Patent ID: 6398995
Filing Date: 2002-06-04
Classification: B29C

Abstract:
A process of molding a high impact resistant door comprising the steps of:providing a mold having an interior for defining a hollow rotationally molded six sided door including; a front door surface; a rear door surface; a top door edge; a bottom door edge; a hinge door edge; and, an opening door edge; said surfaces and edges of said provided mold forming an integral hollow cavity in the interior of said door, providing an elongate hinge member for placement into said mold; providing a U-shaped perforate metal member having opposite side edges of the U spaced a sufficient distance apart to enable each respective opposite side edge to embed in a skin of the rotationally molded door, integrally attaching the U-shaped perforate metal member to the elongate hinge member; placing the elongate hinge member into said mold extending along said hinge door edge within said integral hollow cavity of said door with the U-shaped perforate metal member having the respective opposite side edges disposed adjacent to the front door surface and rear door surface; placing plastic in said mold and rotationally molding said plastic to the interior of said mold to form a hollow plastic door having said front surface, said rear surface, said top door edge, said bottom door edge, said hinge door edge, and said opening door edge with upper and lower hinge member cavities defined in said door; and, embedding the opposite side edges of the perforate U-shaped metal member in the skin of the rotationally molded door during the rotational molding.