of the first door skin 11 is above and in direct contact with the exterior surface 15 of the angled portion 38b of the second door skin 14. The angled portion 38a nests on the angled portion 38b to space the interior surface 13 of the outer body portion 24a of the first door skin 11 from the exterior surface 15 of the outer body portion 24b of the second door skin 14.
A first bump (or bead) 36a of the first sloping portion 34a of the first door skin 11 is immediately adjacent to and within (or interior to) the angled portion 38a. The exterior surface 12 of the first bump 36a extends convexly continuously from the angled portion 38a to a center base portion 30a. Likewise, a first bump (or bead) 36b of the first sloping portion 34b of the second door skin 14 is immediately adjacent to and within (or interior to) the angled portion 38b. The exterior surface 15 of the first bump 36b extends convexly continuously from the angled portion 38b to a center base portion 30b. The interior surface 13 of the first bump 36a contacts the exterior surface 15 of the first bump 36b of the second door skin 14 while the skins 11 and 14 are stacked or nested, as best shown in
The center base portion 30a of the first door skin 11 is immediately adjacent to and positioned within the first bump 36a. The center base portion 30a is substantially parallel to the outer body portion 24a and an inner panel 20a of the first door skin 11. The exterior surface 12 of the outer body portion 24a and the inner panel 20a are coplanar with one another. Likewise, the central based portion 30b of the second door skin 14 is immediately adjacent to and positioned within the first bump 36b. The center base portion 30b of the second door skin 14 is substantially parallel to the outer portion 24b and an inner panel 20b of the second door skin 14. The exterior surface 15 of the outer body portion 24b and the inner panel 20b are coplanar with one another. In the nested position shown in
The first and second door skins 11 and 14 include second sloping portions 32a and 32b, respectively. A second bump (or bead) 42a of the second sloping portion 32a of the first door skin 11 is immediately adjacent to and within (or interior to) the central base portion 30a. Likewise, a second bump (or bead) 42b of the second sloping portion 32b of the second door skin 14 is immediately adjacent to and within or interior to the central base portion 30b. The interior surface 13 of the second bump 42a contacts the exterior surface 15 of the second bump 42b of the second door skin 14 while the skins 11 and 14 are stacked or nested.
The second sloping portion 32a of the first door skin 11 further includes a third bump (or bead) 44a immediately adjacent to and within (or interior to) the second bump 42a, such that the second bump 42a and the third bump 44a meet at a V-shaped intersection 46a. Likewise, the second sloping portion 32b of the second door skin 14 further includes a third bump (or bead) 44b immediately adjacent to and within or interior to the second bump 42b, such that the second bump 42b and the third bump 44b meet at a V-shaped intersection 46b. The interior surface 13 of the third bump 44a of the first door skin 11 contacts the exterior surface 15 of the third bump 44b of the second door skin 14 while the skins 11 and 14 are stacked or nested.
The exterior surface 12 of the second bump 42a of the first door skin 11 extends convexly continuously from the central base portion 30a to the third bump 44a, and the exterior surface 15 of the second bump 42b of the second door skin 14 extends convexly continuously from the central base portion 30b to the third bump 44b. The exterior surface 12 of the third bump 44a of the first door skin 11 extends convexly continuously from the second bump 42a to the inner panel 20a, and the exterior surface 15 of the third bump 44b of the second door skin 14 extends convexly continuously from the second bump 42b to the inner panel 20b.
The inner panel 20a of the first door skin 11 is located at an opposite end of the second sloping portion 32a. Similarly, the inner panel 20b of the second door skin 14 is located at an opposite end of the second sloping portion 32b. The interior surface 13 of the inner panel 20a is above and spaced from the exterior surface 15 of the inner panel 20b.
Although
The nestable/stackable door skins 11, 14 allow for stacking of multiple door skins with one another, such as for shipping and storage, without the need for spacers. Preferably, nesting contact is limited to the relatively narrow beaded and angular portions 38a/38b, 36a/36b, 42a/42b, and 44a/44b, so that surface texture of the exterior surfaces of the larger area inner panels 20a/20b and the outer body portions 24a/24b is not adversely affected, such as by the movement of door skins 11 and 14 relative to one another during processing and shipping.
Also, the first and second door skins 11 and 14 may have thicknesses that vary over their lengths. For example, as best shown in
While
The door skins 11 and 14 may have a different arrangement of inner panels and other surface features (e.g., embossed wood grain) on their respective exterior surfaces 12 and 15 than shown in
The door skins with woodgrain exterior surfaces of
The foregoing detailed description of the certain exemplary embodiments has been provided for the purpose of explaining the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use contemplated. This description is not necessarily intended to be exhaustive or to necessarily limit the invention to the precise embodiments disclosed.
This application is a continuation of U.S. application Ser. No. 16/747,747 filed Jan. 21, 2020, now U.S. Pat. No. 10,920,481, which is a continuation of U.S. application Ser. No. 16/510,272 filed Jul. 12, 2019, now U.S. Pat. No. 10,538,955, which is a continuation-in-part of U.S. patent application Ser. No. 15/794,404 filed Oct. 26, 2017, the complete disclosure of which is incorporated herein by reference and to which priority is claimed.
Number | Date | Country | |
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Parent | 16747747 | Jan 2020 | US |
Child | 17174817 | US | |
Parent | 16510272 | Jul 2019 | US |
Child | 16747747 | US |
Number | Date | Country | |
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Parent | 15794404 | Oct 2017 | US |
Child | 16510272 | US |