Note: Descriptions are shown in the official language in which they were submitted.
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DOOR HAVING DEPRESSED SURFACE PORTIONS ~
. ~
BACKGROUND OF THE INVENTION
The pres~nt lnv~ntion relates to a door formed with a
rigid fram~ and with two skins being molded to prov~de the
door with decorative patterns.
My U.S. Patent No. 5,003,745, issued April 2, 1991,
discloses a door consisting of a solid board having
opposed depressed portions in major opposed side walls a~d
two moldable sheets made of P.V.C. or A.B.S. respectively
attached to the major side walls of the solid board and
having depressed portions, which are embossed with decorative
patterns, to be fitted in the depressed portions of the
solid board. The solid board is usually 3' x 7' x 2~ in sizP
and heavy in weight rendering difficultias in machining Of
the depressed portions.
SUMMARY OF THE INVENTION
An object of the present invention is therefore to
provide an improved door in which the door can be provided
very easily with a great variety of decorative patterns, and
in which the assembling of the door requires only a few
operations.
It is another object of the present invention to
provide an improved door which needs no foam material for
filling into empty spaces between opposed door skins to
maintain an essential rigidity of the door.
- 25 It is a further object of the present invention to
provide an improved door with concave major surfaces for
securing designs or patterns shaped therein from being
fractured.
It is yet a further object of the present invention to
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provide an improved door which is light in weight and formed
with concave major surfaces for labour and space savings in
packaging.
According to the present invention, there is provided
a door which comprisss a door frame made of a rigid material,
a first skin made of a modable material and shaped with
depressed decorative patterns, a first backing sheet prefer-
ably of a plywood sheet attached to a bottom side of the
first skin and formed with cut-away portions for firmly
receiving the depressed decorative patt~rns and mounted on
the door frame, a second skin also made of a moldable mater-
- ial and shaped with dscorative patterns and a second backing
sheet attached to a bottom side of the second skin and
formed with cut-away portions for firmly receiving the
depressed decorative patterns and mounted on the door frame.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with my claim parti-
cularly pointing out and distinctly claiming the subject
matter which is regarded as the present invention, it is
believed that the invention will be better understood from
the following description taken in connection with the
accompaning drawings in which:
FIG. 1 is a perspective view showing a preferred embodiment
of the present invention:
FIG. 2 is a perspective exploded view showing the different
non-assembled parts of the embodiment shown in FIG. l; and
FIG. 3 is a cross-sectional view showing a vacuum forming
process of a moldable or thermalplastic sheet.
,
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FIG. 4 is a p~rspective view showing the backing she~t
formed with cut-away portions and its cut-down parts.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrat~d on FIG. 1, the door 1 according to the
present invPntion includes a rigid and sturdy fram8 20 which
can be advantag~ously made of light wood, a first skin 10
shaped with dPpressed decorative patterns 101 and mounted on
the frame 20, and a second skin 30 also shaped with depressed
decorative patterns (not shown) and mounted on the frame 20.
Referring now to FIG. 2, plywood or backing sheets
102, 302 ar~ provided for respectivPly backing the first and
second skins 10, 30. Each of the plywood sheets 102, 302 is
substantially of the same size as the skins 10, 30 and
formed with cut-away portions 103, or 303.
The plywood sheet or backing sheet 102, as best shown
in FIG. 4, can advantageously be machined by punch with a
pre-arranged mold or blade to cut off cut-down parts 104 so
that the cut-away portions 103 is located in the plywood
sheet 102. The cut-away portions 103 of the plywood sheet
102 generally corresponds with the depressed decorative
patterns 101 in the first skin 10 for firmly receiving the
depressed decorative patterns 101 when the plywood sheet 102
is attached to bottom of the first skin 10 in manners with
contact glue. The depressed decorative patterns 101 in the
first skin 10 can maintain a very clear and original contour
under protection of corresponding cut-away portions 103 in
the plywood sheet 102 from fracturing.
The skins 10, 30 can advantageously be shaped by
J vacuum forming to provid8 the corresponding faces of the
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door with decorative patterns. Referring to FIG. 3, as it is
well known, in such a vacuum forming proc~ss, a moldable
~ sheet constituting the skin 10 is supported over a mold
between a male die 11 and a female die 12 in a sealed condi-
tion. Heat is applied to the moldable sheet 10 to a tempera-
ture at which it can be reshaped. The male die 11 is provided
with a plurality of passages 110 extending downwardly to
connect an air conduit 13 which is connected to a vacuum
pump (not shown) to establish a vacuum between the mold and
the sheet 10 that will pull in the soften d sheet 10 to the
mold contour where it hardens to the desired shape.
The plywood sheet 102 has a shape adapting with the
shape of the door frame 20 for mounting thereto with the
skin 10 forming one of the two faces of the door 1. In
alternative, the plywood sheet 102 can be dimensioned to be
accommodated within the door frame 20 so that the skin 10
can be directly mounted on the door frame 20. The second
skin 30 is identical with the first skin 10 in processing to
form the other one of the two faces of the door 1. Under
serial tests, the thickness range of each plywood sheet is
preferably between a quarter to a half inch so as to maintain
sufficient rigidity of the door 1.
A door as described with reference to FIGS. 1, 2 and 4
of the drawings have the following advantages over the
conventional doors as described in the preamble of the
present disclosure:
A) The skins 10, 30 backing with respective plywood
sheets 102, 302 render sufficient rigidity of the door 1.
Therefore, no stuffing, such as styrofoam and polyurethane
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foam, is necessary to be filled or injected into spaces
between the skins 10, 30;
B) The depressed decorative patterns of the skins 10,
30 are firmly received in corresponding cut-away portions in
the plywood sheets and thus protected from fracturing to
maintain a clear and original contour;
- C) The decorative patterns of the skin are depressed
below a level with its surface so that there is no disturba-
nce between stacked doors in package;
D) Such a door is generally light in weight and easy
and space saving in package; and
E) The materials, namely high impact polystyrenP,
P.V.C. and/or A.B.S., forming the skins 10, 30 provide to
the door of the invention a durable, scuff and scratch
resistant, and maintenance free elegant finish.
