Patent ID: 8845847
Filing Date: 2014-09-30
Classification: B29C,B32B,C08G,C09J,E06B

Abstract:
1. An accelerated low toxicity method of making an assembled composite door, comprising: a. forming a door frame; b. installing a processed polyurethane foam block within the door frame without using a liquid resin that produces volatile organic compounds (VOC) forming a door frame assembly; c. applying a first thin coating of 1 milliliter to 4 milliliters of a rapid curing water initiated adhesive curable in less than 8 minutes at ambient temperature to a front side of the door frame assembly, wherein the rapid curing water initiated adhesive consists of 10 weight percent to 20 weight percent of an isocyanate and 1 weight percent to 4 weight percent of an alkylating agent and simultaneously applying a second thin coating of 1 milliliter to 4 milliliters of the rapid curing water initiated adhesive to a back side of the door frame assembly; d. misting the rapid curing water initiated adhesive with water within 5 seconds to 5 minutes of applying the rapid curing water initiated adhesive; e. placing the door frame assembly on a back skin within 10 seconds to 3 minutes of misting the rapid curing water initiated adhesive, wherein the misted rapid curing water initiated adhesive on the door frame assembly contacts the back skin, while overlaying a front skin on the misted rapid curing water initiated adhesive of the door frame assembly opposite the back skin, forming a door assemblage; and f. inserting the door assemblage into a low pressure press and applying a temperature from 50 degrees Fahrenheit to 250 degrees Fahrenheit to the door assemblage by the low pressure press while applying a pressure of 2 psi to 80 psi forming a low toxicity assembled composite door in less than 180 minutes without producing additional volatile organic compounds.