US4238544A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Door panel and manner of making
Assignee: Virginia Door Co
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Filing: 1979-05-16
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Granted: 1980-12-09
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Expires: 1999-05-16
Abstract
Abstract A door panel A,B having inner and outer skins 10 and 11, 110 and 111 and a rigid expanded core 15,115, filling the cavity between the skins with stiles 19,119 extending across the ends of the cavity, said panel being made by the method comprising continuously supplying two strips of sheet material 10c,110c and 11a,162b, spraying the undersurface of strip 11a,162b with expansible thermal insulating foam 34,134, bringing the strips together and moving them under heat and pressure in pressure conveyor F to expand the foam and fill the cavity between the strips, progressively forming marginal sealing portions 11b,160 of strip 11a,162b into sealing relation with the contoured edges 12,112 and 14,114 of the other strip at stations G and H, and shearing the moving composite strip into lengths at station I.
Inventors
- 👤 Willis J. Mullet
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 23:11
CPC Classifications
B; B29; B29C; B29C44/00; B29C44/20; B29C44/32; B29C44/326; B32; B32B; B32B5/00; B32B5/18; B32B15/00; B32B15/04; B32B15/046; B32B27/00; B32B27/06; B32B27/065; B32B3/00; B32B3/02; B32B3/26; B32B3/30; B32B5/20; E; E06; E06B; E06B3/00; E06B3/32; E06B3/48; E06B3/485; E06B3/70; B29L; B29L2007/00; B29L2009/00; B32B2266/00; B32B2266/02; B32B2266/0214; B32B2266/0278; B32B2607/00; E06B3/7015; E06B2003/7023; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T428/00; Y10T428/23; Y10T428/233; Y10T428/239; Y10T428/24; Y10T428/24777; Y10T428/249921; Y10T428/249953; Y10T428/249987; Y10T428/24999; Y10T428/249991; Y10T428/249992
Claims Analysis
Total Claims: 9
Claim 1
Independent Claim
180 words
The method for continuously manufacturing overhead door panels having inner and outer skins and a core of expanded polyurethane foam, at least one of said skins being metal and having contoured edges and longitudinal reinforcing ribs and the other skin being of plastic materials, the method comprising continuously supplying horizontal strips of sheet material for both skins, continuously roll-forming vertically disposed male and female contoured edges and longitudinal ribs in said metal strip, preheating both strips, applying expandable polyurethane foam to the underside of the other strip and then bringing it into proximity with said one strip to form a composite strip having a cavity therein, and in which the marginal edges of the other strip extend beyond the contoured edges of said metal strip continuously pulling the composite strip through a pressure conveyor under controlled temperature to expand the foam and completely fill said cavity, progressively forming marginal edge portions of said other strip by bending said edge portions into sealing relation with the contoured edges of said one strip, and shearing the moving composite strip into predetermined lengths.
Claim 2
Independent Claim
180 words
The method for continuously manufacturing overhead door panels having inner and outer skins and a core of expanded polyurethane foam, at least one of said skins being metal and having contoured edges and longitudinal reinforcing ribs and the other skin being of plastic materials, the method comprising continuously supplying horizontal strips of sheet material for both skins, continuously roll-forming vertically disposed male and female contoured edges and longitudinal ribs in said metal strip, preheating both strips, applying expandable polyurethane foam to the underside of the other strip and then bringing it into proximity with said one strip to form a composite strip having a cavity therein, and in which the marginal edges of the other strip extend beyond the contoured edges of said metal strip continuously pulling the composite strip through a pressure conveyor under controlled temperature to expand the foam and completely fill said cavity, progressively forming marginal edge portions of said other strip by bending said edge portions into sealing relation with the contoured edges of said one strip, and shearing the moving composite strip into predetermined lengths.
Claim 3
Dependent Claim
33 words
The method as described in claim 1, wherein said other strip is vinyl material, and the marginal edge portions thereof are progressively overlapped and bonded with the contoured edges of said metal strip.
Claim 4
Dependent Claim
11 words
An overhead door panel made by the method of claim 1.
Claim 5
Dependent Claim
11 words
An overhead door panel made by the method of claim 2.
Claim 6
Independent Claim
161 words
The method for continuously manufacturing overhead door panels having inner and outer metal skins and a core of expanded polyurethane foam, at least one of said skins having contoured edges and longitudinal reinforcing ribs, the method comprising continuously supplying horizontal strips of sheet metal for both skins, continuously roll-forming vertical male and female contoured edges and longitudinal ribs in one of said strips, preheating both strips, inserting transverse stiles at longitudinal intervals between said strips, inserting plastic liner strips longitudinally within said contoured edges to form vertical extensions thereof, bringing said other strip progressively into proximity with said one strip to form a composite strip having a cavity therein and inserting expandable polyurethane foam between said metal strips, continuously pulling the composite strip through a pressure conveyor under controlled temperature to expand the foam and fill the cavity, and progressively forming the marginal portions of said other strip into overlapping bonded contact with the vertical extensions of said plastic liner strips.
Claim 7
Independent Claim
161 words
The method for continuously manufacturing overhead door panels having inner and outer metal skins and a core of expanded polyurethane foam, at least one of said skins having contoured edges and longitudinal reinforcing ribs, the method comprising continuously supplying horizontal strips of sheet metal for both skins, continuously roll-forming vertical male and female contoured edges and longitudinal ribs in one of said strips, preheating both strips, inserting transverse stiles at longitudinal intervals between said strips, inserting plastic liner strips longitudinally within said contoured edges to form vertical extensions thereof, bringing said other strip progressively into proximity with said one strip to form a composite strip having a cavity therein and inserting expandable polyurethane foam between said metal strips, continuously pulling the composite strip through a pressure conveyor under controlled temperature to expand the foam and fill the cavity, and progressively forming the marginal portions of said other strip into overlapping bonded contact with the vertical extensions of said plastic liner strips.
Claim 8
Dependent Claim
36 words
The method as described in claim 5, wherein a longitudinal bead is formed in said liner strip between each contoured edge of said one strip and the edge of said marginal portion of the other strip.
Claim 9
Dependent Claim
11 words
An overhead door panel made by the method of claim 5.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-12-09 | 1984-06-09 | 1984-12-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-12-09 | 1988-06-09 | 1988-12-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-12-09 | 1992-06-09 | 1992-12-09 | $7700.00 | Window Closed / Lapsed |