Patent ID: 8418427
Filing Date: 2013-04-16
Classification: E06B,Y10T

Abstract:
1. A method of making an insulated door comprising: providing first and second exterior panels for a door shell; providing a plurality of stiffeners; providing a hardenable flowable foam; suspending the plurality of stiffeners between the first and second exterior panels such that each of the stiffeners has a first side facing the first exterior panel and a second side facing the second exterior panel, whereby cavities are formed between adjacent stiffeners and between the first and second exterior panels and whereby at least the first side of each of the stiffeners is spaced from the adjacent first exterior panel sufficient to allow the flowable foam to flow between the at least first side of the stiffeners and the adjacent first exterior panel; flowing the foam into the cavities and between the at least first side of the stiffeners and the adjacent first exterior panel until cavities are filled with the foam; and allowing the flowable foam to harden whereby the exterior panels and the stiffeners are bonded to the foam.