Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1999-09-09
2001-10-30
Mayes, Curtis (Department: 1734)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S278000, C427S262000, C427S269000, C427S267000, C427S408000, C053S311000
Reexamination Certificate
active
06309503
ABSTRACT:
This invention relates to hollow core door, and corresponding method of making same. More particularly, this invention relates to a hollow core door made from flat door skins that simulates a three-dimensional molded door.
BACKGROUND OF THE INVENTION
Hollow core doors are known in the art. For example, see U.S. Pat. No. 5,560,168, the disclosure of which is incorporated herein by reference. A typical hollow core door includes a perimeter frame with vertically extending stiles and top and bottom rails, with a pair of opposing door skins secured to the frame parameter.
Three dimensional molded hollow core doors are also known. For example, three dimensional molded hollow core doors are disclosed in the aforesaid '168 patent. Molded hollow core doors include at least one door skin which is molded, e.g. so as to define a plurality of recessed panels and adjacent planar portions. Such doors are viewed by many in the trade as aesthetically attractive in certain settings.
Unfortunately, molded hollow core doors, while being attractive, suffer from at least the following problems. First, they are more expensive to make than flat-skinned hollow core doors due to the increased cost of a molded skin relative to a flat skin. Second, problems may arise in the manufacture of molded door skins when molds misregister. Third, the molding requirements limit the types of material (which are often expensive) that the base door skin may be made of.
It is apparent from the above that there exists a need in the art for a door which has the aesthetically pleasing qualities of a molded hollow core door (or of a wood carved door), yet the economic practicality and efficiency of a flat-skinned hollow core door.
It is a purpose of this invention to fulfill the above-described needs in the art, as well as other needs which will become apparent to the skilled artisan from the following detailed description of this invention.
SUMMARY OF THE INVENTION
Generally speaking, this invention fulfills the above-described need in the art by providing a hollow core door comprising:
a door frame including first and second stiles that are oriented substantially parallel to one another, a top rail member, and a bottom rail member;
first and second door skins, each of said door skins being substantially planar in shape;
said first door skin affixed to a first side of said door frame and said second door skin affixed to a second side of said door frame;
at least one of said first and second door skins including the following layers formed thereon:
a) a basecoat layer of a first color disposed over substantially an entire surface of said at least one door skin;
b) a wood grain pattern layer forming a wood grain pattern being disposed over substantially the entire surface of said at least one door skin;
c) a panel ink layer disposed over only a first portion of the surface of said at least one door skin, for the purpose of simulating recessed panels in said at least one door skin;
d) a shadow ink layer disposed over only a second portion of the surface of said at least one door skin, wherein said second portion is mostly located on said substrate at locations not including said first portion so that said shadow ink layer is formed where said panel ink layer is not present; and
e) a polymerized substantially transparent protective overcoat layer.
In preferred embodiments, each of the first and second skins have each of the same layers a)-e) disposed thereon so that each skin simulates a three dimension molded or carved door skin.
It is further an object of this invention to provide a method of making a flat-skinned door that aesthetically simulates a three dimension molded or carved door.
This invention will now be described with reference to certain embodiments thereof as illustrated in the following drawings.
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Liniak, Berenato, Longacre & White LLC
Mayes Curtis
MDF Inc.
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