Patent ID: 11920405
Assignee: MASONITE CORPORATION
Field: Civil engineering (Other fields)
Classification: CPC E | IPC E

Claim 16:
17. A method for making a shaker door, comprising the steps of:
a) providing a rectangular frame;
b) attaching a first door facing to one side of the rectangular frame, wherein the first door facing is made from a wood composite and contains a raised peripheral region, a transition surrounded by and immediately adjacent to and contiguous with the raised peripheral region, and a planar recessed panel that is surrounded by, immediately adjacent to, and contiguous with the transition, the recessed panel being recessed from the raised peripheral region;
c) laying a core on to an inner side of the first door facing; and
d) attaching a second door facing formed from a wood composite to a second side of the rectangular frame and on top of the core, wherein the second door facing is identical to the first door facing, wherein a first distance between the first and second door skins at the peripheral region is greater than a second distance between the first and second door skins at the panel, wherein the laying step comprises:
i) placing a first portion, having a first density, on an inner surface of the recessed panel, and
ii) placing a second portion, having a second density, on the inner surface of the raised peripheral region, wherein the second density is less than the first density and the second portion is thicker than the first portion, or
i) placing a first filler layer at an inner surface of the raised peripheral region,
ii) placing a first portion, which spans substantially the entire area within the frame, on the first filler layer and an inner surface of the recessed panel, and
iii) placing a second filler layer on the middle layer at the raised peripheral region, or
i) placing a first portion filling on an inner surface of the recessed panel, wherein the first portion extends beyond an area covered by the recessed panel, and
ii) placing a second portion at the raised peripheral region, wherein sections of the first portion that extends beyond the area covered by the recessed panel interlocks with the second portion.