COMPRESSION MOLDED, INSERTED THERMOSET DOOR LIGHT FRAMES, PLANT-ON MOLDINGS, AND DECORATIVE PANELS

Abstract: Door assemblies contain compression molded skins (1, 4) and separately manufactured door light frames, panels, and/or plant-on molding (10) comprised of a thermoset material wherein the separately molded members display substantially the same stainability, gloss, texture, etc., as the compression molded skins (1, 4), and are further strippable without damage to the member. The non-integral door elements may be adhesively bonded to the surface onto which they are affixed.

Description: COMPRESSION MOLDED, INSERTED THERMOSET DOOR LIGHT FRAMES, PLANT-ON MOLDINGS, AND DECORATIVE PANELS TECHNICAL FIELD The present invention is directed to the manufacture of insertable or adherable, strippable door light frames, plant-on moldings, and decorative panels, which are durable, match the stain color applied to the exterior door or sidelite on which they are mounted, and avoid significant degradation when the stain and topcoat are stripped with aggressive finish strippers such as those based on methylene chloride. BACKGROUND ART Door lights are windows mounted in an exterior door or sidelite. Door light assemblies or cassettes generally consist of inner and outer molded peripheral frame members, which are the door light frames, both secured together with fasteners surrounding the central panels between the frames of glass, plastic or other material. The door light frames clamp from opposite sides to the door or sidelite, in particular to allow for differences in the thickness of the doors to which they are to be applied. Decorative panels are generally made analogous to door light frame assemblies with a solid panel substituted for the transparent or translucent panels such as may be made from glass. The panel may be integral to the peripheral frame or inserted as desired, as predetermined by the process used in the frame and central panel manufacture. Plant-on moldings are singular peripheral frame members secured to the exterior door or sidelite on which they are mounted. Fastening may involve screws or barbed mounting members integral to the frame member. Door light frames, plant-on moldings, and decorative panel designs are known in prior art as illustrated by McConnell United States Patents 4,523,408 and 4,839,989, and Jouanny French Patent 2328095. In general, door light frames, plant on moldings, and decorative panels are typically manufactured from stamped, press braked, and/or rollformed steel; injection molded polystyrene, polyvinyl chloride (PVC) or fiberglass reinforced thermoplastic; cast polyurethane foam; as well as extruded and assembled thermoplastic, such as PVC, styrene-maleic- anhydride/PVC coextruded laminates (SMA/PVC); or shaped wood. The performance and aesthetic properties of the door light frames, plant-on moldings, and decorative panels relative to the door on which they are mounted are generally determined by the forming processes and the materials used. The doors and sidelites into which the door light frames, plant-on moldings, and decorative panels are inserted are typically made of wood, steel, polyvinyl chloride, fiberglass reinforced sheet molding compound, and thermoset phenolics filled with wood fibers. It is notable that in the door and sidelite industry, doorlights from one manufacturer may be used in doors and sidelites manufactured by a second manufacturer Staining of exterior doors and sidelites to mimic the color and grain of wood is desired by many customers. Discerning customers object when the staining of the door light frames, plant-on moldings, and decorative panels do not match the darkness, color, or graining texture of the door or sidelite into which the door light cassette is assembled. Numerous problems are common in staining doors, door light frames, plant-on moldings, and decorative panels. Steel doors and sidelites, door light frames, plant-on moldings, and decorative panels are generally not acceptable as imitations of stained wood doors and sidelites, even when textured to simulate wood. Such doors are usually painted, not stained. PVC doors and sidelites, door light frames, plant-on moldings, and decorative panels typically are also not stained; dark colors allow greater heating of the surface of the door during direct sun exposure. It is typical that PVC will warp and twist as the skin temperature increases above approximately 85 °C. For reference, the temperature in the air space between a glass storm door and a door may reach 95 °C at least once a year in most regions of the U.S. In addition, stain coats on thermoplastics may experience witness lines caused by significant expansion and contraction due to the relatively high coefficient of linear thermal expansion of PVC. Recent modifications to thermoplastics, such as additions of fiberglass reinforcements, and microcellular foaming, whether of PVC or other thermoplastics, e.g., acrylonitrile-butadiene-styrene (ABS), reduce linear thermal expansion and improve heat resistance, thereby mitigating, but not eliminating, the distortion and witnessing issues. However, the resultant products when stained still do not match compression molded thermoset doors. Reinforced PVC and microcellular foamed thermoplastic doors are not commercially available. Stainable steel doors and sidelites are known in the prior art. These products consist of steel door and sidelite assemblies coated with a thin plastisol coating of PVC. The surface of the PVC may be textured to imitate wood grain. No door light frames, plant-on moldings, or decorative panels currently are manufactured to duplicate this door or sidelite surface. But, even if they were, stripping of the topcoat and stain from these PVC surfaces with the aggressive solvents which are typically used, damages the plastisol PVC surface irreparably. Wood doors and sidelites, door light frames, plant-on moldings, and decorative panels have been aesthetically acceptable, especially when veneers are used. However, such products are notoriously difficult to maintain due to expansion and contraction with humidity as well as degradation of the wood substrate by ultraviolet light due to exposure to the sun. Color and texture variation of the wood due to species differences, frequent use of joining random wood cuttings, as well as natural variation within species and within individual boards makes matching exceptionally difficult. Stripping the topcoat and stain from these doors is a very difficult, and frequently unsuccessful process that may include substantial use of bleaching compounds. In addition, decorative panels are often made integral to the door or sidelite assembly and therefore the entire door or sidelite assembly must be replaced when a single panel is damaged. Doors and sidelite assemblies have been made by compression molding of sheet molding compound or phenolic-based resol resins with wood fiber. These doors are intended for staining and additionally feature texture to simulate wood graining. Examples include door assemblies shown in U.S. Patent No. 4,550,540 and U.S. provisional application Serial No. 60/010,838. Examples of materials needed to simulate wood graining are shown in U.S. patent 5,537,789. All these are incorporated herein by reference. Compression molded door and sidelite assemblies with integrally molded thermoset decorative panels and with integrally molded thermoset door light frames such as those disclosed in U.S. Patent No. 4,720,951. allow production of products with improved aesthetics, durability, and matching stainability. In addition, topcoat and stain are more easily removed from these products by stripping. However, when the integrally molded glass unit fails the entire door or sidelite assembly must be replaced at considerable expense. The warehousing cost and/or lead time for product delivery necessary to maintain an equivalent number of stocking units, as opposed to using insertable door light frames, plant-on moldings, and decorative panels is increased unacceptably. Moreover, manufacturing and shipping of door or sidelite assemblies with integrally molded decorative panels is very difficult. The datum surface area of the doorlight or sidelite face is small, requiring extra strength in the thermoset material to prevent crushing, or requiring a formed tray to protect the upraised surfaces. Both these alternatives add substantial manufacturing costs. For these reasons, door light frames, plant-on moldings, and decorative panels that may be inserted later into the door or sidelite have been accepted by the market as the preferred approach to lower manufacturing and inventory costs as well as ease of handling. Molded door light frames, plant-on moldings, and decorative panels providing stainable peripheral frames have been prepared using cast polyurethane foam with densities of 190-400 kg/m 3 . However, to accept stain, a primer coating containing relatively high percentages by weight of pigments and inorganic solids must first be applied. Door assemblies using exterior surfaces of cast solid polyurethane or polyurethane laminates have not been economical, and have not met with commercial success. Smaller sidelite panel assemblies of solid cast polyurethane into which door light frames and decorative panels have been inserted have been commercially introduced and later withdrawn, replaced by compression molded thermoplastic sidelite assemblies. Cast polyurethane foam inserted frames, plant-on moldings, and decorative panels with primer most closely approximate the stainability of compression molded doors. The match is still generally not acceptable to discerning customers, however. At polyurethane foam densities that are economically viable (approximately 190-400 kg/m 3 ), these frames, plant-on moldings, and decorative panels are still very fragile during shipping and installation. They are susceptible to thread stripping by screws used to assemble them, and subject to easy abrasion of the primer coating. Unless the polyurethanes are prepared from aliphatic disocyanates, door lights and other products which become exposed to the sun due to wear or weathering of stain and top coat may be rapidly degraded. Door light frames, plant-on moldings, and decorative panels with a density of range of approximately 300-1200 kg/m 3 that are durable and stainable have been prepared using low pressure injection molding of reinforced thermoplastics. The resulting products are more porous than the skins manufactured by compression molding. As a consequence, applying equivalent amounts of stain to the door or sidelite skin and door light frame surfaces results in a darker stain on the door light frame. Discerning customers find that difference unacceptable. Significant effort and skill must be expended to reduce the porosity effects during the staining of frames, plant-on moldings, and decorative panels produced by low pressure injection molding. These include soaking the decorative panels' or door light frames' aesthetic surfaces with a volatile diluent such as paint thinner, priming the aesthetic surfaces of the door light frames or decorative panels with a sealant, or diluting the stain with a compatible solvent. All techniques require increased elapsed time to finish the door skin and door light frame assembly. Therefore, there is a generally unacceptable economic penalty to the user. In addition, exposure in excess of 20 minutes to aggressive paint strippers, such as methylene chloride-based strippers, softens aesthetic surface material and removes primers. Therefore, there is a need for materials and processes that produce durable, insertable door light frames, plant-on moldings, and decorative panels that can be economically stained to match the color and aesthetics of the compression molded thermoset door skins upon which they are installed. The materials and processes must produce door light frames, plant-on moldings, and decorative panels that allow easy stripping of topcoat and stain without damage to the aesthetic surface, and which are capable of withstanding use temperatures without distortion. It would be further desirable to produce doorlight frames, plant-on moldings, and decorative panels which can be applied to door frames without requiring complicated fastening means, and in panels, without requiring cutting holes in the door. DISCLOSURE OF INVENTION The present invention is directed to insertable, strippable door light frames, plant-on moldings, and decorative panels manufactured by compression molding a curable material into a thermoset, non-foam resin material. These door lights, plant-on moldings, and decorative panels are separately manufactured from the door skin or slab, and may be termed herein "non-integral door elements. " The curable material is composed of organic resins that are pre-polymerized or which further polymerize upon molding, reinforcement fibers, inorganic or organic fillers, and such additives typically used to aid molding or add properties such as fire retardancy or fungal degradation resistance, which cure during or after the molding process into a thermoset, solvent-resistant material. The door light frames, plant-on moldings, and decorative panels have an exterior aesthetic surface and an interior surface. The exterior surface may include textured patterns analogous to the compression molded thermoset door skin which it is desired to match, these patterns generally consisting of level portions or depressions predetermined by the texture of the molding tool texture These depressions are generated in tool surfaces by etching or other means to produce a pattern simulating wood grain in order to enhance the aesthetic appearance likeness to wood grain as well as to aid in mechanical trapping of pigment during the staining process. It is the primary object of the present invention to provide durable, insertable door light frames, plant-on moldings, and decorative panels that can be economically stained to match the color and aesthetics of the compression molded thermoset door skins upon which they are installed. Other objects and advantages of the invention shall become apparent upon review of description of the preferred embodiments and accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS FIGURE 1 is a frontal elevation view of a door lite frame as a component of a door light assembly; FIGURE 2 is a cross-sectional view taken along axis 2-2 of Figure 1 ; FIGURE 3 is a frontal elevation view of a plant-on molding; FIGURE 4 is a cross-sectional view taken along axis 4-4 of Figure 3 showing the plant-on molding; FIGURE 5 is a frontal elevation view of a decorative panel; and FIGURE 6 is a cross-sectional view taken along axis 6-6 of Figure 5 showing the two decorative panels as components in a decorative panel assembly. BEST MODE FOR CARRYING OUT THE INVENTION Example 1 The present invention will now be described in detail with reference being made to the accompanying drawings. In this example, the door light frame 1 is composed of molding compound taken from the following families of compounds: bulk (or dough) molding compound; kneading molding compound; an injection molding compound known as AMC; thick molding compound; and sheet molding compound, both chemically thickened and physically thickened varieties; more preferably the epoxy, vinyl ester, phenolic, dicylcopentadiene-based and polyester bulk and sheet molding compounds, and most preferably unsaturated polyester sheet molding compound. This is a material comprised of 5 to 72 weight percent fibrous glass reinforcement, preferably 17-25 weight percent, and most preferably 19-22 weight percent of 2-3 mm long, chopped strand S-glass fibrous glass; inert fillers; mold releases; and other additives in the molding resin. Other reinforcements may be substituted for fibrous glass such as wood and lignocellulose fibers, aramide fibers, carbon fibers, or mineral reinforcements such as mica. Fillers may include wood, sawdust and excelsior as well as inorganic fillers such as calcium carbonate. Unsaturated polyester polymers blended with vinyl monomers such as styrene are molding resins that may be cured under heat and pressure to form thermoset compression molded door light frames. Suitable molding compounds are disclosed in U.S. Patent No. 3,772,241 to Kroekel and U.S. Patent No. 3,883,612 to Pratt et al., which are herein incorporated by reference. Curable materials which produce foam materials are not suitable in the present invention. The preferred sheet molding compositions are prepared by blending a resin portion with an additive portion, the additive portion containing conventional SMC additives such as thickeners, fillers, pigments, etc., and the resin portion containing curable resin, catalyst, and other components. The relative amounts of resin portion and additive portion may be varied to suit the particular application, but is normally about 18: 1 by weight. The resin portion preferably contains a 60:40 ratio of an alkyd modified propylene glycol maleate resin thinned with styrene, and high impact polystyrene thinned with styrene. Both resins are commercially available, for example from Cook Composites and Polymer, Kansas City, Missouri. The resin portion also contains, relative to 100 parts of the foregoing resins, 4.0 parts polyvinylacetate; 1.56 parts t-butylperoxybenzoate catalyst; 1.56 parts calcium stearate; and 2.08 parts microfine polyethylene, available as FN 510 from Quantum Chemical, Cincinnati, Ohio; 0.31 parts PEP 100, an organocobalt compound on calcium carbonate support available from Air Products, Allentown. Pennsylvania; and 197.60 parts calcium carbonate filler available from Huber, Norcross, Georgia, as Huber W-4 calcium carbonate. To the total mixture, chopped S-glass, 1 " nominal length, is added in an amount of approximately 22 weight percent. This door light frame has a thickness between 1.25 mm and 4 mm, preferably 1.25-2.5 mm in the wall and 2.0-2.6 mm in the screw bosses, if present. Density of the product ranges between approximately 1500-2350 kg/m 3 , as determined primarily by the quantity of material charged in the press and the press pressure. The compression pressure may vary from 1000 to 15,000 kPa, preferably 2,500 to 5,100 Kpa at temperatures of 150°C to 180°C. The exterior, aesthetic surface of the door light frame is essentially devoid of reinforcement fibers for a predetermined depth of 0.10 mm. This resin rich surface aids in accepting the stain. A door light frame without texture may have fibers effectively at the surface, and requires a decorating surface applied either in situ during molding or during a secondary decorating operation to make an aesthetically acceptable door light frame so that the fibers do not witness through the stain. Referring to Figures 1 and 2, the door light frame has an exterior aesthetic surface 4 and an interior surface 10. In a door light assembly, a pair of opposed compression molded door light frames surround a central panel comprised of one or a plurality of the following: glass sheets 3, decorative cut glass 8, earning 7, and sealant 6. In addition, not shown for sake of clarity are well known items such as high temperature plastic inserts, spacers, desiccant, and coatings and films designed to lower heat transmission. The interior surface of the exterior door light frame may have an adhesive, water-impervious sealant 5 attached between the frame and the exterior surface of the central panel. Essentially the same material may be used in forming compression molded door skins. A compression molded door or sidelite skin assembly is prepared with a hole to receive the insertable door light assembly. The interior surface of the exterior door light frame of the assembly adjacent to the door or sidelite skin surface may have a water-impervious sealant 9 attached between the frame and the exterior surface of the compression molded door assembly. The door light assembly is fastened to the door or sidelite assembly by any of several fastening methods including the following: press fit barbs, interlocking toothed grips, and most typically screws. In this example, the screws 2 are applied from the outermost side of the interior door light frame into screw bosses integrally molded in the door light frame. Figures 3 and 4 illustrate a plant-on molding consisting of frame 17 and snap fasteners 18. Example 2 In this example, the decorative panel 20 (Figures 5, 6) is composed primarily of phenolic-formaldehyde-based resin systems and wood fiber of less than 19 μm maximum cross-section and greater than 1.25 mm minimum length, preferably 3 mm to 6 mm. The materials that may be used in this example in the weather exposed faces are given in PCT Patent Application Serial No. PCT/US97/ 14290 and U.S. Application Serial No. 08/791,023, incorporated herein by reference. The phenol-formaldehyde resin system may be selected from the resin families including phenol and formaldehyde resols; phenol-formaldehyde -melamine resols; phenol- formaldehyde resols with separate melamine resin coating; phenol-formaldehyde novolacs; or phenol-formaldehyde novolacs with either silane, siloxane, polysiloxane, or high molecular weight polyurethane coatings; preferably the resols with melamine coatings or the novolacs with siloxane coatings; most preferably the novolacs with a plurality of pre-press siloxane coatings including intimately mixed siloxane coatings for moisture vapor transmission control and separate water-based siloxane coatings for water repulsion. A decorative panel peripheral frame exposed only to interior conditions 12 may employ a urea-formaldehyde, melamine fortified urea- formaldehyde, or a melamine-urea resin. The interior areas 14 and 16 of the panel are composed of the same materials as exterior and interior peripheries 12 and 15, respectively. The panel is attached via screws 13. Sealing gasket 17 seals around the exterior of the panel. -10- SUBSTTTUTE SHEET (RULE 26) In this embodiment for the exterior decorative panel 15, it is preferable to use phenol-formaldehyde novolacs applied to the lignocellulosic fiber material, most preferably wood fiber, under steam pressure of 350-2370 Kpa, more preferably 920-1750 Kpa, and most preferably 1400-1700 Kpa, in a single-disk or a double-disk refiner. Green hardwood wood chips are a preferred source of lignocellulose; however, dried wood, urban wood waste such as pallets, and agricultural lignocellulosic materials may be used. The resin system from which to manufacture the interior decorative panels is not as sensitive to weatherability as the exterior aesthetic surfaces. The base color of the material is predetermined by the density of the molded product, the temperature to which the fiber was exposed, and the duration of that exposure. The density is predetermined by the quantity of material charged in the press and the compressing pressure required. The temperature is predetermined by the steam pressure employed. In this embodiment, the preferred densities range from 1.02 - 2.08 kg/cm 3 , most preferably 1.33 - 1.66 kg/ cm 3 . The compression pressure may vary from 1000 to 15,000 Kpa, preferably 2,500 to 5,100 Kpa. For exterior weatherability, the resin should constitute 4-24 weight percent of the oven dried basis weight of the total material, preferably 10-15 weight percent. Fiber and fillers should constitute 70-90 weight percent, with the balance of the formulation comprised of additions for processing aids and other properties. For decorative panels used on the interior side of the assembly, the resin content can range from 1-24 weight percent of the oven dried basis weight of the total material, preferably 4-8 weight percent. Referring again to Figures 5 and 6, the decorative panel walls 16 and 14 range from 1.75 mm to 22.5 mm thickness. In the present embodiment, the wall thickness is nominally 3 mm while screw boss walls 21, if used, are nominally 5 mm. It is preferred to match the decorative panels with the door skins in terms of resin system and density. -11- SUBSTΓΓUTE SHEET (RULE 26) Example 3 To achieve the light colored stains preferred by some customers, it may be necessary to use a light colored decorative surface, such as paint primer, on the darker colored decorative panels. These darker panels may be created by the methods and materials outlined in Example 2 where the density range is 1.02 - 2.08 kg/cm 3 , most preferably 1.66-2.08 kg/cm 3 , and steam pressure of 350-2370 Kpa system, more preferably 1700-2300 Kpa, most preferably 1800-2200 Kpa in a single- disk or a double-disk refiner. The phenolic novolac resin content can range from 1- 24 weight percent with 10-15 weight percent preferred for panels exposed to weather of the exterior of the house and 4-8 weight percent preferred for panels exposed to interior conditions. A decorative surface may be created using films, resin-impregnated webs, veneers, laminates or paint hold-out primers. Preferred are paint holdout primers that may be developed from relatively high molecular weight polyurethane polymers, preferably thermoplastic urethane coatings in excess of approximately 50,000 weight-averaged molecular weight; polysaccharide resins with number- averaged molecular weight of 100,000-300,000, most preferably 100,000 to 200,000; acrylic-urethane hybrid polymers; styrene-acrylic polymeric resins; vinylidene chloride coatings; ethylene-vinyl chloride coatings, preferably formulated from an emulsion of 20-40 weight percent of 43% solids alkylalkoxysiloxane; such as Wacker ™ 43A, 0.1-5 weight percent of 50% solids siloxane polymer such as Sealer Science ™ Siloxane Plus ™ or Wacker 1306; 30-50 weight percent 43% solids acrylic resin, such as BF Goodrich ™ Carboset ™ , and 0.1-10 weight percent of a resin with lower glass transition temperature than the siloxane and acrylic resins such as ethylene vinyl chloride resin with glass transition temperature between 11 and 35 °C, such as Air Products ™ Airflex ™ 4514, as well as additional solvents, adjuvants, fungicide, mildewcide, fillers and extenders that may be added up to 49.8 weight percent; waxes; as well as combinations thereof. In this preferred embodiment, polysaccharide resins with number- average molecular weights of 100,000-300,000, most preferably 100,000 to 200,000 -12- SUBSTΓΓUTE SHEET (RULE 26) are used with styrene-acrylic polymeric resins; vinylidene chloride coatings; ethylene- vinyl chloride coatings, preferably formulated from an emulsion of 20-40 weight percent of 43% solids alkylalkoxysiloxane; such as Wacker ™ 43A, 0.1-5 weight percent of 50% solids siloxane polymer; such as Sealer Science ™ Siloxane Plus ™ or Wacker 1306; 30-50 weight percent 43% solids acrylic resin, such as BF Goodrich ™ Carboset ™ ; and 0.1-10 weight percent of a resin with lower glass transition temperature than the siloxane and acrylic resins such as ethylene vinyl chloride resin with glass transition temperature between 11 and 35 °C, for example Air Products ™ Airflex ™ 4514, as well as additional solvents, adjuvants, fungicide, mildewcide, fillers and extenders that may be added up to 49.8 weight percent; waxes; as well as combinations thereof. In this preferred embodiment, polysaccharide resins with number- averaged molecular weight of 100,000-300,000, most preferably 100,000 to 200,000 are used with styrene-acrylic polymeric resins. This primer enhances the aesthetic benefits by permitting relatively uniform dispersal of lighter colored pigments over the surface while limiting differential absorption into the various areas of differing porosity inherent on the surface of a decorative panel formed from the materials outlined in Examples 2 or 3. This results in a wider range of stain colors available for discerning customers, but reduces the economic and durability benefits of using unprimed surfaces. Thus the subject invention pertains to a door light frame or decorative panel comprised of opposing inner and outer molded members, these members generally being formed from the same material, and featuring approximately the same surface texture as the molded door skin or side light skin into which the door light frame is to be inserted, these components manufactured from thermoset molding resins or molding resins which become thermoset during the molding process or through a post-molding treatment. The door light frames or decorative panels are preferably made from a thermoset molding resin which is a glass-fiber reinforced sheet molding compound or a thermoset molding resin which is a lignocellulosic fiber filled phenolic compound. The outer molded members are preferably suitable for prolonged exposure to the weather. To this end, for example, the outer molded door light frame may consist of a thermoset molding resin which is lignocellulosic fiber filled phenolic compound containing or coated with one or more hydrophobicizing agents. Preferably, the lignocellulosic fiber-filled phenolic compound is primarily a phenol- formaldehyde novolac, and the hydrophobicizing agent contains organosiloxane and/or organosilane resins bearing reactive functional groups. Preferable hydrophobicizing agents contain organosiloxane or silane resins bearing reactive functional groups. A linear amino-functional siloxane may be intimately mixed with the lignocellulosic fiber in a refiner, or the silane may be applied to the surface of lignocellulosic fiber mat prior to molding. The subject invention further pertains to a door light frame or decorative panel comprised of opposing inner and outer molded members, these members being formed with approximately the same surface texture as the molded door skin or side light skin into which the door light frame or decorative panel is to be inserted, wherein the door light frame or decorative panel demonstrates staining color, color uniformity, and gloss, as well as texture appearance closely matching the staining color, color uniformity, and gloss as well as texture appearance of the door skin or side light skin into which the door light frame or decorative panel is inserted. The door light frame or decorative panel is composed of materials such that the stain and topcoat applied to the door light frame or decorative panel is strippable without damage visible to the unaided eye using paint strippers, particularly those employing powerful solvents such as methylene chloride as a primary ingredient. The door light frames, decorative panels, or plant-on molding members of the present invention preferably are made from composites based on thermoset molding resins or molding resins that become thermoset during the molding process or through a post-molding treatment, which are molded under pressure of 1,000 to 15,000 Kpa to a predetermined thickness of 1.25 to 19 mm, the molding operation occurring at temperatures of 121°C-218°C. In one preferred embodiment, the door light frame, decorative panel, or plant-on molding member is molded from sheet molding compound molded at 2,500 to 5,100 Kpa at molding -14- SUBSTTTUTE SHEET (RULE 26) temperatures of 150°C-180°C. In a second preferred embodiment, the door light frame, decorative panel, or plant-on molding member is molded from a composition containing 1-24 weight % novolac phenol-formaldehyde mixed with wood fiber, molded under pressure ranging from 2,500 to 51,000 Kpa at molding temperatures of 200°C-218°C. Such molding compositions are termed herein "novalac/partially digested wood fiber compositions" . In a further embodiment, the door light frame, decorative panel, or plant-on molding member is suitable for prolonged exterior exposure, and is made from composites based on thermoset molding resins or molding resins that become thermoset during the molding process or through a post-molding treatment, these composites being of approximately the same material as the door skin or side light skin in to which they are inserted, the composite having been impregnated with coatings restricting moisture and moisture vapor transmission into the member, the member being molded under pressure of 1,000 to 15,000 Kpa to a predetermined thickness of 1.25 to 19 mm at temperatures of 121 °C-218°C. Most preferably, the door light frame, decorative panel, or plant-on molding member is produced from a composite containing 1-24 weight % novolac phenol-formaldehyde intimately mixed with wood fiber applied in the fiber refining process, mixed with the fiber before mat forming, or impregnated on the mat before pressing, the composite having alkylalkoxy-siloxane intimately mixed with the fibers that are part of the composite during refining, mixed in the fiber before mat forming of the composite, impregnated on the composite mat before pressing, or applied to the composite mat or tool surface in contact with the composite mat as part of the pressure forming operation, and the surfacial layer of the composite mat impregnated with silane compounds, the composite molded under pressure from 2,500 to 5,100 Kpa at molding temperatures of 200°C-218°C. In a yet further embodiment, a plant-on molding is comprised of a molded member, this member being formed from approximately the same material and featuring approximately the same surface texture as the molded door skin or side light skin into which said plant-on molding is to be affixed, these members made with thermoset molding resins or molding resins that become thermoset during the molding process or through a post-molding treatment, preferably glass-fiber reinforced sheet molding compound or lignocellulosic fiber filled phenolic compound. As with other embodiments, these exterior plant-on moldings are suitable for prolonged exposure to the weather, and most preferably comprise lignocellulosic fiber-filled phenolic compound with a hydrophobicizing agent. The hydrophobicizing agent preferably comprises organosiloxane and/or organosilane resins bearing reactive functional groups. Most preferably, the plant-on molding is formed with approximately the same surface texture as the molded door skin or side light skin on to which the plant-on molding is placed or inserted, and further demonstrates staining color, color uniformity, and gloss, as well as texture appearance which closely matches the staining color, color uniformity, and gloss as well as texture appearance of the door skin or side light skin into which the plant-on molding is placed or inserted. These plant-on moldings are preferably strippable without damage visible to the unaided eye using paint strippers, even when strippers employing methylene chloride as a primary ingredient are used. The subject invention also pertains to door assemblies comprising at least one compression molded skin and at least one separately manufactured door light frame, decorative panel, or plant-on molding of the subject invention which is stainable with the same or substantially the same stain as the door panels proper, to provide a stained door light frame or other component described above which has substantially the same color and depth of color as the door skin itself. In other words, the separately manufactured component will stain in approximately the same manner as the door skin itself. It is believed that door light frames, plant-on moldings, and decorative panels have not been previously produced from the thermoset resin compositions of the present invention because of the difficulties expected in molding articles such as those described by U.S. patents 4,523,408 and 4,839,989. However, it has been surprisingly discovered that even relatively complex moldings can be produced by the subject process. -16- SUBSTTTUTE SHEET (RULE 26) Moreover, it has been surprisingly discovered that doorlights and plant-on moldings and panels may be produced without the need for physical methods of attachment, these elements being mounted onto the door by means of a film adhesive which may also serve as a sealant in the case of door lights. In the case of decorative panels and the like, the use of film adhesives allows the mounting of panels and the like without first forming a hole in the door to receive oppositely inserted mating elements as disclosed by the prior art. This construction allows for a stronger and more weatherproof assembly. In an alternative embodiment, one doorlight frame member may be simply molded and designed for adherence by means of adhesive, while the mating member may be designed for conventional mounting by screws, deformable inserts, etc. In such a case, if the glass in the doorlight is broken, it may be readily replaced by removing the conventionally mounted member. For example, standard doorslabs equipped with ten panels were measured for thermal deflection and twist. The doorslab having the panels mounted with adhesive tape exhibited approximately the same overall thermal deflection, with greater deflection at the top of the door but less at the bottom. Torsional stiffness of the adhesive-applied panel door was outstanding, however, exhibiting almost three times the torsional stiffness of a similar door having cutouts and panels mounted within the cutouts by conventional (screw) fastening methods. Numerous adhesive tapes are suitable, and many are commercially available. A preferred tape, however, is VHB 4930 tape manufactured by the 3M Company. It is generally necessary to wash the areas on the door slab which will be bonded to the panels with an aggressive solvent to remove waxes, mold releases, etc. A suitable solvent is Tape Primer 94 available from 3M. Isopropanol, methylethylketone, and similar solvents are also suitable. Adhesively bonded elements showed no sign of adhesion loss upon weathering, or exposure to mineral spirits, Glass Plus™ Window Cleaner, Fast-n Easy™ Amonia Cleaner, Acetone, 3M brand Safest Stripper Stripping Compound, or Zar™ methylene chloride-based paint and varnish remover. -17- SUBSTTTUTE SHEET (RULE 26) In the claims, the term "outside" as it refers to surfaces, is the surface of the door skin, sidelite surface, etc., to which a door light frame, plant-on molding, or decorative panel is to be affixed, as opposed to an "inside" surface which is internal to the door, etc. By the term "exterior" is meant a surface which is exposed to the elements in a house or building, as opposed to an "interior" surface which faces the building interior. -18- SUBSTTTUTE SHEET (RULE 26)

Claims: WHAT IS CLAIMED IS: 1. A stainable, strippable, non-integral door element comprising a cured, non-foam thermoset compression molding. 2. The non- integral door element of claim 1 wherein the cured thermoset compression molding is prepared from a thermosettable composition selected from the group consisting of sheet molding compound, bulk molding compound, thick molding compound, and novolac/partially digested wood fiber compositions. 3. A door or sidelite manufactured with a compression molded outside surface, and mounted to the outside surface one or more of the stainable, strippable non-integral door elements of claim 1. 4, A door or sidelite manufactured with a compression molded outside surface, and mounted to the outside surface one or more of the stainable, strippable non-integral door elements of claim 2. 5. The door or sidelite of claim 3 wherein the non-integral door element accepts stain to the same degree as said outside surface of said door or sidelite without different treatment of the non-integral door element as compared to the treatment received by the outside surface. 6. The door or sidelite of claim 4 wherein the non- integral door element accepts stain to the same degree as the outside surface of said door or sidelite without different treatment of the non-integral door element as compared to the treatment received by the outside surface. 7. The door or sidelite of claim 3 wherein at least one side of a pair of mating sides of a non-integral door element is affixed to the outside surface by means of a tape adhesive. -19- SUBSTTTUTE SHEET (RULE 26) 8. The door or sidelite of claim 4 wherein both sides of a pair of mating sides of a non-integral door element is affixed to the outside surface by means of tape adhesive. 9. The door or sidelite of claim 5 wherein both sides of a pair of mating sides of a non-integral door element is affixed to the outside surface by means of tape adhesive. 10. The door or sidelite of claim 6 wherein both sides of a pair of mating sides of a non-integral door element is affixed to the outside surface by means of tape adhesive. 11. A process for the preparation of a door or sidelite having affixed thereto a non-integral door element, said non-integral door element comprising a stainable, strippable, non-foam thermoset compression molded element which accepts stain to the same degree as an outside surface of the door or sidelite to which the non- integral door element is affixed, the process comprising wiping the outside surface of the door or sidelite to which the non-integral door element will be affixed with an adhesion promoting amount of one or more organic solvents, and subsequently bonding the non-integral door element to the outside surface by means of a tape adhesive positioned between the outside surface and the non-integral door element. 12. The process of claim 11 wherein said non-integral door element comprises two mating sides, one of the sides to be affixed to each of two opposing sides of the door or sidelite, wherein only one of the two sub-elements is adhesively bonded with said tape adhesive, the second of the two sub-elements affixed to the door or sidelite by non-adhesive means.

Inventors: DAVIS EUGENE R, MINKE RONALD C, TEMPLETON G DANIEL, DAVIS, EUGENE, R., MINKE, RONALD, C., TEMPLETON, G., DANIEL
Applicants: DAVIS EUGENE R, MINKE RONALD C, TEMPLETON G DANIEL, THERMA TRU CORP, DAVIS, EUGENE, R., MINKE, RONALD, C., TEMPLETON, G., DANIEL, THERMA-TRU CORPORATION
Application year: 1998
Main classification: B44F7
IPC codes: B44C3, E06B3