Claims
- 1. A door frame having an inner panel and outer panel, each panel having a central essentially rectangular opening for a window, said door frame having side edges, a top edge, and bottom edge, said central opening having side edges, a top edge, and a bottom edge, all of said edges being integrally formed in said panels from which said edges extend from the panel, comprising:
- said outer edges forming a dam wall assembly surrounding the exterior periphery of the door and the central opening edges forming, with the outer edges, an essentially continuous pre-filling unblocked hollow inside of the door panels,
- all of said edges being formed as a unitary one piece molded circumambient extension from the panels,
- each of said edges engaging the opposed edge in foam blocking relationship,
- the edges of the door also serving as the dam wall assembly in the absence of secondary stiles, rails, or other independent elements inserted interiorly of the essentially continuous rectilinear dammed uninterrupted and unblocked hollow space interiorly of the door,
- a continuous pre-filling void for foam filling being defined by the circumambient side edges, top edge, and bottom edge for uninterrupted foam filling,
- and a foamed in place interior essentially filling the hollow space defined by the edges,
- whereby the finished door has a uniform and unitary uninterrupted foamed in place core to fill the hollow space, add to structural integrity, enhance the monocoque effect of the overall door structure, and adhere the inner and outer skin to each other without the use of secondary mechanical assembly steps in the formation and filling of the interior hollow space by blocking the escape of foam at the joints between the edges and permitting the foam access to the entire hollow space from any exterior location.
- 2. In the door according to claim 1,
- outer and inner extensions into the window area to define overlapping opposed framing borders for receiving the window.
- 3. In the door according to claim 1,
- said dam wall edge and window portion extensions from both the outer skin and the inner skin to overlappingly engage the opposed wall portions.
- 4. A door having an outer panel and an inner panel, each panel having a central opening for a window, said panels defining a door frame having side edges, a top edge, and bottom edge, said central opening having side edges, a top edge, and a bottom edge, comprising:
- said edges surrounding the outer extremes of the door and the inner boundary of the central opening thereby forming a circumambient dam wall assembly,
- all of said dam walls assembly being formed by edge portions extending circumambient from each panel and integrally molded in said panels,
- each of said extending edge portion engaging an opposed overlapping foam blocking means forming an uninterrupted hollow interior between the opposed panels,
- the dam wall assembly and hollow interior characterized by the absence of secondary stiles, rails, or other independent elements inserted interiorly of the hollow interior,
- an uninterrupted pre-filling hollow interior surrounding the window edges and interior of the outer edges,
- and a foam filled uninterrupted interior essentially filling the pre-filling hollow interior from any opening in the otherwise dammed hollow area defined by the edges and adhesively securing the inner and outer panels to each other,
- whereby the finished door has a foam filled core to fill the hollow interior, add to structural integrity, enhance the monocoque effect of the overall door structure, and adhere the inner and outer panels to each other.
- 5. A molded door frame having two frame panels, an outer panel and an inner panel, which panels are secured to each other by a foamed in place filling between the outer panel and the inner panel, the improvement comprising,
- side wall edges, a top wall edge, and a bottom wall edge on the inner door panel and the outer door panel defining circumambient outer edges;
- each of said edges overlappingly engaging the opposite edge;
- a window opening surrounded by circumambient side edges, top, and bottom edges defining inner edges and an open window area;
- said inner edges overlapping each other and defining an essentially uninterrupted hollow space between the inner and outer edge;
- all of said edges being formed integrally in said panels and extending from the panels; and
- a continuous hollow void between the panels which is unblocked and open so that foam may flow freely in any direction in said hollow void,
- whereby a continuous foam fill can occupy the hollow void and move into the entire hollow area without blockage and is surrounded by edges to adhesively secure the two frames together and to add strength to the structure and insulate the door.
- 6. A door having an outer panel and an inner panel, comprising,
- circumambient side edges, a top edge and a bottom edge integral with each of said panels formed for interlockingly engaging the opposite side, top and bottom edges of said outer and inner panels;
- further edges forming a window opening having interlocking engagement means for engaging the opposite panel;
- all of said edges forming an uninterrupted pre-filling unblocked hollow interior between the panels, and
- a foam filled interior passing continuously without interruption through the pre-filling hollow interior between the panels in the absence of secondary independently formed securing means for securing the outer frame to the inner frame;
- whereby a door is formed with a foam filled interior, the foam for which is uninterrupted in its penetration of the entire hollow interior, and foam leakage is prevented by the interlocking engagement of the edges which prevent the seepage of blow-by experienced with a butt joint when foam is filled under pressure.
- 7. A method for forming a door having an outer panel, and an inner panel, said outer panel and inner panel each having outer side, top, and bottom edges, and an interior window opening having interior side, top, and bottom edges in each of said panels, said edges interlockingly engaging with the opposed edges,
- proportioning the edges to entirely and uninterruptedly circumambiate the exterior portion of the door and similarly to surround the interior window opening without interruptions in the hollow space so that foam can propagate throughout the entire hollow space without being blocked at any portion of the hollow space and seeping out a gap at the joint between the panels;
- forming a hollow interior in the door which is continuous and unblocked to thereby permit the uninterrupted and unblocked filling with foam,
- the further step of securing said panels to each other by filling the hollow space between the panels and inner and outer edges with a foam in the absence of secondary independently formed and inserted securement means.
RELATED APPLICATIONS
This Application is a Continuation of application Ser. No. 09/211,058, filed Dec. 14, 1998, now abandoned, which is a Continuation of Continuation-In-Part of Ser. No. 08/864,628, filed May 28, 1997, now abandoned, which is a Continuation-In-Part of Ser. No. 08/480,693, filed Jun. 7, 1995, now U.S. Pat. No. 5,634,508, which is a Divisional of application Ser. No. 08/735,019, filed Oct. 22, 1996, now abandoned.
US Referenced Citations (8)
Divisions (1)
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Number |
Date |
Country |
Parent |
735019 |
Oct 1996 |
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Continuations (1)
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Number |
Date |
Country |
Parent |
211058 |
Dec 1998 |
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Continuation in Parts (2)
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Number |
Date |
Country |
Parent |
864628 |
May 1997 |
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Parent |
480693 |
Jun 1995 |
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