Method of manufacturing a molded door skin from a flat wood composite, door skin produced therefrom, and door manufactured therewith

摘要

A method of manufacturing a hollow core door is disclosed, as well as a corresponding hollow core door. The method includes the steps of providing a solid flat door skin, moisturizing the flat skin, applying a conditioning resin thereto, pre-heating the flat door skin, and thereafter pressing the flat door skin between a pair of heated platens in a press in order to reform the flat skin into a molded skin including a plurality of panels defined therein. The press continuously closes in order to reform the flat skin into the molded skin, with the rate of press closure being a function of the determined hardness of the flat skin to be reformed. The resulting door skins have an improved bond strength, and are efficiently manufactured.

主权项

1. A molded door skin comprising:
a first planar portion, a second planar portion, and an angled offset portion extending between and integrally connecting said first and second planar portions, wherein said angled offset portion has a first thickness, said first and second planar portions have a second thickness, and said first thickness is less than said second thickness, and wherein said molded door skin is formed of wood composite comprising a thermosetting resin and has a bond strength of at least 2.0 N/mm2.