Method for making a stainless steel composite door

Details Method for making a stainless steel composite door Method for making a stainless steel composite door

2011-01-18

2011-01-18

Chang, Rick K (Department: 3726)

Metal working

Method of mechanical manufacture

Structural member making

C029S897300, C052S309130, C052S784100, C052S794100

Reexamination Certificate

active

07870672

ABSTRACT:
A method of making a stainless steel composite door is accomplished by forming an oversized composite core by gluing a sheet of lightweight plywood to a sheet of brushed metallic laminate formed of a layer of metal and phenolic plastic. The thus formed core is cut to form an undercut step through only a portion of the plywood section, leaving the laminate intact. A pan is then laid down on a flat table with flanges pointing up. One-quarter inch thick spacer pads are placed in each of the four corners of the pan. The oversized metallic laminated core, with an undercut step, is placed on top of the pan and centered. Overhead clamps are tightened to hold the core in place in the pan. The metallic laminated core is routed by a trim router having a rotatable bearing and a cutting bit, with the bearing having a lesser radius than the router bit. The difference in radii between the bearing and the router bit is equal to the thickness of the flanges of the pan.

REFERENCES:
patent: 4121561 (1978-10-01), Cote
patent: 4529343 (1985-07-01), Adams
patent: 5215134 (1993-06-01), Gudeman
patent: 5570560 (1996-11-01), Thompson et al.
patent: 5682935 (1997-11-01), Bustamante
patent: 7344433 (2008-03-01), Wilson

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