Masonite Corporation

The Celotex Corporation

Allen Ray Hill

Robert C Allen

Timothy D Gouge

John Peter Walsh

Geoffrey B Hardwick

Henry M Coghlan

Thomas M Ruffin

William E Betzner

Richard K Holtman

Thomas A Lehtinen

Geoffrey Brian Hardwick

Molded articles are provided. An exemplary molded article includes an inner panel portion, a main body portion, and a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion. The contoured portion includes contoured corner segments and contoured elongated segments extending between respective pairs of the contoured corner segments. The contoured corner segments have a first maximum thickness. The contoured elongated segments have a second maximum thickness that is greater than the first maximum thickness. Related methods, assemblies, and apparatus are also provided.

Stackable molded articles, and related assemblies and methods

A molded article includes an exterior surface and an opposite interior surface spaced apart by a thickness of the molded article and defining, on opposite sides of the molded article, an inner panel, a main body, and a contoured portion. The contoured portion extends between and interconnects the inner panel and the main body so as to surround the inner panel and be surrounded by the main body. The contoured portion includes contoured corner segments and contoured intermediate segments extending between respective pairs of the contoured corner segments lengthwise. The thickness of the molded article includes a first maximum thickness at the contoured intermediate segments measured from the exterior surface to a closest point of the interior surface, and a second maximum thickness at the contoured corner segments measured from the exterior surface to a closest point of the interior surface that is less than the first maximum thickness.

Molded articles are provided. An exemplary molded article includes an inner panel portion, a main body portion, and a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion. The contoured portion includes an outer angular region extending from the main body portion, an inner angular region extending from the inner panel portion, and a vertex region interconnecting the outer angular region and the inner angular region. The outer angular region includes contoured corner segments and contoured intermediate segments extending lengthwise between respective pairs of the contoured corner segments. The contoured intermediate segments have a first maximum thickness. The contoured corner segments have a second maximum thickness. The first maximum thickness is greater than the second maximum thickness. Related methods, assemblies, and apparatus are also provided.

Molded articles are provided. An exemplary molded article includes an inner panel portion, a main body portion, and a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion. The contoured portion includes contoured corner segments and contoured intermediate segments extending between respective pairs of the contoured corner segments. The contoured intermediate segments have a first maximum thickness. The contoured corner segments have a second maximum thickness. The first maximum thickness of the contoured intermediate segments is greater than the second maximum thickness of the contoured corner segments. Related methods, assemblies, and apparatus are also provided.

The present invention is directed to a method of forming a molded core component. A mat formed from cellulosic fiber and resin is provided. The mat is consolidated in a first press until the resin is substantially fully cured, and then removed from the first press. The consolidated mat is then placed in a second press having a mold cavity shaped to form at least one depression in at least one of the major surfaces. The consolidated mat is reformed in the second press to form a molded core component having at least one depression in at least one of the major surfaces. The molded core component has a variable density, preferably of between about 10 lbs/ftand 80 lbs/ft.

Method of forming a core component

Core component and door comprising thereof

A core component is molded to include surface depressions to compensate for varying widths and depths of the shell or framing of a building or structural member. The component includes two major surfaces defining respective front and rear sides of the component, and the rear side of the component is preferably the mirror image of the front side. The core component is preferably pre-formed and the surface layers are wetted to contain at least 2%, preferably about 4% to 20%, more moisture than at the thickness center of the mat to provide surfaces capable of adhesive coating for adherence to surrounding structural members, preferably two prefabricated molded doorskins. The core component is preferably made from a composite soft board material.

Method of producing core component, and product thereof

Disclosed herein is a cellulosic composite article and steam injection press methods of making the same by combining a phenolic resin with cellulosic material to form a mixture and, thereafter, providing a catalyzing agent, such as aluminum chloride, to the mixture. As an alternative, the method may include the steps of combining a catalyzing agent with a cellulosic material to form a mixture and, thereafter, providing a phenolic resin to the mixture. The method further includes the steps of forming a mat from the catalyzing agent-containing mixture and consolidating the catalyzing agent-containing mat in a pressing apparatus under heat, steam, and pressure to form the consolidated cellulosic product.

Composite article and method of making same

A method of forming a consolidated wood product is disclosed wherein zinc borate and resin are mixed with cellulosic material to form treated cellulosic material, followed by applying heat and pressure to form a consolidated cellulosic product. A consolidated product comprises zinc borate, resin, and cellulosic material, wherein the zinc borate is distributed throughout the lignocellulosic material. A steam injection process is also disclosed.

Method of making cellulosic composite articles

A method for producing a synthetic board from cellulosic and/or lignocellulosic materials wherein a polyisocyanate binder is applied to the hot and wet fibrous material in the blow line out of the refiner of the board forming process. Polyphenylpolyisocyanates, such as a mixture of diphenylmethane-4,4'-diisocyanate and polymethylene polyphenyl polyisocyanates, are a particularly suitable binder.

Growing community of inventors

Laurel, MS, United States of America

Allen Ray Hill