Articles of composite structure having appearance of wood

Abstract

A door or other entryway component of synthetic resin composite construction and closely resembling the appearance of stained real wood. Skin portions of doors and other structures have a surface layer of clear gel coat resin molded to include the texture of a wood grain surface. A subsurface layer adjacent the clear gel coat layer is of pigmented gel coat resin. A structural support layer of the skin is of reinforced resin. Skins of a door or similar article are mounted on frames, and dense micro porous resin foam is provided between the skins to form a solid structure such as a door. Moldings retaining glass panels in openings defined in the door or similar structure are attached to the skins by adhesively fastening the moldings to the skins. Fasteners mounted in the moldings so that there are no plugged holes in the exterior surfaces of the moldings are used to locate the moldings properly with respect to the skins by inserting the fasteners into predrilled holes in the skins. The assembled doors and other structures can be finished by staining and coating with a finish system such as a urethane varnish to provide an appearance closely resembling real wood.

1 - 10 . (canceled)  
     
     
         11 . A method for manufacturing an article of composite construction, comprising: 
 (a) forming a main component of an article of composite synthetic resin construction;    (b) defining an opening extending through said main component in position to receive a panel;    (c) providing a flange in said opening;    (d) defining a fastener receiving hole through an exterior skin of said main component in a predetermined location with respect to said opening;    (e) providing a panel-retaining molding;    (f) mounting an elongate fastener securely in said molding in a predetermined location with said fastener extending from a mating face of said molding; and    (g) placing said molding in registration with said opening and said flange.    
     
     
         12 . The method of  claim 11  further comprising placing said panel within said opening through said main component of said article.  
     
     
         13 . The method of  claim 11  wherein said elongate fastener extends into and securely engages said fastener receiving hole.  
     
     
         14 . The method of  claim 11 , wherein each of said main component and said molding comprises: 
 a transparent outer gel coat layer having an outer surface molded to imitate the appearance of wood;    a subsurface pigmented gel coat layer; and    a reinforced synthetic resin structural support layer.    
     
     
         15 . A composite structure comprising: 
 a main component of an article of composite resin construction resembling the appearance of wood;    an opening extending through said main component adapted to receive a panel;    a first flange surrounding an area where said panel is to be received;    a fastener receiving hole formed adjacent to said opening and surrounded by said first and second flanges; and    a panel-retaining molding in registration with said opening and said first flange.    
     
     
         16 . The composite structure of  claim 15  further comprising: 
 a fastener mounted in said panel-retaining molding, wherein said fastener extends from a mating face of said panel retaining molding; and    said panel placed within said opening.    
     
     
         17 . The composite structure of  claim 15  further comprising a second flange surrounding said area where said panel is to be received, wherein said first and second flanges are directed inwardly toward one another.  
     
     
         18 . The composite structure of  claim 15 , wherein each of said main component and said panel-retaining molding comprises: 
 an outer gel coat layer having an outer surface molded to resemble the appearance of wood;    a subsurface layer of pigmented gel coat layer; and    a reinforced synthetic resin structural support layer, wherein the subsurface layer is substantially opaque and appears solidly colored as viewed through the outer layer.