Door and method of manufacturing

Abstract

A door construction is illustrated with plural bumpers formed during the door manufacturing process. Respective sets of edges of the door body, such as trailing edges of door panel sections of the door body and top edges of the door panel sections, may be trimmed to establish the width and the height of the desired door. A closure or spacer member may be used to connect the trimmed edges. The door may be supported by a hinge assembly for pivoting about an upright pivot axis. The door body may be a monolithic one-piece construction, apart from any such closure members, and optional any window and window support. The door body may be formed by rotational molding.

1 - 25 . (canceled)  
   
   
       26 . A door for mounting within a doorway so as to pivot about an upright pivot axis, the door comprising: 
 first and second panel sections each of which comprises a trailing edge portion;    a spacer disposed at least in part between the trailing edge portion of said first and second panel sections;    an elongated spine, the spine defining a channel for receiving at least a portion of the trailing edge portion of the first and second panel sections, the spine defining first and second hinge openings which communicate with respective first and second elongated hinge receiving spine pocket portions, wherein the second hinge opening faces upwardly and the first hinge opening faces downwardly and with the second hinge opening being above the first hinge opening when the door is installed;    a first cam member sized for insertion through the first hinge opening and into the first hinge receiving pocket with the first cam member being mounted within the first hinge receiving pocket, the first cam member having a first cam surface which is angled relative to the pivot axis and which faces the first hinge opening;    a first door installation bracket adapted for mounting to a lower portion of the doorway;    a second cam member coupled to the first bracket, the second cam member having a second cam surface which is angled relative to the pivot axis, a portion of the second cam member being inserted through the first hinge opening and into the first hinge pocket with the respective first and second cam surfaces facing one another;    a stop sized for insertion through the second hinge opening and into the second hinge-receiving pocket, the stop being mounted within the second hinge-receiving pocket;    a second door installation bracket adapted for mounting to an upper portion of the doorway;    a plug coupled to the second bracket, a portion of the plug being inserted through the second hinge opening and into the second hinge opening;    a biasing spring positioned within the second hinge-receiving pocket and between the stop and plug, the biasing spring being adapted to apply a biasing force through the spine to the first and second cam members;    whereby upon pivoting of the door about the pivot axis, the upper and lower cam surfaces are pivoted relative to one another to create a gap between such surfaces with the biasing spring urging the upper and lower cam surfaces toward one another following pivoting of the door.    
   
   
       27 . A door according to  claim 26  wherein the first bracket comprises a first support post which is oriented to project upwardly when the first bracket is installed in the doorway, the second cam member defining a first support post receiving opening with the first support post being inserted into the first post receiving opening, the second cam member being connected to the lower bracket to thereby mount the second cam member to the lower bracket, and wherein the second bracket comprises a second support post which is oriented to project downwardly when the second bracket is installed in the doorway, the plug defining a second support post receiving opening positioned to receive the second support post to thereby couple the plug to the second bracket.  
   
   
       28 . A door according to  claim 27  wherein the biasing spring comprises a coil spring with first and second end portions, the first end portion of the coil spring being below the second end portion of the coil spring when the door is installed in the doorway, the door further comprising at least one spacer between the stop and first end portion of the coil spring and at least one spacer between the second end portion coil of the coil spring and the plug.  
   
   
       29 . A method of making a door comprising: 
 molding a door shell comprising first and second panel sections each with a leading edge portion and a trailing edge portion, the first and second panel sections also comprising top and bottom edge portions with at least one set of edge portions of the first and second panel sections being joined together during molding of the door shell, the act of molding also comprising molding a plurality of outwardly projecting elongated bumpers into the first and second panel sections;    inserting at least one spacer at least partially between the first and second panel sections along at least a portion of the trailing edge of the respective first and second panel sections; and    positioning at least one closure member along at least a portion of one of the set of top edges and the set of bottom edges of the first and second panel sections.    
   
   
       30 . A method according to  claim 29  comprising the act of trimming the trailing edge portions of the first and second panel sections to establish the width of the door and the act of inserting the at least one spacer is accomplished following the trimming of the trailing edge portions.  
   
   
       31 . A method according to  claim 30  comprising the act of positioning the at least one closure member only along the top edges of the respective first and second panel sections with the positioning of the at least one closure member being accomplished following the trimming of the upper edges of the first and second panel sections to establish the height of the door.  
   
   
       32 . A method according to  claim 31  further comprising the act of installing a gasket along the leading edge of the door and a hinge coupling spine along the trailing edge of the door.  
   
   
       33 . A method of making a door comprising: 
 molding a door shell comprising first and second panel sections each with a leading edge portion and a trailing edge portion, the first and second panel sections also comprising top and bottom edge portions with at least one set of edge portions of the first and second panel sections being joined together during molding of the door shell; and    the method further comprising the act of trimming at least one set of the trailing edge portions and leading edge portions of the first and second panel sections to adjust the width of the door shell and positioning at least one first closure member along at least a portion of the set of trimmed edges.    
   
   
       34 . A method according to  claim 33  wherein the act of trimming comprises the act of trimming only the set of trailing edge portions of the first and second panel sections to adjust the width of the door shell.  
   
   
       35 . A method according to  claim 33  comprising the act of trimming at least one set of the top and bottom edge portions of the first and second panel sections to adjust the height of the door shell and positioning at least one second closure member along at least a portion of the set of trimmed edges.  
   
   
       36 . A method according to  claim 35  comprising the act of trimming only the top edge portions of the first and second panel sections to adjust the height of the door shell.  
   
   
       37 . A method according to  claim 34  comprising the act of trimming only the top edge portions of the first and second panel sections to adjust the height of the door shell.  
   
   
       38 . A method of making a door comprising: 
 molding a door shell comprising first and second panel sections each with a leading edge portion and a trailing edge portion, the first and second panel sections also comprising top and bottom edge portions with at least one set of edge portions of the first and second panel sections being joined together during molding of the door shell; and    the method further comprising the act of trimming at least one set of the top and bottom edge portions of the first and second panel sections to adjust the height of the door shell and positioning at least one first closure member along at least a portion of the set of trimmed edges.    
   
   
       39 . (canceled)