United Dominion Industries, Inc.

Michael A Frost

Donald B Kyle

A door assembly and method for making a door assembly that has a front steel skin with a predetermined embossed pattern, a back steel skin that has a substantially textured flush surface and a polystyrene core one side of which has an embossed design substantially identical to the embossed design of the front steel skin and a back surface that is substantially flush. The front and back steel skins have a pressure sensitive hot melt adhesive applied thereto and the center polystyrene core is attached between the front and back steel skins and passed through a series of pinch rollers to apply predetermined pressure to the front and back skins to secure the front and back skins to the polystyrene core. The front and back skins are preheated to a predetermined temperature sufficient to maintain the pressure sensitive hot melt glue in a soft and tacky state. The assembly is then passed through a series of pinch rollers to apply a predetermined pressure at a predetermined rate to the front and back skins to cause the bonding between the adhesive and the front and back metal skins and the polystyrene core. End caps are placed on the panel and, where a garage door may be involved or a door requires a weather seal, a retainer is placed on the bottom of the panel with weatherstripping inserted in the retainer to provide a weather-tight seal at the bottom of the door.

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Little Rock, AR, United States of America

Michael A Frost