Rotationally molded door with integrally molded hinge member

摘要

A high impact resistant rotationally molded door and process for molding the door has the hinge post integrally attached to the rotationally molded skin of the door. A hinge member is provided that has a perforate U-shaped metal sheet bonded to preferably the upper portion of the hinge post. The sides of the U-shaped metal sheet are spaced sufficiently apart so that registration with the subsequently rotationally molded plastic skin of the door occurs. This hinge member at the perforate metal sheet rapidly heats during rotational molding. The perforate metal thus bonds to integrally mold with the skin of the door. This bonding occurs as the hinge post is molded within the hollow door construction along its hinging edge. The hinge member attaches at the perforate U-shaped metal sheet to the skin of the door while all other portions of the hinge post are free to move with respect to the door. The door is thus formed without door warping during curing and shrinking of rotationally molded plastic door body. Door warping is avoided. At the same time, when the door is in use, the perforate U-shaped metal sheet in its integral attachment to the rotationally molded skin of the door prevents dislodgment of the hinge post relative to the door.