Patent ID: 6161363
Filing Date: 2000-12-19
Classification: E06B

Abstract:
A door frame having an inner panel and outer panel, each panel having a central essentially rectangular opening for a window, said door frame having side edges, a top edge, and bottom edge, said central opening having side edges, a top edge, and a bottom edge, all of said edges being integrally formed in said panels from which said edges extend from the panel, comprising:said outer edges forming a dam wall assembly surrounding the exterior periphery of the door and the central opening edges forming, with the outer edges, an essentially continuous pre-filling unblocked hollow inside of the door panels,all of said edges being formed as a unitary one piece molded circumambient extension from the panels,each of said edges engaging the opposed edge in foam blocking relationship,the edges of the door also serving as the dam wall assembly in the absence of secondary stiles, rails, or other independent elements inserted interiorly of the essentially continuous rectilinear dammed uninterrupted and unblocked hollow space interiorly of the door,a continuous pre-filling void for foam filling being defined by the circumambient side edges, top edge, and bottom edge for uninterrupted foam filling,and a foamed in place interior essentially filling the hollow space defined by the edges,whereby the finished door has a uniform and unitary uninterrupted foamed in place core to fill the hollow space, add to structural integrity, enhance the monocoque effect of the overall door structure, and adhere the inner and outer skin to each other without the use of secondary mechanical assembly steps in the formation and filling of the interior hollow space by blocking the escape of foam at the joints between the edges and permitting the foam access to the entire hollow space from any exterior location.