A method of forming a composite product is described. An example of the method comprises providing a layer (34) comprising a sheet-form moulding material and providing a substrate (36). The layer of sheet-form material is applied onto a surface of the substrate (36); and pressed to the substrate in a mould (30). In some examples, the substrate (36) is an open celled foam and gas and/or vapour can be displaced from the pressing region.

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.

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 door panel manufacturing process is provided by constructing a high load conveyor line capable of controlling speed and duration, subsequently placing a finished door panel mold on the high load conveyor line. The conveyor line can be used to control a shifting speed and duration, and a de-molding agent can be sprayed inside the door panel mold, followed by spraying a high-density foam resin to form a shell. The door panel mold further has a framework or a reinforcement member mounted therein, and a low-density foam resin is injected; after the foam resin is formed and cooled, the door panel made of foam resin is completed. The process solve issues of high defective rate and insufficient surface strength associated with the conventional foam door panel, and is capable of significantly reducing the electricity required as well as reducing logging of woods, thereby realizing environmental protection.

The present application provides an apparatus and a method of welding a fabric material to a frame including for removable use in a door opening or a window opening. The method includes receiving the frame having an outer edge defining an interior space at a work surface. The fabric material is then extended across the frame, so that the fabric material to be welded to the frame rests on top and covers the interior space of the frame received at the work surface. An activated welding head is then moved across the work surface and the received frame, wherein the activated welding head is moved so as to trace proximate the frame along the outer edge of the frame, thereby adhering the fabric material to the frame at the outer edge.

The process for the manufacture of windows/doors (1), characterized by the fact that it comprises the following steps: providing at least one inner panel (2) for windows/doors; providing a plurality of plastic profiled elements (3) for windows/doors, each of the profiled elements (3) comprising at least two areas to seal (5), coupleable to the areas to seal (5) of the other profiled elements (3), and at least one longitudinal slot (6), in which a respective perimeter side (4) of the inner panel (2) is insertable; performing a step of mechanical machining by chip removal on at least one of the areas to seal (5); heating the areas to seal (5); coupling the heated areas to seal (5) to one another by pressing the profiled elements (3) one against the other to maintain the areas to seal (5) in mutual contact and define the frame for windows/doors, the coupling taking place with the inner panel (2) inserted in the longitudinal slots (6) to define a window/door (1) which is composed by the frame and by the inner panel (2) contained in the frame.

Provided are a structure and a method of forming a structure that includes a core made, at least in part, of a rice hull composition. The rice hull composition including a combination of separate, unground rice hulls; ground rice hulls; and a rice hull powder, that each have a different particle size. A polymeric binder, such as a recycled plastic polymeric binder binds the separated unground rice hulls, the ground rice hulls and the rice hull powder together.

A fire rated door includes a core, a first decorative panel and a second decorative panel. The core includes: (a) a gypsum-based fire resistant center panel having a bottom, a top, a first side, a second side, a first end and a second end, wherein the gypsum-based fire resistant center panel is made of a first gypsum-based fire resistant material, and (b) an extruded gypsum-based fire resistant border attached to the first side, the second side, the first end and the second end of the gypsum-based fire resistant center panel, wherein the extruded gypsum-based fire resistant border is made of a second gypsum-based fire resistant material having a higher density than the first gypsum-based fire resistant material. The first decorative panel is attached to the top of the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border. The second decorative panel is attached to the bottom of the gypsum-based fire resistant center panel and the extruded gypsum-based fire resistant border.