Masonite Corporation

John Peter Walsh

Geoffrey B Hardwick

Henry M Coghlan

Allen Ray Hill

Bei-Hong Liang

Karine A Luetgert

Thomas M Ruffin

Roger E Koch

Wen-Ning (Sally) Chan

Bob Allen

Hanmin Dong

Thomas A Lehtinen

Geoffrey Brian Hardwick

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

Method of making a composite non-planar door skin

Decorative door skin composite article

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

Fibrous composite articles and method of manufacturing the same are disclosed. The preferred fibrous materials have average fiber lengths of less than about 2 millimeters, and are obtained from industrial hemp hurd, kenaf hurd, and/or the culms of various species of vegetable bamboo. The fibers are combined with a binder resin and, optionally, a sizing agent to form a mat that is consolidated under heat and pressure to form the composite articles. The formed articles exhibit strength and durability characteristics at least roughly equivalent, if not superior, to those of conventional wood-based fibrous composite articles.

Fibrous composite articles and method of making the same

Fibrous composite article and method of making the same

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 the production of a material or article, e.g., an exterior building product such as wood composite siding, having improved weatherability properties. The material or article preferably has improved resistance to migration of wax sizing and moisture. The method preferably includes the use of salts of aluminum, calcium, zinc, and/or lithium cations, including salts of stearic acid and/or palmitic acid.

Composite article including modified wax, and method of making same

An isocyanate bonded wood composite, such as a doorskin, comprising about 95% to about 99% by weight wood fiber, about 1% to about 4% by weight of an organic isocyanate and 0% to about 2% by weight of a wax, and its method of manufacture, are disclosed. The isocyanate bonded wood composite is manufactured by admixing the ingredients, then pressing the admixed ingredients at a temperature of about 200.degree. F. to about 320.degree. F., for a sufficient time and at a sufficient pressure, to provide an isocyanate bonded wood composite having a density of about 0.9 g/cc to about 1.1 g/cc, and that demonstrates improved porosity and adhesive properties.

Growing community of inventors

St. Charles, IL, United States of America

John Peter Walsh