POWDER COATED METAL DOOR WITH CORE

Abstract

A metal door and the method of making a metal door having powder coated, front and back skins, powder coated hinge and lock channels powder coated top and bottom channel and a core positioned within the door assembly.

Claims

1. A method of making a metal core door comprising: providing a core; providing door parts including an exterior skin, an interior skin and channels; powder coating said door parts and curing said powder coated parts; thereafter assembling said door parts about said core to create a pre-assembled door with an interior core.

2. A method of making a metal core door comprising: providing a core; providing door parts including an exterior skin, an interior skin and channels; powder coating said door parts and curing said powder coated parts; whereby said door parts are powder coated and can be assembled about said core to create a powder coated door with an interior core.

3. A metal door comprising; a door assembly including; powder coated, front and back skins; powder coated hinge and lock channels; powder coated top and bottom channels; a core positioned within said door assembly.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a perspective view of the interior of the powder coated door of the present invention.

[0014] FIG. 2 is a perspective view of the exterior of the powder coated door of the present invention.

[0015] FIG. 3 is an exploded view of the powder coated door of the present invention.

[0016] FIG. 4 is a schematic view of the method of making the powder coated door of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0017] The door of the present invention is shown generally at 10 in the drawings. The door has an exterior side or skin 12 and interior side or skin 14 and is mounted in a frame 16. The door 10 illustrated is only an example of a door that can form a part of the present invention. It should be appreciated that other door styles, such as doors with windows, vents, and double doors could be part of the present invention.

[0018] The door 10 is a powder coated door with a core. The parts of the door 10 are powder coated and after the powder coating is complete, the door 10 is assembled for use. In this way, the hollow door 10 with a desired core type 18 can be powder coated on the inside and outside to reduce or prevent corrosion. Additionally, the frame and other components of the door and door assembly can be powder coated to prevent corrosion.

[0019] With reference to FIG. 3, a typical hollow door 10 is illustrated. The door 10 includes an exterior skin 12 and an interior door skin 14. The skins 12 and 14 are made of metal. The skins 12 and 14 are connected by a top channel 20, a bottom channel 22, a hinge channel 24 and a lock channel 26, which are disclosed at metal parts. The channels 20, 22, 24 and 26 are connected to the skins 12 and 14 by typical connections known to those of ordinary skill in the art. The core 18 is mounted within the hollow door 10. The core 18 can be one of any desired core material.

[0020] The door 10 is powder coated prior to assembly. The parts of the door 10, the skins 12 and 14, and channels 20, 22, 24 and 26 are powder coated, and in the preferred embodiment powder coated on all surfaces. Still further, if desired, the frame 16 can be powder coated.

[0021] Powder coating is a dry finishing process that provides a high-quality, durable finish. It can be used as a functional (protective) and decorative finish. Powder coatings are based on polymer resin systems, combined with curatives, pigments, leveling agents, flow modifiers, and other additives, which are well known to those of ordinary skill in the art. These ingredients are melt-mixed, cooled, and ground into a uniform powder. A process called electrostatic spray deposition (HD) is typically used to achieve the application of the powder coating to the metal substrate, i.e., the parts of the door 10 and if desired the frame 16.

[0022] With reference to FIG. 4, the application method first includes the step of cleaning the door 10 parts at step 30. At step 32, a spray gun applies an electrostatic charge to the powder particles, which are then sprayed on the grounded parts 10 in step 34. Alternatively, the powder coating can be applied using a fluidized bed application. Preheated parts are dipped in a hopper of fluidizing powder and the coating melts and flows onto the part.

[0023] At step 36, after application of the powder coating in step 34, the parts enter a curing oven at 350-400 degrees F. This allows the electrostatically charged powder to adhere to the part. After getting up to temperature, the part is left in the oven for the cure time specified by the powder manufacturer. With the addition of heat, the coating chemically reacts to produce long molecular chains, resulting in high cross-link density. These molecular chains are very resistant to breakdown.

[0024] It will be understood by those of ordinary skill in the art that other types of powder coating are available and would be within the scope of the present invention.

[0025] After the parts of the door 10 are cured they are assembled about the desired core in step 38 creating a pre-assembled powder coated door 10.

[0026] Powder coating provides a more durable finish than liquid paints can offer, while still providing an attractive finish. Powder coated products are more resistant to diminished coating quality because of impact, moisture, chemicals, ultraviolet light, and other extreme weather conditions. In turn, this reduces the risk of scratches, chipping, abrasions, corrosion, fading, and other wear issues.

[0027] The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and do come within the scope of the invention. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims.