公开(公告)号：US20200254732A1

公开(公告)日：2020-08-13

申请号：US16793220

申请日：2020-02-18

Applicant: Masonite Corporation

Inventor： Bei-Hong LIANG ,  Karine A. LUETGERT ,  Henry Coghlan ,  John Peter Walsh ,  Geoffrey B. Hardwick

IPC: B32B21/14 ,  B27N7/00 ,  B32B37/06 ,  B32B37/10

Abstract: 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.

公开(公告)号：US20200248499A1

公开(公告)日：2020-08-06

申请号：US16781512

申请日：2020-02-04

Applicant: Masonite Corporation

Inventor： Timothy D. GOUGE ,  Robert C. ALLEN ,  Allen R. HILL

IPC: E06B3/78 ,  B27N3/04 ,  E06B3/70 ,  B27N7/00 ,  B27N3/20

Abstract: 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.

公开(公告)号：US20200149343A1

公开(公告)日：2020-05-14

申请号：US16747747

申请日：2020-01-21

Applicant: Masonite Corporation

Inventor： Patrick C. EGE ,  Dale DI IULIO ,  Timothy D. GOUGE

IPC: E06B3/70 ,  E06B3/78 ,  E06B3/74

Abstract: A door skin is provided that includes at least one inner panel, an outer body portion surrounding the at least one inner panel, and at least one contoured portion surrounding the at least one panel and interconnecting the at least one panel to the outer body portion. The at least one contoured portion is recessed from the at least one panel and the outer body portion and includes a center base portion that interconnects with the outer body portion via a first sloping portion and with the panel via a second sloping portion. The first sloping portion includes a first angled portion and a first bump. The second sloping portion includes second and third bumps.

公开(公告)号：US10562339B2

公开(公告)日：2020-02-18

申请号：US15688399

申请日：2017-08-28

Applicant: Masonite Corporation

Inventor： Robert C. Allen

IPC: E06B3/70 ,  B44F9/02 ,  B29C59/02 ,  B44B5/02 ,  B44C5/04

Abstract: A door skin featuring a facing having an exterior surface and an interior surface can be provided. A wood grain pattern portion can be formed in the exterior surface of the facing. The wood grain pattern portion can feature a plurality of grooves formed in the exterior surface of the facing, the grooves are recessed from a first plane of the exterior surface, and tonal portions formed in the exterior surface of the facing. The tonal portions can include at least a first protrusion, a second protrusion, and a third protrusion. Spacing between the first protrusion and the second protrusion can be different from spacing between the second protrusion and the third protrusion.

公开(公告)号：US10562280B2

公开(公告)日：2020-02-18

申请号：US16242436

申请日：2019-01-08

Applicant: Masonite Corporation

Inventor： Bei-Hong Liang ,  Karine A. Luetgert ,  Henry Coghlan ,  John Peter Walsh ,  Geoffrey B. Hardwick

IPC: B32B21/14 ,  B27N7/00 ,  B32B37/06 ,  B32B37/10

Abstract: 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.

公开(公告)号：US20190301235A1

公开(公告)日：2019-10-03

申请号：US16369245

申请日：2019-03-29

Applicant: Masonite Corporation

Inventor： Jan H. ETTRICH ,  Hubert BRETON

IPC: E06B7/14 ,  E06B3/74 ,  E06B3/663

Abstract: A door is provided that includes a door panel having a periphery and opposite first and second panel surfaces, stiles and rails collectively surrounding the panel, and sealant. The stiles have channeled stile surfaces extending across a thickness of the stiles and facing one another. The rails have channeled rail surfaces extending across a thickness of the rails and facing one another. The channeled stile surfaces and the channeled rail surfaces include channels with open ends that receive the periphery of the panel, first grooves positioned at first interfaces of the first panel surface and first edges of the open ends of the channels, and second grooves positioned at second interfaces of the second panel surface and second edges of the open ends of the channels. The sealant is received in the first and second grooves, preferably forming a water-proof seal.

公开(公告)号：US10427393B2

公开(公告)日：2019-10-01

申请号：US15370250

申请日：2016-12-06

Applicant: Masonite Corporation

Inventor： George Cucchi ,  Bei-Hong Liang

IPC: B30B15/06 ,  B32B37/10 ,  B32B37/12 ,  B32B37/18 ,  B32B39/00 ,  E06B3/70 ,  E06B3/82

Abstract: A system and method for 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 with a pressed having platens. Movable shims may be used to vary the pressed force and pressing area.

公开(公告)号：US10392857B2

公开(公告)日：2019-08-27

申请号：US15365106

申请日：2016-11-30

Applicant: Masonite Corporation

Inventor： John Robinson ,  Steven Swartzmiller ,  Steven Gutkowski ,  Robert Allen ,  Roland Karsch ,  Michael MacDonald

IPC: E04C2/54 ,  E06B3/70 ,  E06B3/72

Abstract: The present invention relates to shaker doors with solid cores and methods for making the same. The shaker doors contain different core materials at the recessed panel than the raise peripheral region to provide dimensional stability and reduced distortion when the doors are exposed to high humidity. The devices and methods also provide for easy assembly of solid core shaker doors, including fire rated doors.

公开(公告)号：US20190195004A1

公开(公告)日：2019-06-27

申请号：US15784306

申请日：2017-10-16

Applicant: MASONITE CORPORATION

Inventor： Alan Pepin ,  Patrick C. EGE

IPC: E06B3/70

CPC classification number: E06B3/7001 ,  E06B3/72 ,  E06B2003/7049

Abstract: A door skin is provided that includes at least one inner panel, an outer body portion surrounding the at least one inner panel, and at least one contoured portion surrounding the at least one panel and interconnecting the at least one panel to the outer body portion. The at least one contoured portion includes a substantially V-shaped indent area adjacent to and within the outer body portion, a planar area that is substantially parallel to the outer body portion and is adjacent to and within the substantially V-shaped indent area, and a declining area adjacent to and within the planar area and terminating at the inner panel. A door including at least one door skins and a doorframe is also provided.

公开(公告)号：USD851784S1

公开(公告)日：2019-06-18

申请号：US29623303

申请日：2017-10-24

Applicant: Masonite Corporation

Designer： Timothy D. Gouge ,  Robert C. Allen ,  Jason M. Walsh ,  Mark Albrighton