Stackable molded articles, and related assemblies and methods

Patent metadata

Field	Value
Publication number	US-9752378-B2
Application number	US-201715397119-A
Country	US
Kind code	B2
Filing date	Jan 3, 2017
Priority date	Aug 7, 2014
Publication date	Sep 5, 2017
Grant date	Sep 5, 2017

Abstract

Molded articles are provided. An exemplary molded article includes an inner panel portion, a main body portion, and a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion. The contoured portion includes contoured corner segments and contoured intermediate segments extending between respective pairs of the contoured corner segments. The contoured intermediate segments have a first maximum thickness. The contoured corner segments have a second maximum thickness. The first maximum thickness of the contoured intermediate segments is greater than the second maximum thickness of the contoured corner segments. Related methods, assemblies, and apparatus are also provided.

First claim

What is claimed is:

1. A molded article, comprising:
an inner panel portion having a plurality of inner panel corners;
a main body portion; and
a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion, the contoured portion comprising contoured corner segments adjacent to the inner panel corners of the inner panel portion and contoured intermediate segments extending lengthwise between respective pairs of the contoured corner segments, the contoured intermediate segments having an exterior surface, an interior surface, and a first maximum thickness measured from the exterior surface of the contoured intermediate segments to a closest point on the interior surface of the contoured intermediate segments, the contoured corner segments having an exterior surface, an interior surface, and a second maximum thickness measured from the exterior surface of the contoured corner segments to a closest point on the interior surface of the contoured corner segments, wherein the first maximum thickness is greater than the second maximum thickness.

2. The molded article of claim 1 , wherein the molded article is a door skin.

3. The molded article of claim 1 , wherein the molded article is stackable with an identical molded article, one on another, in a stacked relationship in which the contoured intermediate segments of the stacked molded articles abut against one another to establish contact zones, and wherein the contoured corner segments of the stacked molded articles are spaced from one another to establish corner relief areas.

4. The molded article of claim 1 , wherein the molded article is stackable with an identical molded article, one on another, in a stacked relationship in which the difference in thickness between the first and second maximum thicknesses displaces a load of the upper stacked molded article on the lower stacked molded article from the contoured corner segments to the contoured intermediate segments so that the contoured intermediate segments bear a majority of the load.

5. The molded article of claim 1 , wherein the first maximum thickness is uniform along the entire lengths of the contoured intermediate segments, and wherein the second maximum thickness is uniform along the entire lengths of the contoured corner segments.

6. The molded article of claim 1 , wherein the contoured corner segments comprise two legs that are perpendicular to one another, and wherein the contoured intermediate segments extend linearly lengthwise between the respective pairs of the contoured corner segments.

7. A door comprising:
a frame having first and second sides; and
a door skin secured to the first side of the frame, the door skin comprising the molded article of claim 1 .

8. A molded article, comprising:
an inner panel portion having a plurality of inner panel corners;
a main body portion; and
a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion, the contoured portion comprising contoured corner segments adjacent to the inner panel corners of the inner panel portion and contoured intermediate segments extending lengthwise between and interconnecting respective pairs of the contoured corner segments, the contoured intermediate segments having a first maximum thickness, the contoured corner segments having a second maximum thickness,
wherein the first maximum thickness is greater than the second maximum thickness, and
wherein the molded article is stackable with an identical molded article, one on another, in a stacked relationship in which the difference in thickness between the first and second maximum thicknesses displaces a load of the upper stacked molded article on the lower stacked molded article from the contoured corner segments to the contoured intermediate segments so that the contoured intermediate segments bear a majority of the load.

9. The molded article of claim 8 , wherein the molded article is a door skin.

10. The molded article of claim 8 , wherein the molded article is stackable with the identical molded article, one on another, in a stacked relationship in which the contoured intermediate segments of the stacked molded articles abut against one another to establish contact zones, and wherein the contoured corner segments of the stacked molded articles are spaced from one another to establish corner relief areas.

11. The molded article of claim 8 , wherein the first maximum thickness is uniform along the entire lengths of the contoured intermediate segments, and wherein the second maximum thickness is uniform along the entire lengths of the contoured corner segments.

12. The molded article of claim 8 , wherein the contoured corner segments comprise two legs that are perpendicular to one another, and wherein the contoured intermediate segments extend linearly lengthwise between the respective pairs of the contoured corner segments.

13. A door comprising:
a frame having first and second sides; and
a door skin secured to the first side of the frame, the door skin comprising the molded article of claim 8 .

14. A molded article, comprising:
an inner panel portion having a plurality of inner panel corners;
a main body portion; and
a contoured portion extending between and interconnecting the inner panel portion and the main body portion so as to surround the inner panel portion and be surrounded by the main body portion, the contoured portion comprising contoured corner segments adjacent to the inner panel corners of the inner panel portion and contoured intermediate segments extending in a lengthwise direction between and interconnecting respective pairs of the contoured corner segments, the contoured intermediate segments having a first maximum thickness, the contoured corner segments having a second maximum thickness,
wherein the first maximum thickness is greater than the second maximum thickness, and
wherein the first maximum thickness is uniform along the entire lengths of the contoured intermediate segments, and the second maximum thickness is uniform along the entire lengths of the contoured corner segments.

15. The molded article of claim 14 , wherein:
the contoured intermediate segments have an exterior surface, an interior surface, and the first maximum thickness measured from the exterior surface of the contoured intermediate segments to a closest point on the interior surface of the contoured intermediate segments; and
the contoured corner segments have an exterior surface, an interior surface, and the second maximum thickness measured from the exterior surface of the contoured corner segments to a closest point on the interior surface of the contoured corner segments.

16. The molded article of claim 14 , wherein the molded article is a door skin.

17. The molded article of claim 14 , wherein the molded article is stackable with an identical molded article, one on another, in a stacked relationship in which the contoured intermediate segments of the stacked molded articles abut against one another to establish contact zones, and wherein the contoured corner segments of the stacked molded articles are spaced from one another to establish corner relief areas.

18. The molded article of claim 14 , wherein the molded article is stackable with an identical molded article, one on another, in a stacked relationship in which the difference in thickness between the

Assignees

• Masonite Corp

Inventors

• Gouge Timothy D
• Allen Robert C
• Hill Allen R

Classifications

• B27N3/04

  from fibres · CPC title

• E06B3/78 Primary

  with panels of plastics {(E06B3/721 - E06B3/725 take precedence)} · CPC title

• B27N3/00

  Manufacture of substantially flat articles, e.g. boards, from particles or fibres · CPC title

• B27N7/005

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

• B27N3/20 Primary

  characterised by using platen-presses · CPC title