A method of making a gasket track for a gasket is provided. A first section of a c-shaped channel comprising from 50% to 75% of the c-shaped channel of a first plastic material is formed. A second section of a c-shaped channel comprising from 25% to 50% of the c-shaped channel of a second plastic material is formed. The first section is joined together with the second section to form all of the c-shaped channel. The c-shaped channel has a circular cross section that forms at least 65% of an ellipse.

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

A method is disclosed for making an improved insulated door panel having an outer and inner spaced apart skins and an internal foam core. The insulated door panel includes a first spacer disposed between a top end of the outer skin and a top end of the inner skin and a second spacer disposed between a bottom end of the outer skin and a bottom end of the inner skin. The first and second spacers include first and second protrusions, respectively, on an inner face of the first and second spacers. The first and second protrusions secure the first and second spacers to the foam core.

The present invention is directed to an impact resistant door facing. The facing includes a rectangular sheet of molded hardened polymeric material having first and second opposing major surfaces. A mat having a continuous structure is integrally molded into the sheet. The mat is sufficiently porous to allow the polymeric material to permeate the mat prior to the polymeric material having hardened. The mat is disposed within the sheet so that at least one of the major surfaces is unbroken. The present invention also relates to a method of forming the disclosed door facing, and a door formed therewith.

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.

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 caustic-free polyurethane resin binds the separated unground rice hulls, the ground rice hulls and the rice hull powder together.

A device and method for checking an integrity of a glue joint that connects one portion of a body box and a body skin are provided. The body box and body skin connected by the glue joint define an inner volume therebetween. The method includes arranging at least one ultrasound sensing device in the inner volume; emitting a pressurized directional air jet opposite a predetermined area of the glue joint; recording a noise level detected by the ultrasound sensing device in the inner volume; and determining an integrity defect in the glue joint according to the recorded noise level.

Embodiments herein relate to fenestrations and components of the same exhibiting reduced thermal bowing and/or enhanced localized strength. In an embodiment, a fenestration assembly is included with a sash including a bottom rail, a top rail, a first side stile, and a second side stile, along with an insulating glazing unit, wherein the insulating glazing unit is disposed between the top rail and the bottom rail and between the first side stile and the second side stile. At least one of the rails or stiles includes a first lineal extrusion formed with a first composition including at least 5 wt. % fibers and a first polymer resin. At least one of the rails or stiles includes a second lineal extrusion formed with a second composition including a second polymer resin. Other embodiments are also included herein.

A method of manufacturing a door skin and a fuselage wall having a doorway and a member extending into the doorway for abutting the door includes placing a first sheet of uncured composite material on a mold plate to define the door and fuselage skin, disposing an insert over the first sheet overlapping a desired periphery of the door, placing a second sheet of uncured composite material on a peripheral portion of the insert and over the first sheet adjacent the peripheral portion of the insert to form the member, curing the sheets and bonding the sheets together adjacent the insert during the cure, removing the insert from between the sheets after cure, and separating the door skin from the wall skin after cure by moving a cutting tool through the first sheet and without penetrating the second sheet around the desired periphery of the door. An assembly for manufacturing the door skin and a fuselage wall is also discussed.

A closure member of a preferred configuration and the method of making the same. The closure member has a board with a major axis and two panels to sandwich a hollow interior that is partitioned by a plurality of ribs positioned at intervals within the hollow interior, the hollow interior is delimited in a first direction by a pair of opposite end walls. The hollow interior is accessible in a second direction which is substantially traverse to the first direction, and at least one of the two panels is textured during the formation of the board to form a textured outer surface of the closure member, or the hollow interior is filled with a preferred reinforcement means.