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.

Composite door systems are provided for use in a protective barrier structure. The composite door systems provide for quick assembly, safety, security, and resistance to physical impacts or threats. The composite door systems may include a shell and a core that can be factory completed or finished on site. The shell may be shipped to the assembly location of the barrier structure, and the core may be formed on site by pouring liquid fill material into a cavity of the shell, which is allowed to cure into a solid fill material. Hardware housings may be operatively coupled to the shell that are made to receive door hardware but resist the liquid full material from filling the hardware housings. The shell, core, and/or hardware housings may provide resistance to damage, such as projectiles to provide enhanced security protection to the occupants or contents of the building structure.

The present invention relates to a door skin comprising an exterior surface having outer portions lying on a first plane, spaced grooves recessed from the plane of the outer portions, and tonal portions having a planar area and a plurality of spaced depressions recessed from the plane of said planar area. The present invention is also directed to a method of etching a plate, for use with a molded die set, for embossing a wood grain pattern in the door skin, and the etched plate formed therefrom.

The present invention relates to a door skin comprising an exterior surface having outer portions lying on a first plane, spaced grooves recessed from the plane of the outer portions, and tonal portions having a planar area and a plurality of spaced depressions recessed from the plane of said planar area. The present invention is also directed to a method of etching a plate, for use with a molded die set, for embossing a wood grain pattern in the door skin, and the etched plate formed therefrom.

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.

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.

A door assembly can include a core layer, a backing layer, and a faade layer. The core layer can define a faade side and a back side opposite the faade side. The core layer can include a rail and a plurality of stiles coupled to the rail. The backing layer can be adhered to the back side of the core layer. The faade layer can be adhered to the faade side of the core layer. The faade layer can include a plurality of frame segments defining an outer surface comprised of polymer and the plurality of frame segments defining a mating surface adhered to the faade side of the core layer.

A door assembly can include a core layer, a backing layer, and a faade layer. The core layer can define a faade side and a back side opposite the faade side. The core layer can include a rail and a plurality of stiles coupled to the rail. The backing layer can be adhered to the back side of the core layer. The faade layer can be adhered to the faade side of the core layer. The faade layer can include a plurality of frame segments defining an outer surface comprised of polymer and the plurality of frame segments defining a mating surface adhered to the faade side of the core layer.

A method of making a door involves providing a first door facing including a first raised region and a first panel recessed from the first raised region by a first dimension, and securing a first core insert having a thickness equal to the first dimension to the first raised region. A second door facing including a second raised region and a second panel recessed from the second raised region by a second dimension is provided. A second core insert having a thickness equal to the second dimension is secured to the second raised region. A central core component is secured to the first panel and the first core insert after the first core insert has been secured to the first raised region. The second panel and the second core insert are secured to the central core component after the second core insert has been secured to the second raised region.

A method of making a door involves providing a first door facing including a first raised region and a first panel recessed from the first raised region by a first dimension, and securing a first core insert having a thickness equal to the first dimension to the first raised region. A second door facing including a second raised region and a second panel recessed from the second raised region by a second dimension is provided. A second core insert having a thickness equal to the second dimension is secured to the second raised region. A central core component is secured to the first panel and the first core insert after the first core insert has been secured to the first raised region. The second panel and the second core insert are secured to the central core component after the second core insert has been secured to the second raised region.