Method of sealing a porous fibrous substrate, and door skins, produced by the method

Patent metadata

Field	Value
Publication number	US-10035282-B2
Application number	US-201313828614-A
Country	US
Kind code	B2
Filing date	Mar 14, 2013
Priority date	Aug 28, 2006
Publication date	Jul 31, 2018
Grant date	Jul 31, 2018

Abstract

A method of surface sealing a porous fibrous substrate is provided. According to the method, a porous fibrous substrate possessing a moisture content and a surface with pores is provided. A sealant composition is applied to a surface of the porous fibrous substrate and permitted to penetrate the surface pores of the porous fibrous substrate and undergo cure while participating in a foaming reaction with the moisture content to establish a water-resistant polymeric foam sealant impregnated into the porous fibrous substrate. The water-resistant polymeric foam sealant contains a polyurethane and/or polyurea.

First claim

What is claimed is:

1. A door, comprising:
a door frame having a first frame side and an opposite second frame side;
a first door skin comprising a porous fibrous substrate having an exterior surface possessing surface pores and an interior surface, the first door skin being attached to the first frame side;
a water-resistant polymeric foam sealant comprising a member selected from the group consisting of a polyurethane and polyurea impregnated in the surface pores of the porous fibrous substrate; and
a second door skin attached to the second frame side.

2. The door of claim 1 , wherein the water-resistant polymeric foam sealant is prepared from a sealant composition comprising a two-part polyurethane composition comprising a first part containing a polyol, and a second part containing a polyisocyanate.

3. The door of claim 1 , wherein the water-resistant polymeric foam sealant is prepared from a sealant composition comprising a two-part polyurea composition comprising a first part containing a polyamine, and a second part containing a polyisocyanate.

4. The door of claim 1 , wherein the water-resistant polymeric foam sealant is present in an amount of about 3 grams to about 4.5 grams per square foot of porous fibrous door skin.

5. The door of claim 1 , wherein the porous fibrous substrate possesses a mean pore size of about 1 micron to about 300 microns.

6. The door of claim 1 , wherein the porous fibrous substrate comprises a cellulosic fiber and phenolic resin.

7. The door of claim 1 , wherein the water-resistant polymeric foam sealant penetrates about 50 to about 75 microns below the exterior surface of the porous fibrous substrate.

8. The door of claim 1 , wherein the porous fibrous substrate comprises medium density fiberboard.

Assignees

• Masonite Corp

Inventors

• Pfau James
• Hart Stephen

Classifications

• B27N7/005

  Coating boards, e.g. with a finishing or decorating layer · CPC title

• E06B3/72

  consisting of frame and panels {, e.g. of raised panel type (E06B3/7001 - E06B3/7015 and E06B3/82 take precedence)} · CPC title

• B27N1/006 Primary

  for increasing resistance to swelling by humidity · CPC title

• B29C44/1209

  by impregnating a preformed part, e.g. a porous lining · CPC title

• Y10T428/249958

  Void-containing component is synthetic resin or natural rubbers · CPC title