MXPA99009144A - Method of manufacturing a molded door skin from a wood composite, door skin produced therefrom, and door manufactured therewith - Google Patents

Abstract

La presente invención se refiere a un nuevo método para manufacturar una cubierta de puerta que incluye las etapas de proporcionar un material plano inicial compuesto de madera. El material es colocado entre las planchas de una prensa calentada, las planchas son calentadas a una temperatura suficiente, para ablandar la resina en el material inicial y por medio, de eso ablandar el material inicial. Se aplica presión suficiente para cerrar las planchas y subsecuentemente la presión es aplicada cíclicamente para incrementar los niveles de presión para provocar por medio de eso que el material inicial sea deformado en una forma moldeada determinada por la configuración de las planchas. El material moldeado es entonces retirado de entre las planchas.

Description

METHOD FOR MANUFACTURING A MOLDED DOOR COVER FROM A COMPOSITE WOOD MATERIAL, A COVER FOR DOOR PRODUCED FROM IT AND THE MANUFACTURED DOOR WITH THE SAME Field of the Invention The disclosed invention is a method for manufacturing a molded door cover from a wood composite material, as well as a resulting cover and a door produced therefrom. More particularly, the disclosed invention is a method for manufacturing a molded door cover in which an initial material composed of solid wood in a press is heated to a temperature sufficient to soften the initial material, after which the press plates are actuated by pressure to close and thereafter pressurized in cyclic increments to consequently form the material in a molded configuration appropriate for a door cover and finally to be assembled in a door.

Background of the Invention Hollow interior doors are used in both exterior and interior applications. A hollow interior door can be a smooth door, which REF .: 31445 is a flat door in most of its two surfaces. Alternatively, the hollow interior door may be a "molded" door, which is a door having a series of three-dimensional panels, formed on the roofs, at the time they are manufactured. Molded door covers are relatively expensive, since the cost of capital is certainly high, because lathes, presses and the like are needed. On the other hand, the covers used for the smooth doors are relatively inexpensive, but do not provide the aesthetic characteristics required by consumers. Many hollow interior doors are made from door covers formed from wood composite materials. These wood composites may include particle sheets, flake sheets and medium density fiber sheets ("MDF sheets"). The wood composites use a resin agglomerator, which is often a thermal setting resin, in order to keep the wood fibers that form the compound in a solid form. Wood composites are not resistant to moisture, so doors that use such covers may not be suitable for outdoor applications. When the material of the compound absorbs moisture, either in liquid or gaseous form, the components of the door can expand and the door will deform. Wood and steel fiber doors do not have the same tendency to absorb moisture and are therefore more frequently used for outdoor applications. Because of the cost differential between a smooth deck of wood composite and a molded deck of wood composite, several attempts have been made to transform the smooth covers into molded covers. Said prior efforts have not resulted in a commercially acceptable door covering, mainly because the appearance of the surface is not satisfactory. Previous efforts to transform a smooth cover into a molded cover have generally resulted in covers having a shape and appearance that is cut, swollen or otherwise unsightly. The standard molded door covers are formed from a relatively thick board, which is then compressed in a press to a relatively thin thickness. The table has a very high water content, with the water being swollen during the pressing operation. Since the board is relatively in a fluid type state during the pressing operation, then the resulting deck has clearly defined characteristics acceptable to consumers, since the wood fibers can flow, in order to conform to the mold. Due in part to the high capital costs involved in creating molded covers, the manufacturer frequently requires that an individual order be for a large number of covers, in order to allow maximum operating efficiency. Smaller orders become prohibitive because of their cost. Those skilled in the art will recognize that there is a need for a method of manufacturing a molded door cover from wood composite that allows an initial standard smooth roofing material to be used as a base material and which results in in a molded door cover having general characteristics and surface characteristics acceptable to consumers. There is still a need within the art for a door manufactured from wood composite door covers that have adequate resistance to moisture, such that the door can be used for outdoor applications. The invention discovered meets this and other needs within the art.

Objectives and Brief Compendium of the Invention A primary objective of the discovered invention is a method for manufacturing a door cover from an initial wood composite material by cyclically applying an ever increasing pressure to a softened initial material, such that the resulting cover have the general characteristics and surface characteristics that are acceptable to consumers. A further object of the invention is a door cover that is impermeable to moisture, resulting in the door not being deformed and therefore suitable for outdoor applications. A method for manufacturing a door cover, in accordance with the invention, comprises the steps of providing a smooth initial material of wood composite. The material is placed between the plates of a heated press, with the plates being heated to a temperature sufficient to soften the resin that is in the initial material and therefore, to soften the material. Sufficient pressure is applied to close the plates and with this, the pressure is applied cyclically to increasing levels to cause the initial material to be deformed into a molded shape, determined by the configuration of the plates. The initial molded material is then removed from between the plates. A door cover, according to the invention, comprises a three-dimensional initial sheet material of medium density fiber. The initial material has a first portion with a first thickness previously selected. The initial material has a second portion with a second previously selected thickness. The second thickness is smaller than the first thickness. A door cover, according to the invention, comprises a three-dimensional initial sheet material of medium density fiber sheet having a density of about 800 to about 1000 Kg / m3. A door, according to the invention, comprises a peripheral frame having opposite sides. They are provided to the first and second molded covers. Each deck has a first and a second side. Each first side of each cover has a barrier impervious to moisture applied throughout its length. Each of the second sides of the door cover is secured to one of the sides of the frame.

These and other objects and advantages of the invention will be immediately apparent, in view of the following description and the following drawings.

Description of the Drawings The above objective and other objects and advantages, as well as the novel features of the present invention will be apparent in view of the following detailed description of the preferred embodiment of the invention, illustrated in the accompanying drawings, in which: Figure 1 is a diagram schematic flow of a process used in the manufacture of the door cover of the invention; Figure 2 is a fragmentary cross-sectional view of the initial flat material used with the invention; Figure 3 is a fragmentary cross-sectional view of the molded cover of the invention; Figure 4 is a fragmentary cross-sectional view of the initial material of Figure 2, being between the plates of the press used with the invention; Figure 5 is a graph illustrating the pressure against time, in a first cycle in accordance with an embodiment of the invention; Figure 6 is a graph illustrating the pressure against time, in a second cycle according to the invention; Figure 7 is an elevation view of a molded door in accordance with the invention; and Figure 8 is a fragmentary cross-sectional view taken along line 8-8 of Figure 7.

Detailed description of the invention The smooth initial material of flat wood composite 10, as best shown in Figure 2, has opposing, parallel, flat surfaces 12 and 14. The initial material 10 is preferably a wood composite, agglomerated with thermal setting resins, such as a medium density fiber sheet . The medium density fiber sheet often uses a formaldehyde urea resin as an agglomerator, whose material softens and melts at temperatures of between about 160 C and about 218 C. The initial material of medium density fiber sheet is available in various thicknesses and weights, ranging from 4 mm to 7 mm. The raw materials 10 that are relatively thick are preferred, with the aim of making available the wood fiber material that can be lengthened during the pressing operation, with the aim of providing well defined rim characteristics. The flat initial material 10 is formed in the form of a molded cover 16, as shown in Figure 3, through the process illustrated in Figure 1. Figure 3 illustrates the design element 18 which is formed in the cover, with the aim of providing the aesthetic appearance of, for example, the cover used with the door 20 of Figure 7. The cover 16 of Figure 3 has opposite surfaces 22 and 24, formed from the surfaces 12 and 14 of the initial material 10. The cover 16 has a first portion 26 and a second portion 28 parallel, each having a different thickness due to the elongation process that forms the cover 16. In an initial material 10 having a thickness of 4 mm, the first portion 26, which forms part of the majority of the surface of the cover, will have a thickness slightly less than 4 mm, with the second portion 28 having a thickness of approximately 3 mm due to the resulting compression from the elongation made on the initial material 10, with the objective of creating the design element 18. The second portion 28 is integrated with the first flat portion 26 through the displaced portions 30 and 32. The displaced portions 30 and 32 preferably have a configuration that facilitates the removal of cover 16 from the press plates at the conclusion of the training process. The smooth starting material 10 is received in the loading station 32 of Figure 1. The starting material 10 has a density of about 750 about 800 Kg / m3, and a thickness of about 4 mm to about 7 mm. The initial material 10 has an initial moisture content of about 8% of its weight. The initial material 10 is then transferred to the sealing station 36, where a sealant is applied by means of roll coating, atomization or curtain coating. The sealant is applied at a weight of approximately 2 to 3 g / ft2 (grams per square foot). The sealant is applied only to what will be the outer surface of the cover 16, which results from the initial material 10, such that the fiber of the wood of the opposite surface 22 is available to accept the polyvinyl acetate (PVA). ) used to adhesively secure the cover 16 to the door frame. The sealant can be dried by means of the dryer 38, such as an infrared lamp. The sealant applied to the surface 14 may contain a colorant, when the door 20 is to be an interior door suitable for inking. Various sealants are already known in the art. Preferably, the sealant will be a printing sealer, such as that available from Azko Noble. The sealer helps to clean the mold, participates in the elasticity of the wood fiber and improves the definition of surface characteristics. From the dryer 38, the initial material 10 is then preferably and / or serially transferred to the vaporization vessel 40, the temperature of the initial material 10 increases and the initial material 10 also absorbs moisture, such that it leaves the container 40 with a moisture content of about 15% to about 20% of its weight. As denoted above, the resins that agglomerate the wood composite and the wood fibers of the starting material 10 are resins that thermally set and the temperature increase within the container 10 initiates the process of remelting the resin and consequently causing that the initial material 10 becomes a relatively soft material. It has also been found that the increasing moisture content within the container 10 can be facilitated by sanding the initial material 10 on its non-insulated surface 12. Sanding to the surface 12 appears to remove the resin located on the surface, such that moisture absorption is increased. Those skilled in the art will recognize that the wood fibers swell as moisture is absorbed, such that the steam applied in the container 40 serves for purposes of expanding the wood fibers, so that they can be consequently , elongated during the forming process and also, melting the resin in order to soften the initial material 10. It has been found that low pressure steam can be used within the container 40. Moreover, care must be taken with the time in the container. which initial material 10 is exposed to steam. If the material is exposed to steam for at least 30 seconds, then there will not be enough moisture absorption for the wood fiber to swell, nor enough heat for the resin to soften. If the initial material 10 is exposed to steam for a long time, such as more than one minute, then we have found that the surfaces 12 and 14 of the initial material 10 tend to become swollen and discolored. If the surface is swollen or discolored, then the resulting cover may not be appropriate for a commercially acceptable door cover or may require additional processing.

Although it is preferable that the initial material 10 be exposed to moisture in the vapor form, those skilled in the art will recognize that other processes may be used. For example, clouds of water may be scattered on the surfaces of the initial material 10, followed by infrared or microwave heating. Regardless of how it is applied, moisture absorption is desirable in order to make it easier to inflate the wood fiber. As explained in all the above, the absorption of moisture may not be necessary in certain instances, where more extensive press times are available. With the vaporization vessel 40 and an initial material of 4 mm thickness 10 of medium density fiber sheet, the cycle time can be as fast as 90 seconds. From the steaming vessel 40, the initial material 10 can be transported to the barrier application station 42 where a moisture impervious barrier is applied to the outer surface 14 on the sealant. The moisture-proof barrier needs to be applied only for covers that are intended for outdoor applications. It is preferred that the moisture impermeable barrier be a crepe paper of phenolic resin impregnated with melamine, applied over the sealant. An appropriate paper can be purchased at Azko Nobel down the film name of FIRST flexible SWEDOTEC® TGPN and TXP. It is preferred to use a crepe paper substrate to apply the resin, since the crepe paper has a sufficient expansion factor to charge the expansion that occurs when the design element 18 is formed. Therefore, the crepe paper will not be cut, broken or in any way will provide an interrupted surface through which moisture can enter. Those skilled in the art will recognize that the bonding polymer resin system that forms the moisture impervious barrier may alternatively be applied in the form of a two component liquid, be similar by atomization or undercoat, spread by atomization or applied to the surface 14 in any other way. Other forms of moisture impervious barriers may also be useful. An additional advantage of the crepe paper barrier is that it can be colored, thus allowing a wood grain pattern or any other pattern or ornament to be applied to the resulting surface 24. The moisture barrier also - adds hardness to the cover and provides resistance to abrasion. Improved abrasion resistance is useful during the shipping and distribution of the product, where covers and doors could be scraped or otherwise cut. The resin takes about 40 seconds to cure and seal the face of the cover. The elongated portion of the initial material 10 forming the design element 18 is susceptible to swelling, such that the moisture impervious barrier reduces this possibility. The initial material 10 is then transferred to the press 44, in which the configuration of Figure 3 is printed. It is preferred that the press is a high pressure press, of approximately 2000 tons, with the aim of applying as much as a pressure from 1.5 tons per square inch to the initial material 10 during the pressing operation. Press 44 has plates 46 and 48, as shown in Figure 4. Plates 46 and 48 are preferably each one, a chromium-plated steel die, preferably with a hard chromium bath having a hardness of 70 Rockwells . It is preferred that the surfaces 50 and 52 of the plates 46 and 48 have a hard chromium plating, in order to resist the accumulation of wood sugars that might otherwise occur. Each of the plates 46 and 48 preferably have a thickness of approximately 10 centimeters and each of the plates 46 and 48 are heated. It is preferred that the plates 46 and 48 be electrically heated, such as by means of a Kalrod heater, although it can be accepted as a heating medium, to heating by means of oil circulation or steam circulation. Whichever way they are heated, it is preferred that the plates are maintained at a relatively high temperature or between about 160 cc and 220 cc and more preferably between 188 cc and 193 cc. The high temperature must be maintained throughout the pressing operation, which takes approximately 90 seconds, in order to ensure that the agglomeration resin which is in the initial material 10, re-forms and remains fluid during the pressing operation. The plates 46 have a male die element 54, with the plate 48 having a female die element 56. Preferably the die elements 54 and 56 are positive and negative images, in order to avoid the formation of variations in the thickness of the die. the resulting cover. The press 44 causes the portion of the initial material 10 forming the design element 18 to be expanded or lengthened, such that variations in thickness, as could occur if the die elements 5456 were not positive and negative images, can result in a non-uniform fluid of the softened wood composite material. While Figure 4 shows only a single set of die elements 54 and 56, those skilled in the art will recognize that the molded door of Figure 7 will have a plurality of said cooperating die elements, the exact number and shape, depending on the configuration, size and appearance of the door. It has been found that the initial material 10 can be transformed into a commercially acceptable molded cover 16 by smoothing the starting material 10 initially within the vaporization vessel 40 and then exerting pressure on the initial material 10 between the plates 46 and 48, in response to an increasing cyclical pressure regime. Moreover, it has been found that an acceptable molded cover 16 can be formed, when the press 40 has the means to allow the degassing of the initial material 10 in order to remove air, steam and other volatile substances, which could otherwise be used. inflate to the surfaces of the cover. Degassing can be achieved by opening the plates, as shown in the graph of Figure 5, or by providing vents in the plates, as shown in the graph of Figure 6. Regardless of the As the degassing is performed, we have found that an acceptable molded cover can be formed where the pressure is applied cyclically to constant increase levels, with the aim of causing the fiber of the wood and the resin to flow until the desired configuration, at the same time providing means to remove the gases. Figure 5 shows a graph of the pressure against time for a press 40, in which the plates 46 and 48 are opened cyclically, with the aim of degassing the initial material 10. As shown in Figure 5, the material The initial 10 is placed between the plates 46 and 48, as shown in Figure 4, within the region 58. The pressure is then slowly increased by 60, at a first predetermined pressure. Once the first predetermined pressure is achieved, then this is maintained at 62 for a period of time sufficient to further heat the resin and to cause the wood fibers and the resin to begin to flow. The plates 46 and 48 are then opened at 64 and the initial material 10 is degassed at 66. The pressure is then increased at 68 and maintained at 70. The pressure maintained at 70 is higher than the pressure maintained at 62. The ratio of increase in pressure at 68 is much faster than the relatively slow increase at 60, since it has been found that a relatively low rate of pressure increase causes less stress to be applied to wood fibers and resin. These move more slowly, in view of their relatively hard and expanded condition. Once the configuration of the cover 16 has been achieved through the application of pressure at 62, then the subsequent cycles serve for the purpose of sharpening the definition of the design elements 18 at the same time of smoothing the surface 24 by means of of allowing the resin to accumulate on the surface. After the pressure has been maintained at 70, then plates 46 and 48 are opened again at 72, in order to allow degassing to occur at 74. The pressure is increased by 76, maintained at 72 at a higher level that in 70, and then released in 80 with the aim of allowing degassing in 82. The pressure is then applied quickly in 84, maintained in 86 and then released in 88. Degasification occurs in 90, followed by the application of pressure in 92, maintaining the pressure at 94 and releasing pressure at 96. The cover 16 can then be removed from the mold at 98. It has been found that the pressures 70, 78, 86 and 94 should each be higher than the peak pressure achieved in the immediately preceding cycle. The peak pressure at 94 can be 1.5 tons per square inch, which is a relatively high pressure. We have also found that the final maintenance periods at 86 and 94 should be longer than the previous cycles 62, 70 and 78, in order to provide a better definition to the design element 18. It is preferred that there are between 3 and 6 cycles of pressure with a peak pressure always increasing. Peak pressures in constant increment, in combination with maintenance plates 46 and 48 which are maintained at elevated temperatures, cause the wood fibers to change their state to form the contour of the design element 18, causing the initial material 10 to remain relatively soft and improve the finish of the surface 24, in such a way that it is commercially acceptable and suitable for painting, inking or making any other ornamentation. It has been found that the number of pressure cycles and the degree to which the plates 46 and 48 close, will vary depending on the thickness of the initial material 10 and the material from which it is made. The pressure can be controlled, either by regulating the space between plates 46 and 48, or by regulating the pressure applied to the plates to close them. Typically, only one of the plates 46 and 48 will be able to move relative to the other, such that control over the hydraulic pressure, applied to the movable plate, is effective to control the pressure cycle. As noted above, although it is preferred that the initial material 10 be wetted in a vaporization vessel 40, with the aim of softening the resin and swelling the wood fibers, this is no longer necessary if the cycle of the press is long enough. In this event, the initial material 10 is dried when placed in the press 54, with a moisture content of about 8%. Since the plates 46 and 48 are heated, they then provide sufficient heat through radiation, such as to soften the resin and consequently to the initial material 10. Although the wood fibers that are in the initial material 10 do not they will inflate and consequently have an improved further fluidity, a relatively long press cycle will minimize the impacts in this regard. Figure 6 shows a graph of pressure against cycle time, where plates 46 and 48 have vents passing through them, to allow degassing to occur. Thus, there is no need to open the plates, but we have found that the need continues to have a constantly increasing peak pressure and the need to maintain these peak pressures. The initial material 10 is placed in the mold at 100 and the pressure is slowly increased by 102. The pressure is maintained at 104 and then, increased by 106. It should be recognized that with the ventilated plates 46 and 48, a continuous degassing occurs through the pressure cycle. The pressure is maintained at 108 and then increased by 110. The pressure is then increased by 114, and maintained by 116. The pressure is increased by 118 and maintained by 120. The pressure is increased by 122, maintained by 124 and then, reduced at 126, in order to allow the initial material 16 to be removed at 128. We have found that the conclusion of the pressure cycles of Figure 5 and 6 causes the cover 16 to have a moisture content, as when it is removed, from about 3% to about 4% of its weight. Thus, because of the heat applied by means of the plates 46 and 48, the moisture content of the initial material 10 is substantially reduced during the forming process. Additionally, the resulting finished cover 16 has a density of about 800 to about 1000 Kg / m3, greater than the density of the starting material 10. The increased density makes the cover 16 harder and thus, increasing the strength of the resulting door . Additionally, the increased density provides a better surface for painting. This increased density is attributable to the pressure applied to the initial material 10 by means of plates 46 and 48.

The formation of the design element 18 causes the portion of the initial material 10 forming the design element 18 to be expanded or elongated by approximately 15% to approximately 25% of its length, as shown in Figure 3, through the dates AA. Moreover, the portion 28 of the design element 18 is of reduced thickness, on the order of about 25%, due to the need to provide wood fibers for the increased length. Once the cover 16 has been removed from the press at 98 or 128, then it is transferred to the reconditioning station 130 in which the cover 16 is cut, first coated and moistened again to a moisture content of approximately 8%. The application of the primer layer is not necessary if the crepe paper barrier is used. Humidification can be done by means of water clouds or something similar. Once it has been reconditioned, the cover is then transferred to the door forming station 132, where each cover is adhesively secured to a door frame, preferably a wooden frame, in order to form a door. Figure 7 describes an exemplary door. When the door 20 of Figure 7 is an outer door, then an additional moisture impervious barrier can be applied to the exposed edges of the frame at 134, by applying strips.

Figure 8 describes a fragmentary cross-sectional view of an outer door according to the invention, having molded door covers 16 secured adhesively to the frame 136, with a polyvinyl acetate, for example. Those skilled in the art will recognize that frame 136 extends around the periphery of rectangular roofs 16 and typically will comprise two wooden spars extending along the longitudinal edges and two wooden rails extending horizontally and vertically. Additionally, while describing that the covers 16 are separated from each other, they can have a center, such as that provided by a foam disposed therebetween. A crepe paper of phenolic resin impregnated with melamine 138 is placed over the entire extent of the surface 24 of most of the exterior of the cover 16. As previously denoted, crepe paper of phenolic resin impregnated with melamine 138 provides a waterproof barrier to moisture that minimizes the absorption of water in the door 20. Other bindable moisture barriers can be used, of course, together with the invention. In order to further increase the moisture resistance of the door 20 of Figure 7, an additional moisture impermeable barrier 140 can then be applied to the exposed edges 142 of the frame 136 and the edges 144 of the covers 16. This Additional barrier 140 may also be a crepe paper of phenolic resin impregnated with melamine. It has been found that the crepe paper is very thin, that it can overlap the layers 138 without imparting an undesirable appearance to the surface. The barrier 140 must also be interlocked and this may occur by means of infrared heating or the like. The barriers 138 and 140, as well as the surface 24 which has no barrier, are suitable for painting, painting or for applying any other ornamentation. While this invention has been described as having a preferred design, it is understood that it is capable of accepting modifications, uses and / or additional adaptations, generally following the principle of the invention and including said separations of the present description as long as present within the knowledge or common practice in the art to which the invention belongs and insofar as they can be applied to the essential features stated herein and fall within the scope of the invention limited by the appended claims. It is noted that, with regard to this date, the best method known by the requested, to carry out the present invention, is that which is clear from the present, discovering the invention. Having described the invention as above, the content of the following is claimed as property.

Claims (59)

RE VIND CATIONS

1. A method for reforming an initial material formed previously, in a molded door cover, characterized in that it comprises the steps of: a) providing an initial material of solid sheet of medium density fiber; b) moisten the initial material and allow 10 that the fibers swell; c) place the initial material between the plates of a heated press, the plates being heated to a temperature sufficient to soften 15 to the resin that is in the initial material and consequently to soften the initial material. d) apply enough pressure to close the plates and consequently, 20 causing the initial material to be deformed into a molded shape, determined by means of the configuration of the plates e) to degas the initial material; and 25 f) removing the initial molded material from between the plates.

The method according to claim 1, characterized in that it includes the step of: a) apply pressure to the plates in at least three cycles.

The method according to claim 2, characterized in that it includes the step of: a) apply pressure to the plates in no more than six cycles.

The method in accordance with the claim 10 2, characterized in that it includes the step of: a) applying pressure in the first cycle to a first predetermined level for a period greater than the period in which the pressure is applied in any cycle 15 subsequent.

The method according to claim 2, characterized in that it includes the step of: a) maintaining the pressure in the last cycle for a period exceeding the period of 20 time which, the pressure is maintained in the first cycle.

The method according to claim 1, characterized in that it includes the step of degassing the initial material by means of 25 evacuate moisture through the openings that are in at least one of the plates.

The method according to claim 6, characterized in that it includes the step of: a) applying the pressure to approximately 1.5 tons per square inch.

The method according to claim 2, characterized in that it includes the step of: a) reduce the pressure at the conclusion of each cycle.

The method in accordance with the claim 10 8, characterized in that it includes the step of: a) reducing the pressure to a predetermined base level at the conclusion of each cycle.

10, The method according to the claim 15 2, characterized in that it includes the step of maintaining the pressure at a predetermined level for a predetermined period of time during each cycle.

11. The method according to the claim 20, characterized in that it includes the step of: "a) maintaining the pressure at a predetermined level during each cycle, at a level that exceeds the level at which the pressure was maintained during the cycle 25 immediately preceding.

The method according to claim 10, characterized in that it includes the step of: a) increase the pressure in the immediately subsequent cycle until the predetermined period expires.

The method according to claim 12, characterized in that it includes the step of: a) maintaining the pressure in the last cycle for a period of time exceeding 10 period during which, the pressure was maintained in the first cycle.

14, The method according to claim 13, characterized in that it includes the step of: a) reducing the pressure to a base level until 15 that the time period of the last cycle expires.

The method according to claim 1, characterized in that it includes the step of: a) increasing the moisture content of the 20 smooth initial material of about 15% to about 20% of its weight, before placing the initial material between the plates.

16 The method of compliance with the claim 1, characterized in that it includes the step of: a) exposing the smooth initial material to a low pressure vapor, in order to increase the moisture content.

17. The method according to claim 15, characterized in that it includes the step of: a) exposing the smooth initial material to saturated steam for a sufficient period of time, such as to increase the moisture content of approximately 10 15% to approximately 20% of its weight.

18. The method according to claim 1, characterized in that it includes the step of: a) maintaining the plates at a temperature of about 160 se until 15 approximately 218 se.

19. The method according to claim 18, characterized in that it includes the step of: a) maintaining the plates at a temperature of from about 188 to 20 approximately 193 Q C.

20. The method according to claim 15, characterized in that it includes the step of: a) keeping the plates at a temperature of about 160 seconds until 25 approximately 218 se.

21. The method according to claim 1, characterized in that it includes the step of: a) applying a sealant to a first majority of the surface of the initial flat material, before increasing the moisture content.

22. The method according to claim 21, characterized in that it includes the step of: a) applying a sealer that is colored.

23. The method according to claim 20, characterized in that it includes the step of: a) drying the sealant before increasing the moisture content.

The method according to claim 1, characterized in that it includes the step of: a) applying a moisture impervious barrier to a majority of the surface of the initial material, before placing the initial material between the plates.

25. The method according to claim 24, characterized in that it includes the step of: a) applying a moisture impervious barrier to a majority of the surface of the initial flat material, before placing the initial material between the plates.

26. The method according to claim 1, characterized in that it includes the step of: a) applying a phenolic resin or melamine impregnated moisture barrier to a majority of the surface of the initial flat material, before placing the initial material between the plates.

27. The method in accordance with the claim 10 25, characterized in that it includes the step of: a) providing a phenolic or melamine resin system, such as the moisture impermeable barrier.

28. A door cover, characterized in that 15 is produced by means of the method, according to claim 1.

29. A door cover, characterized in that it comprises: a) a three-dimensional initial material of 20 fiber sheet of medium density, the initial material having a first portion with a first preselected thickness and a second portion having a design element 25 three-dimensional with a second pre-selected thickness, smaller than the first preselected thickness.

30. The door cover according to claim 29, characterized in that: a) the first and second portions extend parallel.

31. The door cover according to claim 30, characterized in that: a) the first and second portions are 10 extend parallel to most of the surface of the initial material.

32. The door cover according to claim 29, characterized in that: a) a waterproof barrier is 15 secured to the initial material and extends over the first and second portions.

33. The door cover according to claim 32, characterized in that: a) the barrier is a crepe paper impregnated with melamine or a crepe paper with phenolic resin.

34. The door cover according to claim 33, characterized in that: a) the barrier is a crepe paper with phenolic resin impregnated with melamine.

35. The door cover according to claim 34, characterized in that: a) the paper is intact to the initial material, having been secured to it during the molding of the initial material.

36. The door cover according to claim 34, characterized in that: a) the paper is secured to only a majority of the surface of the initial material.

37. The door cover according to claim 29, characterized in that: a) a sealant covers a majority of the surface of the initial material.

38. The door cover according to claim 37, characterized in that: a) the sealant is colored.

39. A door cover, characterized in that it comprises: a) a three-dimensional initial material molded from medium density fiber sheet, having a density of about 800 to about 1000 Kg per cubic meter, said initial material formed from a reformed planar initial material and the density of the initial flat material being smaller than the density of the initial three-dimensional material.

40, The door cover according to claim 39, characterized in that: a) the initial material has a first and 10 a second portion, the first portion having a thickness that exceeds the thickness of the second portion.

41. The door cover according to claim 40, characterized in that: a) the first and second portions extend parallel.

42. The door cover according to claim 41, characterized in that: a) the first portion forms a majority of 20 the surface of the initial material.

43. The door cover according to claim 40, characterized in that: a) the first and second portions are integral and the second portion comprises 25 to a molded feature.

44. The door cover according to claim 43, characterized by: a) the molded characteristic has a length that exceeds the length of that portion of the initial material, from which the molded characteristic was formed.

45. The door cover according to claim 44, characterized in that: a) the length is greater by about 15% to about 25%.

46. The door cover according to claim 43, characterized in that: a) a moisture impervious barrier is 15 assured and is on a majority of the surface of the initial material.

47. The door cover according to claim 46, characterized in that: a) the barrier is a polymeric material 20 interlaced.

48. "The door cover according to claim 47, characterized in that: a) the material is a phenolic or melamine resin system.

49. The door cover according to claim 46, characterized in that: a) the barrier is a crepe paper impregnated with melamine or a crepe paper with phenolic resin.

50. The door cover according to claim 40, characterized in that: a) a sealant covers a majority of the surface of the initial material.

51. The door cover according to claim 50, characterized in that: a) the sealant is colored.

52. A door, characterized in that it comprises: a) a peripheral frame having opposite sides arranged; and b) a first and a second molded door covers, formed from a medium density fiber sheet and having a three-dimensional design element, each cover having first and second sides and each first side of the cover having a waterproof barrier Moisture, applied entirely on it and on the design element, to provide an exterior surface on the door and each of the second sides of the door cover, are secured to one side of the frame.

53. The door according to claim 52, characterized in that: a) the barrier is an interlaced polymer composition.

54. The door according to claim 52, characterized in that: a) the barrier is a crepe paper impregnated with interlaced melamine, or a crepe paper with phenolic resin.

55. The door according to claim 54, characterized by: a) the frame has exposed outer edges; and b) a moisture impervious barrier covers the edges.

56. The door in accordance with the claim 20 52, characterized in that: a) the frame barrier has exposed edges; and b) a moisture impervious barrier covers the edges.

57. The door according to claim 52, characterized in that: a) the barrier accepts and retains dyes.

58. The door according to claim 57, characterized in that: a) the barrier is colored.

59. The door according to claim 52, characterized in that: a) each of the covers has a 10 density from approximately 800 to approximately 100 Kg per cubic meter.