Nano-composite door facings, and related door assemblies and methods

Abstract

A door skin adapted for construction of a door assembly is provided. The door skin is embodied as a rectangular solid sheet having interior and exterior opposing surfaces. The solid sheet contains a polymeric material and a nanocomponent. Also provided are door assemblies, and related methods.

1 . A door skin adapted for construction of a door assembly, comprising:
 a rectangular solid sheet having interior and exterior opposing surfaces, the solid sheet comprising a polymeric material and a nanocomponent.   
   
   
       2 . The door skin of  claim 1 , wherein the polymeric material comprises a reaction product of an unsaturated polyester and a co-curable unsaturated monomer. 
   
   
       3 . The door skin of  claim 2 , wherein said sheet molding compound comprises at least about 10% by weight chopped fiberglass. 
   
   
       4 . The door skin of  claim 2 , wherein the sheet further comprises calcium carbonate filler and peroxide catalyst. 
   
   
       5 . The door skin of  claim 1 , wherein the sheet further comprises a low profile additive. 
   
   
       6 . The door skin of  claim 1 , wherein the exterior surface includes contoured portions simulating door panels. 
   
   
       7 . The door skin of  claim 1 , wherein said exterior surface has a wood grain texture. 
   
   
       8 . The door skin of  claim 1 , wherein the nanocomponent comprises an intercalated, modified clay mineral. 
   
   
       9 . The door skin of  claim 8 , wherein the intercalated, modified clay mineral comprises montmorillonite. 
   
   
       10 . The door skin of  claim 9 , wherein the intercalated, modified clay mineral further comprises a quaternary ammonium salt as a modifier. 
   
   
       11 . A door assembly, comprising:
 a frame; and   first and second door skins secured to opposing sides of said frame, at least one of the door skins comprising a rectangular solid sheet having first and second opposing surfaces, the solid sheet comprising a polymeric material and a nanocomponent.   
   
   
       12 . The door assembly of  claim 11 , wherein the polymeric material comprises a reaction product of an unsaturated polyester and a co-curable unsaturated monomer. 
   
   
       13 . The door assembly of  claim 12 , wherein said sheet molding compound includes at least about 10% by weight chopped fiberglass. 
   
   
       14 . The door assembly of  claim 12 , wherein the solid sheet further comprises calcium carbonate filler and peroxide catalyst. 
   
   
       15 . The door assembly of  claim 11 , wherein the solid sheet further comprises a low profile additive. 
   
   
       16 . The door assembly of  claim 11 , wherein the exterior surface includes contoured portions simulating door panels. 
   
   
       17 . The door assembly of  claim 11 , wherein said exterior surface has a wood grain texture. 
   
   
       18 . The door assembly of  claim 11 , wherein the nanocomponent comprises an intercalated, modified clay mineral. 
   
   
       19 . The door assembly of  claim 18 , wherein the intercalated, modified clay mineral comprises montmorillonite. 
   
   
       20 . The door assembly of  claim 19 , wherein the intercalated, modified clay mineral further comprises a quaternary ammonium salt as a modifier. 
   
   
       21 . A method of forming a door skin, comprising:
 providing a die mold having first and second dies defining a cavity;   disposing a SMC charge layer comprising a polymeric material, and a nanocomponent into the die mold;   closing the die mold and curing the polymeric material under pressure to establish a door skin; and   solidifying and removing the door skin from the die mold.   
   
   
       22 . A method of forming a door assembly, comprising:
 providing a die mold having first and second dies defining a cavity;   disposing a SMC charge layer comprising a polymeric material and a nanocomponent into the die mold;   closing the die mold and curing the polymeric material under pressure to establish a door skin;   removing the door skin from the die mold; and   attaching the door skin to a door frame.