Masonite Corporation

Geoffrey B Hardwick

Henry M Coghlan

John Peter Walsh

Bei-Hong Liang

Allen Ray Hill

Randy C McGuire

Karine A Luetgert

Jason M Walsh

Steven K Lynch

Mark A Ruggie

Michael J MacDonald

George Cucchi

Bruce Fedio

Robert Ritchie

Bei Hong Liang

Mark A Ruggle

Michael Macdonald

A method of forming a composite article is disclosed that involves providing a press having first and second platens, a cellulosic fiber substrate having a first thickness, and a layer of material such as a wood veneer, foil, or non-creped paper, where the layer of material has a thickness less than the thickness of the cellulosic fiber substrate. A layer of bonding material is placed onto the cellulosic fiber substrate or the layer of material, and the layer of material is placed onto the cellulosic fiber substrate so that the bonding material is between the layer of material and the cellulosic fiber substrate. The cellulosic fiber substrate and layer of material are placed between the first and second platens, and at least one of the first and second platens is moved toward the other of the first and second platens to deform the cellulosic fiber substrate and layer of material into a predetermined configuration while bonding the layer of material to the cellulosic fiber substrate without cracking or wrinkling the layer of material.

Method of manufacturing a decorative substrate and decorative substrate produced thereby

Provided is a system and method of making a door having first and second door skins and an internal frame. The top and bottom surfaces of the frame are coated with an adhesive and the frame is placed on a first door skin. The second door skin is then placed on the opposite surface of the frame. The assembled components are then pressed to bond the first and second door skins to the frame.

Automated door assembly, press, and adhesive therefor

Method of making a composite non-planar door skin

Decorative door skin composite article

A door skin comprises an exterior side and an interior side for being secured to a frame member. First and second molded, spaced stiles lie on a first plane. A flat planar portion is disposed between the stiles and lies on a second plane spaced from the first plane. A first interface portion is disposed between and contiguous with the stiles and the flat planar portion. First and second integrally molded, spaced rails lie on a third plane, wherein the third plane is intermediate the first and second planes.

Door skin, method of manufacturing a door produced therewith, and door produced therefrom

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

The present invention concerns a method of forming a multi-ply core component. A mold press is provided having an upper die and a lower die defining a mold cavity. At least one of the upper die and the lower die has a plurality of protrusions. A first wood composite board and a second wood composite board are disposed within the mold cavity. The first and second boards are fused proximate the plurality of protrusions by compressing the boards in the mold cavity through application of heat and pressure.

Method of making multi-ply door core, multi-ply door core, and door manufactured therewith

Core component and door comprising thereof

Method of making a multi-ply door core, multi-ply door core, and door manufactured therewith

Growing community of inventors

St. Charles, IL, United States of America

Geoffrey B Hardwick