Composite door structure and method of forming a composite...

Static structures (e.g. – buildings) – Composite prefabricated panel including adjunctive means – Having separate attached – elongated edging or stiffener

Reexamination Certificate

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C052S783100

Reexamination Certificate

active

10183998

ABSTRACT:
A method of forming a composite door is disclosed. The method comprises: mixing together a thermoplastic polymer with an organic fibrous material in a ratio such that the organic fibrous material constitutes 40 to 60 percent by weight of the mixture; extruding the mixture under heat and pressure to create a thin sheet form; cutting the sheet to a predetermined size; removing material from at least one surface of the sheet to create a homogeneous appearance devoid of obvious fibrous particles; thermoforming the sheet to impart to the at least one surface an exterior three dimensional door surface to create a thin door facing; and assembling two of the thermoformed thin door facings, a peripheral frame and a core material into a door.

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patent: 6161363 (2000-12-01), Herbst
patent: 6758996 (2004-07-01), Monovoukas et al.

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