Compression molded door assembly

Claim 2

A door assembly comprising, in combination, a rectangular frame, a pair of opposed compression molded skins mounted on said frame, and a foamed core positioned within said frame between and adhered to said opposed compression molded skins, said skins each having an outer side and an inner side, a vertically extending projection positioned on each vertical edge of said inner side of said compression molded skins, said projections engaging said rectangular frame, said compression molded skins being integral, including a molding resin and glass fibers, said outside of said skin being essentially devoid of glass fibers for a predetermined depth of at least 0.005 inch, said outer side of said skin defining a textured pattern simulating the grain and texture of a wood door, said textured pattern having a pattern depth between 0.003 inch and 0.009 inch, but not in excess of such predetermined depth.

Claim 3

A door assembly according to claim 1, wherein said outer side of said skin is essentially devoid of glass fibers for a predetermined depth of between 0.005 inch and 0.009 inch.

Claim 4

A door assembly according to claim 1, wherein said frame extends outwardly from at least a portion of the edge of said skins, whereby such frame may be trimmed for insertion in a door opening.

Claim 5

A door assembly according to claim 1, wherein said inner side of each of said compression molded skins also defines a molded textured pattern, said foamed core adhering to said textured pattern on said inner side.

Claim 6

A door assembly according to claim 1, wherein said skins are constructed of a glass fiber reinforced polyester resin, said skins having a thickness of between 0.050 inch and 0.120 inch.

Claim 7

A door assembly, according to claim 1, wherein said foamed core comprises a rigid urethane foam having a density between 0.8 and 3.5 lbs./ft. 3 .

Claim 8

A door assembly, according to claim 1, wherein said rectangular frame is constructed of wood, a plurality of horizontally extending grippers defined on said inner side of compression molded skins adjacent said rectangular frame, said grippers piercing said wood frame, whereby relative motion between said frame and said skins is retarded.

Claim 9

A door assembly, according to claim 1, including horizontally extending rail stops extending inwardly from said inner side of said compression molded skins, said rail stops engaging the rails of said rectangular frame.

Claim 10

A door assembly, according to claim 1, wherein a pair of vertically extending projections are defined along each vertical edge of the inner side of each skin.

Claim 11

A door assembly comprising, in combination, a rectangular frame, a pair of opposed compression molded skins mounted on said frame, and a foamed core positioned within said frame between and adhered to said opposed compression molded skins, said skins having a thickness of between 0.050 inch and 0.120 inch, said skins each having an outer side and an inner side, said compression molded skins being integral, including a molding resin and glass fibers, said outer side of said skin being essentially devoid of glass fibers for a predetermined depth of at least 0.005 inch, said outer side of said skin defining a textured pattern simulating the grain and texture of a wood door, said textured pattern having a pattern depth between 0.003 inch and 0.009 inch, but not in excess of such predetermined depth, at least one vertically extending projection adjacent each vertical edge of said inner side of said skins, at least one of said projections engaging said perimeter frame, said frame extending outwardly from at least a portion of the edge of said skins, whereby such frame may be trimmed for insertion in a door opening, said foamed core comprises a rigid urethane foam having a density between 0.8 and 3.5 lbs/ft. 3 .

Claim 12

A door assembly comprising, in combination, a rectangular frame, a pair of opposed compression molded skins mounted on said frame, and a foamed core positioned within said frame between and adhered to said opposed compression molded skins, said skins having a thickness of between 0.050 inch and 0.120 inch, said skins each having an outer side and an inner side, said compression molded skins being integral, including a molding resin and glass fibers, said outer side of said skin being essentially devoid of glass fibers for a predetermined depth of at least 0.005 inch, said outer side of said skin defining a textured pattern simulating the grain and texture of a wood door, said textured pattern having a pattern depth between 0.003 inch and 0.009 inch, but not in excess of such predetermined depth, at least one vertically extending projection adjacent each vertical edge of said inner side of said skins, at least one of said projections engaging said perimeter frame, said frame extending outwardly from at least a portion of the edge of said skins, whereby such frame may be trimmed for insertion in a door opening, said foamed core comprises a rigid urethane foam having a density between 0.8 and 3.5 lbs/ft. 3 .

Claim 13

A door assembly comprising, in combination, a rectangular frame, a pair of opposed compression molded skins mounted on said frame, and a foamed core positioned within said frame between and adhered to said opposed compression molded skins, said skins each having an outer side and an inner side, a pair of vertically extending projections defined along each vertical edge of the inner side of each skin, said compression molded skins being integral, including a molding resin and glass fibers, said outside of said skin being essentially devoid of glass fibers for a predetermined depth of at least 0.005 inch, said outer side of said skin defining a textured pattern simulating the grain and texture of a wood door, said textured pattern having a pattern depth between 0.003 inch and 0.009 inch, but not in excess of such predetermined depth.

Claim 14

A door assembly comprising, in combination, a rectangular frame, a pair of opposed compression molded skins mounted on said frame, and a foamed core positioned within said frame between and adhered to said opposed compression molded skins, said skins each having an outer side and an inner side, a pair of vertically extending projections defined along each vertical edge of the inner side of each skin, said compression molded skins being integral, including a molding resin and glass fibers, said outside of said skin being essentially devoid of glass fibers for a predetermined depth of at least 0.005 inch, said outer side of said skin defining a textured pattern simulating the grain and texture of a wood door, said textured pattern having a pattern depth between 0.003 inch and 0.009 inch, but not in excess of such predetermined depth.

Claim 15

A door assembly comprising, in combination, a rectangular frame, a pair of opposed compression molded skins mounted on said frame, said rectangular frame being constructed of wood, a plurality of horizontally extending grippers defined on said inner side of said compression molded skins adjacent said rectangular frame, said grippers piercing said wood frame, whereby relative motion between said frame and said skins is retarded, and a foamed core positioned within said frame between and adhered to said opposed compression molded skins, said skins each having an outer side and an inner side, said compression molded skins being integral, including a molding resin and glass fibers, said outside of said skin being essentially devoid of glass fibers for a predetermined depth of at least 0.005 inch, said outer side of said skin defining a textured pattern simulating the grain and texture of a wood door, said textured pattern having a pattern depth between 0.003 inch and 0.009 inch, but not in excess of such predetermined depth.

Claim 16

A door assembly comprising, in combination, a rectangular frame, a pair of opposed compression molded skins mounted on said frame, said rectangular frame being constructed of wood, a plurality of horizontally extending grippers defined on said inner side of said compression molded skins adjacent said rectangular frame, said grippers piercing said wood frame, whereby relative motion between said frame and said skins is retarded, and a foamed core positioned within said frame between and adhered to said opposed compression molded skins, said skins each having an outer side and an inner side, said compression molded skins being integral, including a molding resin and glass fibers, said outside of said skin being essentially devoid of glass fibers for a predetermined depth of at least 0.005 inch, said outer side of said skin defining a textured pattern simulating the grain and texture of a wood door, said textured pattern having a pattern depth between 0.003 inch and 0.009 inch, but not in excess of such predetermined depth.

Claim 17

A door assembly comprising, in combination, a rectangular frame, a pair of opposed compression molded skins mounted on said frame, and a foamed core positioned within said frame between and adhered to said opposed compression molded skins, said skins each having an outer side and an inner side, horizontally extending rail stops extending inwardly from said inner side of said compression molded skins, said rail stops engaging the rails of said rectangular frame, said compression molded skins being integral, including a molding resin and glass fibers, said outside of said skin being essentially devoid of glass fibers for a predetermined depth of at least 0.005 inch, said outer side of said skin defining a textured pattern simulating the grain and texture of a wood door, said textured pattern having a pattern depth between 0.003 inch and 0.009 inch, but not in excess of such predetermined depth.

Claim 18

A door assembly comprising, in combination, a rectangular frame, a pair of opposed compression molded skins mounted on said frame, and a foamed core positioned within said frame between and adhered to said opposed compression molded skins, said skins each having an outer side and an inner side, horizontally extending rail stops extending inwardly from said inner side of said compression molded skins, said rail stops engaging the rails of said rectangular frame, said compression molded skins being integral, including a molding resin and glass fibers, said outside of said skin being essentially devoid of glass fibers for a predetermined depth of at least 0.005 inch, said outer side of said skin defining a textured pattern simulating the grain and texture of a wood door, said textured pattern having a pattern depth between 0.003 inch and 0.009 inch, but not in excess of such predetermined depth.