A multi-sheet component for a utility vehicle that includes at least one gap between at least two of the sheets, thereby providing a component that enhances worker safety by increasing component stiffness and reducing component thickness. The component is manufactured through multi-sheet thermoforming and uses a conical frustum corrugation to increase stiffness.

Systems and methods for pressing a door assembly involve one or more die sections installed in a press, wherein the die sections each have a raised section that contacts and supports a recessed panel portion of a door skin of the assembly during the pressing operation to facilitate crushing of portions of a core of the door assembly that underlie the recessed panel portion of the door skin. The die sections may be made of plastic and readily changed out for different sizes or styles of doors.

A microwave heating system includes: a variable-frequency microwave source having a usable bandwidth about a center frequency; a waveguide with an input side connected to the source and an output side terminating in a launch structure; and, a metallic reflector plate facing the launch structure and perpendicular thereto and spaced therefrom at a distance of no more than twice the microwave wavelength at an operative frequency of the microwave source, the reflector plate including a recessed area of a selected size and shape located facing the launch structure so that a material to be treated may be placed between the launch structure and the recessed area for exposure to microwave energy. A related method is also disclosed.

Modular components of modular door lite frame systems are disclosed. In some cases, a modular door lite frame system includes matching first and second modular frames, one or more modular male alignment members, and one or more modular female alignment members. In some cases, the modular alignment members can be coupled to modular frames of various sizes. In some cases, the modular components can be formed by casting ABS between no more than two opposed mold portions.

A recyclable polyethylene man-door comprises an interior panel and an exterior door panel, each panel having a horizontal pattern of cut-outs and optionally comprising a blend of mineral additives that do not adversely affect the recyclability of the finished product.

A three-dimensional vacuum thermal insulation element having a compressed three-dimensional porous structure and a shell closed in an airtight manner. The shell includes a thermoformable barrier wall and encloses the porous structure arranged between two major surfaces of said barrier wall. The porous structure has a pressure of between less than 105 Pa and more than 10-2 Pa at ambient external temperature and pressure. The barrier wall is thermoformed at the site of said two major surfaces, between which the porous structure has a curved shape and/or reliefs and/or depressions.

A three-dimensional, vacuum thermal insulating element comprising a compressed three-dimensional porous structure, an envelope closed in an airtight manner comprising a thermoformable barrier wall, enclosing the porous structure, which is interposed between two major surfaces of the barrier wall, and where, at outside ambient temperature and pressure, a pressure between less than 10.sup.5 Pa and more than 10.sup.−2 Pa prevails. The barrier wall is thermoformed at said the two major surfaces, between which the porous structure is bent-shaped and/or has reliefs and/or depressions.

The subject of the invention relates to a laminating method consisting: in disposing in series on the horizontal path of a first face of the part, several first application units (Ua1, Ua2, . . . ) and in series on the horizontal path of the second face of the part, several second application units (Ub1, Ub2, . . . ) each positioned facing a first application unit located on the first face; in placing the first application units (Ua1, Ua2, . . . ) and the second application units (Ub1, Ub2, . . . ) in different vertical positions such that the combined application with overlapping of the protective films on each of the faces of the part corresponds to the height to be covered by the films; in applying, using the first application units and the second application units, the protective films respectively to the first face and to the second face of the part, starting from the front border of the surface to be covered; and in successively cutting out as a function of the horizontal path of the part the protective films at the level of the rear border of the surface.

The present invention is directed to a door facing blank having a first major surface with a design element formed therein, and an opposite second major surface. At least three longitudinally extending spaced stile receiving areas are disposed on the second major surface. Two of the stile receiving areas define a first width, and three of the stile receiving areas define a second width greater than the first width. The door facing blank may be trimmed to form a door facing having a selected width. A method of forming a door facing blank, and a mold press for forming a door facing blank are also disclosed.