Patent ID: 7866730

Claim:
A twinsheet door, comprising: a first door portion; a second door portion connected to said first door portion; one or more closed sections created when said first door portion is thermally bonded to said second door portion and simultaneously a vacuum is applied to form said first door portion and said second door portion, said one or more closed sections providing structure and rigidity to said twinsheet door; a first side formed by a portion of said first door portion; a second side formed by a portion of said second door portion, said first side and said second side being drawn away from each other when said vacuum is applied to form said first door portion and said second door portion, said first side being on the opposite side of said closed section as said second side; a third side formed by a portion of said first door portion and a portion of said second door portion, connecting said first side and said second side; a fourth side formed by a portion of said first door portion and a portion of said second door portion, connecting said first side and said second side, said fourth side being on the opposite side of said close section as said third side; a first outwardly extending flange formed on said first door portion; and a second outwardly extending flange formed on said second door portion, part of said third side of said one or more closed sections being formed by a part of said first door portion extending in continuous fashion from said first side to said first outwardly extending flange and a part of said second door portion extending in continuous fashion from said second side to said second outwardly extending flange, said first outwardly extending flange being heat bonded to said second outwardly extending flange during forming of said first door portion and said second door portion.