Method of sealing a porous fibrous substrate, and door skins, produced by the method

Abstract

A method of surface sealing a porous fibrous substrate is provided. According to the method, a porous fibrous substrate possessing a moisture content and a surface with pores is provided. A sealant composition is applied to a surface of the porous fibrous substrate and permitted to penetrate the surface pores of the porous fibrous substrate and undergo cure while participating in a foaming reaction with the moisture content to establish a water-resistant polymeric foam sealant impregnated into the porous fibrous substrate. The water-resistant polymeric foam sealant contains a polyurethane and/or polyurea.

1 - 20 . (canceled) 
     
     
         21 . A door, comprising:
 a door frame having a first frame side and an opposite second frame side;   a door skin comprising a porous fibrous substrate having an exterior surface possessing surface pores and an interior surface attached to the first frame side; and   a water-resistant polymeric foam sealant comprising polyurethane impregnated in the surface pores of the porous fibrous substrate.   
     
     
         22 . The door of  claim 21 , wherein the water-resistant polymeric foam sealant is a two-part polyurethane composition comprising a first part containing a polyol and a second part containing a polyisocyanate. 
     
     
         23 . The door of  claim 21 , wherein the water-resistant polymeric foam sealant is present in an amount of about 3 grams to about 4.5 grams per square foot of porous fibrous door skin. 
     
     
         24 . The door of  claim 21 , wherein the porous fibrous substrate possesses a mean pore size of about 1 micron to about 300 microns. 
     
     
         25 . The door of  claim 21 , wherein the porous fibrous substrate comprises a cellulosic fiber and phenolic resin. 
     
     
         26 . The door of  claim 21 , wherein the water-resistant polymeric foam sealant penetrates about 50 to about 75 microns below the exterior surface of the porous fibrous substrate. 
     
     
         27 . The door of  claim 21 , wherein the porous fibrous substrate comprises medium density fiberboard. 
     
     
         28 . The door of  claim 21 , wherein the door skin is embossed with a wood grain pattern and comprises at least one panel region. 
     
     
         29 . The door of  claim 28 , wherein the door skin further comprises at least one molded contoured region surrounding the at least one panel region. 
     
     
         30 . A door, comprising:
 a door frame having a first frame side and an opposite second frame side;   a first door skin comprising a first porous fibrous substrate having a first exterior surface possessing first surface pores and a first interior surface attached to the first frame side;   a second door skin comprising a second porous fibrous substrate having a second exterior surface possessing second surface pores and a second interior surface attached to the second frame side; and   a water-resistant polymeric foam sealant comprising polyurethane impregnated in the first and second surface pores of the first and second porous fibrous substrates.   
     
     
         31 . A door, comprising:
 a door frame having a first frame side and an opposite second frame side;   a door skin comprising a porous fibrous substrate having an exterior surface possessing surface pores and an interior surface attached to the first frame side; and   a water-resistant polymeric foam sealant comprising polyurea impregnated in the surface pores of the porous fibrous substrate.   
     
     
         32 . The door of  claim 31 , wherein the water-resistant polymeric foam sealant is a two-part polyurea composition comprising a first part containing a polyamine and a second part containing a polyisocyanate. 
     
     
         33 . The door of  claim 31 , wherein the water-resistant polymeric foam sealant is present in an amount of about 3 grams to about 4.5 grams per square foot of porous fibrous door skin. 
     
     
         34 . The door of  claim 31 , wherein the porous fibrous substrate possesses a mean pore size of about 1 micron to about 300 microns. 
     
     
         35 . The door of  claim 31 , wherein the porous fibrous substrate comprises a cellulosic fiber and phenolic resin. 
     
     
         36 . The door of  claim 31 , wherein the water-resistant polymeric foam sealant penetrates about 50 to about 75 microns below the exterior surface of the porous fibrous substrate. 
     
     
         37 . The door of  claim 31 , wherein the porous fibrous substrate comprises medium density fiberboard. 
     
     
         38 . The door of  claim 31 , wherein the door skin is embossed with a wood grain pattern and comprises at least one panel region. 
     
     
         39 . The door of  claim 38 , wherein the door skin further comprises at least one molded contoured region surrounding the at least one panel region. 
     
     
         40 . The door of  claim 29 , wherein:
 the first door skin comprises a first porous fibrous substrate having a first exterior surface possessing first surface pores and a first interior surface attached to the first frame side;   the door further comprises a second door skin comprising a second porous fibrous substrate having a second exterior surface possessing second surface pores and a second interior surface attached to the second frame side; and   the water-resistant polymeric foam sealant comprises polyurea impregnated in the first and second surface pores of the first and second porous fibrous substrates.