Disclosed is a cover for a utility vault and a method for making such covers. The cover is formed from fiberglass reinforcement layers, a low-density core, and a polymer mix matrix. The reinforcement layers include a bottom reinforcement layer, one or more edge reinforcement layers, and a top reinforcement layer. A first portion of the edge reinforcement layer overlaps a portion of the bottom reinforcement layer and a second portion of the edge reinforcement layer overlaps a portion of the top reinforcement layer. The core is positioned between the top and bottom reinforcement layers. The reinforcement layers are formed from fiberglass fabric and may include fiberglass layers whose fibers are oriented quadraxially. The polymer mix impregnates the fabric layers, encases the core, and binds the components together. The polymer matrix includes a thermoset polymer resin.

A composite sandwich panel includes a first composite part and a second composite part. A plurality of stiffeners extend between the first and second composite parts. A fiberglass composite perimeter edge closeout is positioned along one or more edges of the first and second composite parts. The fiberglass composite perimeter edge closeout controls a magnetic flux to bond the first and second composite parts to the plurality of stiffeners.

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.

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 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.

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.

Disclosed is a cover for a utility vault and a method for making such covers. The cover is formed from fiberglass reinforcement layers, a low-density core, and a polymer mix matrix. The reinforcement layers include a bottom reinforcement layer, one or more edge reinforcement layers, and a top reinforcement layer. A first portion of the edge reinforcement layer overlaps a portion of the bottom reinforcement layer and a second portion of the edge reinforcement layer overlaps a portion of the top reinforcement layer. The core is positioned between the top and bottom reinforcement layers. The reinforcement layers are formed from fiberglass fabric and may include fiberglass layers whose fibers are oriented quadraxially. The polymer mix impregnates the fabric layers, encases the core, and binds the components together. The polymer matrix includes a thermoset polymer resin.

A core for a fire rated door includes a fire resistant center panel and an extruded fire resistant border. The fire resistant center panel has a bottom, a top, a first side, a second side, a first end and a second end. The fire resistant center panel is made of a first fire resistant material. The extruded fire resistant border is attached to the first side, the second side, the first end and the second end of the fire resistant center panel. The extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material.

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.