Method of making a foam-filled door

Details Method of making a foam-filled door Method of making a foam-filled door

1997-12-01

1999-06-22

Kuhns, Allan R.

Plastic and nonmetallic article shaping or treating: processes

Pore forming in situ

Composite article making

264 466, 425812, B29C 4406, B29C 4412

Patent

active

059140780

ABSTRACT:
A foam-filled door manufactured in accordance with the present invention comprises a frame (11) having a pair of ledge areas (58) extending about substantially the entire inner periphery of the frame (11). The frame (11) is formed by the spaced parallel positioning of a pair of rails (12) and a pair of stiles (14). The ledge areas (58) formed in the frame (11) are of substantial width and depth to provide an area of bonding between the facers (20, 21) and the frame (11). The ledge areas (58) also form vents (100) that allow air to escape from a cavity (22) formed between the frame (11) and pair of facers (20, 21) when a foaming material is injected into the cavity (22) to prevent internal air pockets from forming. The facers (20, 21) have flanges (90, 92) that surround substantially the entire outer periphery of the facers (20, 21) and engage the outer periphery of the frame (11). In manufacturing the foam-filled door (10), a force is evenly applied normal to the facers (20, 21) during the foam injection step to prevent the facers (20, 21) from moving away from the frame (11). The force allows the frame (11) to expand as the foam expands so that the frame (11) contacts the flanges (90, 92) of the facers (20, 21), creating tensile forces in the facers (20, 21).

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