Molded door facing blank and method of forming same

Abstract

The present invention is directed to a door facing blank having a first major surface with a design element formed therein, and an opposite second major surface. At least three longitudinally extending spaced stile receiving areas are disposed on the second major surface. Two of the stile receiving areas define a first width, and three of the stile receiving areas define a second width greater than the first width. The door facing blank may be trimmed to form a door facing having a selected width. A method of forming a door facing blank, and a mold press for forming a door facing blank are also disclosed.

We claim: 
     
         1 . A door facing blank, comprising:
 a sheet of wood composite, said sheet having   a first major surface adapted to be exteriorly disposed and an opposite second major surface adapted to be interiorly disposed;   first and second planar, spaced stile receiving areas disposed on said second major surface;   a central portion intermediate said first and second stile receiving areas;   a plurality of grooves formed in said first major surface and defining a design element, wherein at least one of said grooves includes an embossed portion disposed in said first major surface opposite said first and second planar spaced stile receiving areas and a molded portion disposed in said central portion, at least one of said first and second spaced stile receiving areas trimmable to form a door facing having a selected width, at least two of the grooves situated continuous with one another to establish a continuous groove in said first major surface.   
     
     
         2 . The door facing blank of  claim 1 , wherein said plurality of grooves are linearly disposed and extend parallel to one another, thereby defining a plurality of planks. 
     
     
         3 . The door facing blank of  claim 2 , wherein said plurality of grooves are evenly spaced. 
     
     
         4 . The door facing blank of  claim 2 , wherein at least two of planks have differing widths. 
     
     
         5 . The door facing blank of  claim 1 , further comprising first and second rail portions disposed at opposite ends of the door facing blank on said first major surface. 
     
     
         6 . The door facing blank of  claim 5 , wherein said design element is disposed between said first and second rail portions. 
     
     
         7 . The door facing of  claim 1 , wherein said design element forms a geometric design pattern. 
     
     
         8 . The door facing of  claim 1 , wherein said design element forms an organic design pattern. 
     
     
         9 . A door facing blank, comprising:
 a sheet formed from one of wood composite and fiberglass reinforced polymer, said sheet having   a first major surface intended to be exteriorly disposed and an opposite second major surface intended to be interiorly disposed;   a design element formed in said first major surface;   at least three longitudinally extending spaced stile receiving areas disposed on said second major surface, two of said stile receiving areas defining a first width, and three of said stile receiving areas defining a second width greater than said first width, wherein the door facing blank may be trimmed to form a door facing having a selected width and having a first one of said stile receiving areas adjacent a first longitudinal edge of the door facing and a second one of said stile receiving areas adjacent a second longitudinal edge of the door facing, the first and second groove portions situated continuous with one another to establish a continuous groove in the exterior major surface.   
     
     
         10 . The door facing blank of  claim 9 , wherein said design element includes a first portion that is molded into the door facing blank and extending outwardly from said second major surface. 
     
     
         11 . The door facing blank of  claim 9 , wherein said first portion is disposed intermediate said stile receiving areas. 
     
     
         12 . The door facing blank of  claim 9 , wherein said stile receiving areas are planar. 
     
     
         13 . The door facing blank of  claim 9 , wherein said design element includes a second portion that is embossed into said first major surface. 
     
     
         14 . The door facing blank of  claim 9 , wherein said design element comprises a plurality of linear grooves extending parallel to one another and defining a plurality of planks. 
     
     
         15 . The door facing blank of  claim 14 , wherein each of said grooves includes an upwardly extending central bead. 
     
     
         16 . The door facing blank of  claim 14 , wherein said grooves are evenly spaced. 
     
     
         17 . The door facing blank of  claim 9 , further comprising first and second planar rail receiving areas disposed at opposite ends of the door facing blank on said second major surface. 
     
     
         18 . The door facing blank of  claim 17 , wherein said design element is disposed between said first and second rail receiving areas. 
     
     
         19 . A method of forming a door, comprising the steps of:
 providing a perimeter frame having first and second spaced stiles defining a width;   providing first and second door facing blanks, each of the blanks having a first major surface and an opposite second major surface, a design element formed in the first major surface, and a plurality of longitudinally extending spaced stile receiving areas disposed on the second major surface;   selecting first and second stile receiving areas that are spaced by a distance corresponding to the width of the first and second spaced stiles;   trimming the first and second door facing blanks adjacent the selected first and second stile receiving areas to form first and second door facings having selected widths;   securing the first and second door facings to opposite sides of the perimeter frame, thereby forming a door.