ARCHITECTURAL INTERIOR DOOR CONSTRUCTION

Abstract

A door comprising a molded core formed of a rigid foam material, having rigid reinforcing inserts affixed to the molded core.

Claims

1. A frameless molded door formed of a polyisocyanurate/polyurethane rigid foam material, having in situ molded reinforcing inserts incorporated into the frameless molded door, wherein the frameless molded door is coated with a protective coating.

2. The frameless molded door of claim 1, wherein the in situ molded reinforcing inserts are configured to accommodate hinges attached via screws.

3. The frameless molded door of claim 1, wherein the in situ molded reinforcing inserts are configured to accommodate a door handle and/or door lock.

4. The frameless molded door of claim 1, wherein the in situ molded reinforcing inserts are configured to accommodate hanging rollers or a kick plate.

5. The frameless molded door of claim 1, wherein the frameless molded door is contoured to accommodate an external rigid stile or rail.

6. The frameless molded door of claim 1, wherein the protective coating comprises a paint.

7-11. (canceled)

12. The frameless molded door of claim 1, wherein the protective coating comprises a polyaspartic or an epoxy.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Further features and advantages of the present invention will be seen from the following detailed description, taken in conjunction with the accompanying drawings, wherein lines numerals depict like parts, and wherein:

[0022] FIG. 1 is a perspective view of a door formed in accordance with a first embodiment of the present invention;

[0023] FIG. 1A and FIG. 1B are enlarged perspective views of examples of rigid/semi-rigid insert elements of the door of FIG. 1;

[0024] FIG. 2 is a flow diagram of a manufacturing process for forming the door of FIG. 1;

[0025] FIG. 3 is a perspective view of a door in accordance with a second embodiment of the present invention;

[0026] FIG. 4 is a perspective view of still yet another embodiment of the present invention; and

[0027] FIG. 5 is a perspective view of a door made in accordance with yet another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0028] As used herein the term core is intended to include the entirety of the rigid foam portion of the door excluding the inserts or rigid externally attached hardware.

[0029] Referring to FIG. 1, there is illustrated a door 10 comprising a solid rectangularly shaped foam door comprising a main core 12. Core 12, which makes up the bulk of the door, is formed of a rigid foam material such as polyisocyanurate/polyurethane foam and may be textured or shaped 11. Door 10 includes rigid/semi-rigid inserts 14 on hinge edge 16 of the door, and a handle accommodating insert 18 on the handle edge 20 of the door. Inserts 14 and 18 are formed of a structural material such as wood, metal or more preferably rigid/semi-rigid plastic material having sufficient structural strength to securely hold screws to fix hinges (not shown) to the hinge side of the door, and in the case of insert 18, contains a hole 19 to accommodate a door handle and/or lock mechanism.

[0030] Referring to FIG. 2, door 10 is formed as follows:

[0031] A mold 20 is provided in a first step 22.

[0032] Reinforcing inserts 14 and 18 are placed in position in mold 20 in step 24. Polyhydroxy alcohol and diisocyanate components are premixed in a mixing step 26 and poured into mold 20 in a mold filling step 28, the mold may be closed in a step 30, and the mixture allowed to foam and cure. The cured rigid foam with incorporated inserts is then removed from the mold in step 32, and a door formed primarily of polyisocyanurate/polyurethane foam, and having reinforcing inserts 14 and 18 molded in situ results. The door is then coated with a durable coating such as a polyaspartic or epoxy to provide protection, washability, durability, and color at a coating step 34.

[0033] Referring to FIG. 3 there is illustrated another embodiment of the invention. In the FIG. 3 embodiment, a rigid foam door 40 comprises a main core 42. Main core 42 formed with a tongue or tang 44 running a length of a hinge side 46 of the door. A rigid stile 48 formed of wood, metal or a rigid plastic material is fixed over tongue or tang 44 by gluing in place. Alternatively, door 40 may be formed with rigid reinforcing stile 48 molded in situ following the process of FIG. 2.

[0034] FIG. 4 illustrates another embodiment, in which the top of door 50 is provided with a rigid reinforcing rail 52 formed of a wood, metal or a rigid plastic. As in the case of the FIG. embodiment, the reinforcing rail 52 may be glued to the main core or molded in situ or fastened by screwing into inserts in the rigid foam core. Door 50 is designed for hanging as a rolling door. Rollers 54 or a closure fixture may then be fixed to the door through the rigid rail at the top of the door.

[0035] Referring to FIG. 5 in yet another embodiment, door 60 is formed of a polyisocyanurate/polyurethane foam forming a main core 62 and having a rigid kick plate 64 formed on the bottom of the door. Kick plate 64 may be formed of a rigid plastic material, metal, or wood, and fixed to the main body of the door as described above relative to FIGS. 3 and 4.

[0036] A feature and advantage of the present invention is that the polyisocyanurate foam used for forming the main section of the door has a solid heavy door feel yet is remarkably lightweight for ease of handling and installation. Another feature is that the door may be formed with intricate surface patterns which are formed during the molding process.

[0037] The above depiction represents, but is not meant to be limited to, an example of a molded rigid foam door with inserts strategically placed to accept traditional screwed hardware.

[0038] Further, the molded door can be contoured to fit into an external wood-free stile designed for attachment of hinges or an external wood-free rail designed for attachment of hardware for sliding or folding doors.

[0039] The above depiction represents, but is not limited to, an example of a rigid foam door with an external wood-free stile or rail.

[0040] Various changes may be made without departing from the spirit and scope of the invention. For example, a rigid insert 70 may be molded into a top of door 10, for affixing a door closure 72. Still other changes are possible.

[0041] Although this type of rigid foam possesses enough structural integrity to produce a solid feel door, the door may still be prone to denting more easily than a standard door formed of fiberglass or Masonite skins. As a further embodiment of this invention a durable coating is applied over the surface of the rigid foam to provide such protection and durability.