US3731443A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Carved doors
Assignee: Indian Capitol Plastics Inc
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Filing: 1971-12-29
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Granted: 1973-05-08
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Expires: 1991-12-29
Abstract
Abstract Methods are provided for economically producing doors having decorative carvings thereon. After selecting a prefabricated wooden door frame with one or more openings therein for receiving decorative carved panels, which openings have disposed therein thin plywood panels providing decorative panel insert areas, ''''carved'''' panels of polyurethane structural foam are formed by injection molding expandable plastic into a mold of a configuration of the final ''''carved'''' design. The formed foamed panels are subsequently adhered to one or both sides of the surfaces of the plywood panels. Subsequently, the combined woodpolyurethane doors are specially treated to provide an integrated, ''''all wood'''' appearing door having appropriately configured carvings disposed on the surface thereof. Also, disclosed herein are the new doors produced by the new methods.
Inventors
- 👤 F Zaroor
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 22:51
CPC Classifications
E; E06; E06B; E06B3/00; E06B3/70; E06B3/7001; E06B3/82; E06B3/86; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24479; Y10T428/24496; Y10T428/24504; Y10T428/24512; Y10T428/249921; Y10T428/249953; Y10T428/249987
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
169 words
In a method for producing laminated doors having carved panels disposed on the surface thereof, the steps which comprise preselecting a wooden door frame having a first predetermined woodgrain and at least one opening disposed therein with a thin member extending over said opening to provide at least one carved panel insert area on one or both sides of said frame, injecting polyurethane into a mold having a configuration conforming to the desired design of said carved panels, and having a second predetermined grain, expanding said foam in said mold to form said carved panel, adhering at least one of said carved panels to the surface of said thin member in said panel insert area, applying a molding around the circumference of said adhered carved panel adjacent the junction of the edge of said carved panel with said door frame, and treating the surface of said frame and said carved panel to produce an integrally appearing door having at least one decoratively carved panel disposed on the surface thereof.
Claim 2
Dependent Claim
169 words
In a method for producing laminated doors having carved panels disposed on the surface thereof, the steps which comprise preselecting a wooden door frame having a first predetermined woodgrain and at least one opening disposed therein with a thin member extending over said opening to provide at least one carved panel insert area on one or both sides of said frame, injecting polyurethane into a mold having a configuration conforming to the desired design of said carved panels, and having a second predetermined grain, expanding said foam in said mold to form said carved panel, adhering at least one of said carved panels to the surface of said thin member in said panel insert area, applying a molding around the circumference of said adhered carved panel adjacent the junction of the edge of said carved panel with said door frame, and treating the surface of said frame and said carved panel to produce an integrally appearing door having at least one decoratively carved panel disposed on the surface thereof.
Claim 3
Dependent Claim
18 words
A method as recited in claim 1, in which said thin member is comprised of one-fourth inch plywood.
Claim 4
Dependent Claim
17 words
A method as recited in claim 1, in which said adhering step is carried out with mastic.
Claim 5
Dependent Claim
23 words
A method as recited in claim 1, in which said frame, said molding, and said foam panel have generally similar grain patterns herein.
Claim 6
Dependent Claim
33 words
A method as recited in claim 1, in which said treating step includes wire brushing said surfaces, spraying said surfaces with vinyl stain, applying a vinyl barrier coating, and applying a sealing coat.
Claim 7
Dependent Claim
97 words
In a door having a wooden frame with at least one opening disposed therein, the combination which comprises a thin-walled panel disposed in each of said openings and having a thickness less than said wooden frame, at least one injection molded, decorative structural foam panel adhered to a side of said thin-walled panel, a wooden molding disposed around the circumference of said structural foam panel at the intersection of each side of said foam panel with said frame, and said molding being connected to said foam panel and said frame along the entire length of said molding.
Claim 8
Dependent Claim
97 words
In a door having a wooden frame with at least one opening disposed therein, the combination which comprises a thin-walled panel disposed in each of said openings and having a thickness less than said wooden frame, at least one injection molded, decorative structural foam panel adhered to a side of said thin-walled panel, a wooden molding disposed around the circumference of said structural foam panel at the intersection of each side of said foam panel with said frame, and said molding being connected to said foam panel and said frame along the entire length of said molding.
Claim 9
Dependent Claim
41 words
A door as described in claim 6, in which the width and length of said thin-walled panel is slightly larger than said opening, and in which grooves are formed in said frame for insertion of the edges of said thin-walled panel.
Claim 10
Dependent Claim
35 words
A door as recited in claim 6, in which said thin-walled member is one-fourth inch thick and is comprised of a member selected from the group consisting of plywood, pressed fiberboard and a non-flexible resin.
Claim 11
Dependent Claim
16 words
A door as recited in claim 6, in which said structural foam material is rigid polyurethane.
Claim 12
Dependent Claim
23 words
A door as recited in claim 6, in which said frame, said molding, and said foam panels have generally similar grain patterns therein.
References Cited (Backward Citations)
US848661A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1976-05-07 | 1976-11-06 | 1977-05-08 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1980-05-07 | 1980-11-06 | 1981-05-08 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1984-05-07 | 1984-11-06 | 1985-05-08 | $7700.00 | Window Closed / Lapsed |