Method of making annealed door skins and composite door assemblies, and related articles

Abstract

A method is provided for making an annealed door skin or composite door assembly. At least the door skin is formed of a composition comprising a thermoset binder and fiberglass. The door skin, alone or in combination with other parts of a door assembly, is subjected to annealing to make the annealed door skin. The process of annealing comprises the step of heating the door skin, alone or in combination with other parts of the door assembly, above the glass transition temperature yet below the thermal degradation temperature of the thermoset binder for a sufficient amount of time to cause release internal stresses in the door skin, then the step of cooling the door skin.

1 - 20 . (canceled) 
     
     
         21 . A method for making an annealed door skin, comprising:
 annealing a fiberglass-reinforced thermoset door skin comprising a thermoset binder and fiberglass to make an annealed door skin.   
     
     
         22 . The method of  claim 21 , wherein the annealing steps comprises heating the fiberglass-reinforced thermoset door skin to release internal stress from the fiberglass-reinforced thermoset door skin, and cooling the fiberglass-reinforced thermoset door skin. 
     
     
         23 . The method of  claim 21 , wherein the annealing step comprises heating the fiberglass-reinforced thermoset door skin in a range of 180° F. to 220° F. for at least 24 hours, and cooling the fiberglass-reinforced thermoset door skin. 
     
     
         24 . The method of  claim 23 , wherein the cooling step comprises cooling the fiberglass-reinforced thermoset door skin at a rate of about 50° F. or less per hour. 
     
     
         25 . The method of  claim 21 , wherein the annealing step comprises heating the fiberglass-reinforced thermoset door skin in a range of 180° F. to 220° F. for at least 48 hours, and thereafter cooling the heated fiberglass-reinforced thermoset door skin. 
     
     
         26 . The method of  claim 25 , wherein the cooling step comprises cooling the fiberglass-reinforced thermoset door skin at a rate of about 50° F. or less per hour. 
     
     
         27 . The method of  claim 21 , comprising the step of curing a thermosetting resin composition into the fiberglass-reinforced thermoset door skin prior to said annealing. 
     
     
         28 . The method of  claim 21 , wherein the fiberglass-reinforced thermoset door skin is made of a composition comprising at least one unsaturated polyester resin and at least one unsaturated, co-curable crosslinking monomer. 
     
     
         29 . The method of  claim 21 , wherein the fiberglass-reinforced thermoset door skin comprises at least one thermoplastic polymer. 
     
     
         30 . The method of  claim 21 , wherein the fiberglass-reinforced thermoset door skin comprises low shrinkage and low profile additives. 
     
     
         31 . A method for making a composite door, comprising:
 annealing a first fiberglass-reinforced thermoset door skin comprising a thermoset binder and fiberglass to make a first annealed door skin;   securing the first annealed door skin to a first side of a door frame; and   securing a second door skin to a second side of the door frame, the second side being opposite to the first side.   
     
     
         32 . The method of  claim 31 , wherein the annealing step comprises heating the first fiberglass-reinforced thermoset door skin to release internal stress from the first fiberglass-reinforced thermoset door skin, and cooling the first fiberglass-reinforced thermoset door skin. 
     
     
         33 . The method of  claim 31 , wherein the annealing step comprises heating the first fiberglass-reinforced thermoset door skin in a range of 180° F. to 220° F. for at least 24 hours, and thereafter cooling the heated first fiberglass-reinforced thermoset door skin. 
     
     
         34 . The method of  claim 33 , wherein the cooling step comprises cooling the first fiberglass-reinforced thermoset door skin at a rate of about 50° F. or less per hour. 
     
     
         35 . The method of  claim 31 , wherein said annealing step comprises heating the first fiberglass-reinforced thermoset door skin in a range of 180° F. to 220° F. for at least 48 hours, and thereafter cooling the first fiberglass-reinforced thermoset door skin. 
     
     
         36 . The method of  claim 35 , wherein said cooling step comprises cooling the first fiberglass-reinforced thermoset door skin at a rate of about 50° F. or less per hour. 
     
     
         37 . The method of  claim 31 , further comprising the step of curing a thermosetting resin composition into the first fiberglass-reinforced thermoset door skin prior to said annealing. 
     
     
         38 . The method of  claim 31 , wherein the first fiberglass-reinforced thermoset door skin is made of a composition comprising at least one unsaturated polyester resin and at least one unsaturated, co-curable crosslinking monomer. 
     
     
         39 . The method of  claim 31 , wherein the first fiberglass-reinforced thermoset door skin comprises at least one thermoplastic polymer. 
     
     
         40 . The method of  claim 31 , wherein the first fiberglass-reinforced thermoset door skin comprises low shrinkage and low profile additives.