초록 ▼

The present invention is directed to a system and method for forming an arched top door facing, and the resulting facing. The system includes a panel, a table and a cutting assembly. The panel has a first surface intended to be interiorly disposed and a second surface intended to be exteriorly dispo

The present invention is directed to a system and method for forming an arched top door facing, and the resulting facing. The system includes a panel, a table and a cutting assembly. The panel has a first surface intended to be interiorly disposed and a second surface intended to be exteriorly disposed. At least one boss extends from the first surface. The table has a planar surface and a locator extending outwardly from the planar surface. The locator cooperates with the boss to locate the panel on the planar surface. The cutter assembly is operatively associated with the table, and includes a blade spaced from the locator. The blade engages the panel and forms a curved edge in the panel when one of the blade and the panel is rotated about the locator.

대표청구항 ▼

We claim: 1. A system for forming an arched-top door facing, comprising: a panel comprising a panel body having a first surface intended to be interiorly disposed and a second surface intended to be exteriorly disposed, and at least one boss integrally molded with said panel body so that said panel

We claim: 1. A system for forming an arched-top door facing, comprising: a panel comprising a panel body having a first surface intended to be interiorly disposed and a second surface intended to be exteriorly disposed, and at least one boss integrally molded with said panel body so that said panel body and said boss collectively constitute a monolithic structure; a table having a planar surface and comprising a locator extending outwardly from said planar surface for cooperating with said boss to locate said panel on said planar surface of said table; and a cutter assembly operatively associated with said table, said cutter assembly comprising a blade spaced from said locator and extending through a plane coplanar with said panel when said panel is located on said planar surface, said blade engaging said panel and forming a curved edge in said panel when one of said blade and said panel is rotated about said locator. 2. The system of claim 1, wherein said locator comprises a cylindrical pin. 3. The system of claim 2, wherein said boss includes a body portion defining a bore sized to receive said cylindrical pin. 4. The system of claim 3, wherein said body portion is donut-shaped. 5. The system of claim 1, wherein said panel is formed from one of thermosetting polymer material, sheet molding compound, and wood composite. 6. The system of claim 1, wherein said cutter assembly includes a high speed router. 7. The system of claim 6, wherein said cutter assembly includes an arm support and a router arm, said router arm having a first end rotatably connected to said arm support and a second end connected to said high speed router. 8. The system of claim 1, wherein said blade rotates about said locator pin along an arcuate path subtending at least about 90°. 9. The system of claim 1, further comprising a holding device disposed above said planar surface and movable toward and away from said planar surface for securing said panel against said planar surface when said panel is located on said planar surface. 10. The system of claim 9, wherein said holding device is axially aligned with said locator. 11. The system of claim 1, wherein said table includes at least one side wall extending upwardly from a perimeter edge of said planar surface for aligning an edge of said panel. 12. An arched-top door facing, comprising: a panel body comprising first and second major surfaces, said first major surface intended to be interiorly disposed and said second major surface intended to be exteriorly disposed, said first and second major surfaces defined by a first side edge, a second side edge substantially parallel to said first side edge, a bottom edge, and an arcuate top edge; and at least one boss extending from and disposed on said first major surface, said boss having a donut-shaped body portion defining a bore, said boss being integrally molded with said panel body so that said panel body and said boss collectively constitute a monolithic structure. 13. The arched top door facing of claim 12, wherein said panel body is formed from one of thermosetting polymer material, sheet molding compound, and wood composite. 14. An arched-top door, comprising: a perimeter frame comprising first and second stiles, a bottom rail, and an arcuate top rail; and first and second door facings having interiorly disposed surfaces respectively secured to opposite sides of said frame and exteriorly disposed surfaces facing away from said frame, each of said surfaces defined by first and second side edges, a bottom edge, and an arcuate top edge aligned with and secured to said first and second stiles, bottom rail and arcuate top rail, respectively, each of said facings comprising a panel body and at least one donut-shaped boss extending from and disposed on said interiorly disposed surface, said panel body and said donut-shaped boss being integrally molded with one another so that said panel body and said donut-shaped boss collectively constitute a monolithic structure. 15. The arched top door of claim 14, wherein each of said facings are formed from one of thermosetting polymer material, sheet molding compound, and wood composite. 16. A method of forming an arched-top door facing, comprising: providing a panel comprising a panel body having opposite first and second major surfaces, and at least one boss extending from the first major surface, the boss having a body portion defining a bore and being integrally molded with said panel body so that said panel body and said boss collectively constitute a monolithic structure; providing a table having a planar surface and a locator pin extending outwardly from the planar surface; providing a cutter assembly operatively associated with the table, the cutter assembly having a blade spaced by a first distance from the locator pin; aligning the pin with the bore and inserting the pin therein so that the first major surface is disposed on the table planar surface; and rotating one of the panel and the blade about the locator pin so that the blade engages the panel and forms an arcuate edge in the panel. 17. The method of claim 16, wherein: the at least one boss comprises at least first and second spaced bosses extending from the first major surface; said aligning comprises selecting the bore from the first boss; said rotating one of the panel and the blade about the selected bore causes the blade to travel along a first arcuate path and forms an arcuate edge in the panel. 18. The method of claim 17, further comprising: adjusting the blade of the cutting assembly so that the blade is spaced by a second distance from the locator pin, the second distance greater than the first distance; selecting the bore from the second boss; aligning the pin with the bore of the selected second boss and inserting the pin therein; rotating one of the panel and the adjusted blade about the bore of the selected second boss so that the blade travels along a second arcuate path and engages portions of the formed arcuate edge of the panel, the first and second arcuate paths collectively establishing a substantially elliptical shape at the edge of the panel.