Door, deep draw molded door facing and methods of forming door and facing

1. A method of forming a wood composite door facing, comprising the steps of:

disposing a fiber mat in a mold having a lower die and an upper die collectively forming a die cavity when the mold is in a closed position, wherein the lower die has a first flat portion and at least one first downwardly extending contoured design portion, and the upper die has a second flat portion and at least one second downwardly extending contoured design complementary to the at least one first downwardly extending contoured design portion; and

compressing the fiber mat between the lower and upper dies, wherein the compression results in a contoured portion having a vector angle and a draw depth that achieve a satisfactory stretch factor as shown in FIG. 6 .

2. The method of claim 1 , wherein said compressing the mat comprises applying pressure and heat to the mat.

3. The method of claim 1 , wherein the draw depth of the contoured portion is more than 0.125 inches and the vector angle is less than 85 degrees.

4. The method of claim 1 , wherein the draw depth of the contoured portion is at least about 0.5 inches and the stretch factor of about 45%.

5. The method of claim 1 , wherein the draw depth of the contoured portion is about 0.125 inches or less, the vector angle is at least about 85°, and the stretch factor is less than about 90%.

6. A method of forming a door, comprising

securing a first door facing to a first side of a frame, the first door facing having a first contoured portion and a first planar portion, the first contoured portion having a first vector angle and a first draw depth that achieve a satisfactory stretch factor as shown in FIG. 6 ; and

securing a second door facing to a second side of the frame, the second door facing having a second contoured portion and a second planar portion, the second contoured portion having a second vector angle and a second draw depth that achieve a satisfactory stretch factor as shown in FIG. 6 , the contoured portion of the second facing being aligned with and abutting the contoured portion of the first facing.

7. The method of claim 6 , further comprising adhering a core to an interiorly disposed surface of the first door facing prior to securing the second door facing to the second side of the frame.

8. The method of claim 7 , wherein the core comprises corrugated paper.

9. The method of claim 6 , wherein securing the first door facing to the first side of the frame comprises adhesively securing and securing the second door facing to the second side of the frame comprises adhesively securing.

10. The method of claim 9 , wherein adhesively securing the first door facing to the first side of the frame comprises adhesively securing with a hot-melt glue.

11. The method of claim 10 , further comprising pressing the door while the hot-melt glue cures.

12. The method of claim 6 , wherein the first contoured portion comprises a first base and the second contoured portion comprises a second base, and wherein the first base is aligned with and abuts the second base.

13. The door of claim 12 , further comprising adhesively securing the first base to the second base.

14. The door of claim 6 , wherein the first draw depth is more than 0.125 inches and the first vector angle is less than 85 degrees.

15. A method of forming a door, comprising:

disposing a mat in a mold having a lower die and an upper die, wherein the lower die has a first flat portion and a first contoured portion, and the upper die has a second flat portion and a second contoured portion complementary to the first contoured portion;

compressing the mat between the lower and upper dies to form a door facing having a contoured portion and a planar portion, wherein the compression results in the contoured portion having a vector angle and a draw depth that achieve a satisfactory stretch factor as shown in FIG. 6 ;

removing the door facing from the mold; and

securing the door facing to a first side of a frame.

16. The method of claim 15 , the draw depth is more than 0.125 inches and the vector angle is less than 85 degrees.

17. The method of claim 15 , further comprising securing a core to an interior surface of the door facing.

18. The method of claim 17 , wherein the door skin is a first door facing, and wherein the method further comprises, securing a second door facing to a second side of the frame.

19. The method of claim 18 , further comprising adhesively securing the core to the first door facing and the second door facing.

20. The method of claim 15 , wherein said securing the door facing to the first side of the frame comprises adhesively securing.