Patent Publication Number: US-11661790-B2

Title: Door comprising vented stile, and method of making the same

Description:
PRIORITY CLAIM AND CROSS-REFERENCE 
     This application is a continuation of U.S. patent application Ser. No. 16/891,221, filed Jun. 3, 2020, which claims priority to and the benefit of U.S. Provisional Application No. 62/857,010, filed Jun. 4, 2019, which applications are expressly incorporated by reference herein in their entirety. 
    
    
     FIELD 
     The disclosure relates to a door generally. More particularly, the disclosed subject matter relates to a door having an internal foam material and the method of making the same. 
     BACKGROUND 
     Doors include wooden doors and fiberglass doors. Fiberglass doors comprising synthetic polymers are used as substitutes for traditional wooden doors. Fiberglass doors include door skins (facings) secured to opposite sides of a rectangular door frame. A resulting cavity between the door skins and surrounded by the door frame optionally is filled with a core material. Doors so constructed can have wood graining printed, molded, or otherwise applied on the exterior surfaces of the door skins, and also raised paneling formed (e.g., molded) in the door skins. These features give the doors the appearance of natural wood fabricated products. Optionally, paint, stain, lacquer, and/or a protective layer may be applied to the exterior surface. 
     Foam or foamed parts are used to make a foam-filled door. The foam may be relied upon to provide structural support, insulation, and/or sound barrier. The foam can be a pre-made part or can be made by utilizing a poured-in-place process. The poured-in-place process typically includes a step of pouring or injecting foam into the cavity formed by frames. Undesirable air pockets may be formed during the manufacturing process and can cause doors to be of poor quality or to be rejected. Air pockets are formed when foam is injected into the door, trapping air inside the door. 
     SUMMARY 
     The present disclosure includes a door, a vented building component, a kit for making the door, and a method of making the door. More particularly, the present disclosure includes a door having at least one vented stile and an internal foam material. The vented stile advantageously enables the internal foam material to be formed without trapped air bubbles or pockets therein. 
     In accordance with some embodiments, a door comprises a first skin providing a first outer door surface, a second skin providing a second outer door surface, and two stiles aligned in parallel along a first direction. The two stiles are disposed at least partially between the first skin and the second skin. At least one stile defines a vent therein. The door further comprises a core comprising a foam material disposed between the first skin and the second skin, and a gas permeable membrane disposed on the at least one stile. The gas permeable membrane has a first side facing and covering the vent, and a second side opposite to the first side. The second side contacts the foam material in the core. 
     The gas permeable membrane is permeable to gas, but not permeable to the precursor of the foam material. In some embodiments, the gas permeable membrane includes a non-woven polymer backing providing gas permeability, and is selectively coated with an adhesive in areas contacting the at least one stile on the first side of the gas permeable membrane. 
     In some embodiments, the vent is oriented along a longitudinal direction of the at least one stile defining the groove. 
     In some embodiments, the door further comprises two rails aligned in parallel along a second direction, which is perpendicular to the first direction. At least one of the two rails defines a first through hole along the first direction. The first through hole is connected to the vent. 
     In some embodiments, the at least one of the two rails defines a second through hole along the first direction. The second through hole is connected to the core. The at least one of the two rails may also define a third through hole. A tube extends from the third through hole into the foam material in the core. Each of the first, second, and third through holes may be filled with the same foam material or a sealant. 
     Such a door may be a door with an insulation core embedded within a cavity defined by the stiles, the rails, and the skins and extending the whole door. In some embodiments, the door may further comprise a glazing unit having at least glass pane mechanically coupled with the first skin and the second skin. 
     In accordance with some embodiments, an exemplary door comprises a first skin providing a first outer door surface, a second skin providing a second outer door surface, two stiles disposed at least partially between the first skin and the second skin, and two rails disposed at least partially between the first skin and the second skin. At least one stile defines a vent therein. The door further includes a core comprising a foam material, which is disposed between the first skin and the second skin, and inside a cavity defined by the first skin, the second skin, the two rails, and the two stiles. The door further includes a gas permeable membrane disposed on the at least one stile. The gas permeable membrane has a first side facing and covering the vent, and a second side opposite to the first side and contacting the foam material in the core. 
     In some embodiments, the two stiles are aligned in parallel along a first direction, and the two rails aligned in parallel along a second direction perpendicular to the first direction. 
     In some embodiments, at least one of the two rails defines a first through hole and a second through hole along the first direction. The first through hole is connected to the vent. The second through hole connected to the core. The at least one of the two rails may further define a third through hole. A tube extends from the third through hole into the foam material in the core. Each of the first, second, and third through holes is filled with the foam material or a sealant in some embodiments. 
     In another aspect, a vented building component is provided. The vented building component has a body extending from a first end to a second end and having a first side. The first side defines a vent along at least a length thereof that extends to the first side. The vented building component has a gas permeable membrane affixed to the first side of the body such that the gas permeable membrane covers the vent along the first side of the body. In some embodiments, the vented building component is a vented stile or rail for a door. The gas permeable membrane includes a non-woven polymer backing providing gas permeability. One side of the gas permeable membrane is selectively coated with an adhesive configured to be bonded with the body in area contacting the body. 
     In another aspect, the present disclosure provides a method for making a door as described above. The method comprises steps, including providing a first skin providing a first outer door surface and a second skin providing a second outer door surface, and providing two stiles and two rails. At least one stile defines a vent therein. Such a method further includes applying a gas permeable membrane onto the at least one stile. The gas permeable membrane has a first side facing and covering the vent, and a second side opposite to the first side. The two stiles, the two rails, and the first and second skins are assembled together. The two stiles are aligned in parallel along a first direction and placed at least partially between the first skin and the second skin. The two rails are aligned in parallel along a second direction. 
     A foamable material is then injected so as to form a core comprising a foam material between the first skin and the second skin. The second side of the gas permeable membrane contacts the foam material in the core. In some embodiments, the foamable material is injected into a cavity defined by the first skin, the second skin, the two stiles, and the two rails. 
     In some embodiments, at least one of the two rails defines a first through hole along the first direction, which is connected to the vent and configured to vent air and gas during the injecting step. The at least one of the two rails also defines a second through hole along the first direction, and the foamable material is injected from the second through hole. In some embodiments, the at least one of the two rails defines a third through hole, and a tube extends from the third through hole into a gap between the first skin and the second skin. The third through hole is used to vent air and gas in the middle of the cavity during the injecting step. 
     In some embodiments, such a method includes sealing remaining holes on the at least one of the two rails with the foamable material or a sealant. The remaining holes may be one of the first, the second, and the third through holes. 
     The method provided in the present disclosure solves the problems of air bubbles or pockets trapped inside a door. The resulting door has no air bubbles or pockets therein and provides high performance and durability. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not necessarily to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Like reference numerals denote like features throughout specification and drawings. 
         FIG.  1 A  is a plan view of an exemplary door comprising at least one vented stile in accordance with some embodiments. 
         FIG.  1 B  is a bottom-side plan view of the exemplary door of  FIG.  1 A . 
         FIG.  1 C  is a cross-sectional view of one example of a door taken along line  1 C- 1 C in  FIG.  1 A . 
         FIGS.  1 D- 1 E  are enlarged details of the cross-sectional view in  FIG.  1 C  in accordance with some embodiments. 
         FIGS.  1 F and  1 G  are plan views illustrating two exemplary rails used in the exemplary door of  FIG.  1 A  in accordance with some embodiments. 
         FIG.  2 A  is a plan view illustrating an exemplary stile comprising a notch therein used in the exemplary door of  FIG.  1 A  in accordance with some embodiments. 
         FIG.  2 B  is a cross-sectional view of the exemplary stile of  FIG.  2 A  taken along line  2 B- 2 B in  FIG.  2 A . 
         FIG.  3    is a flow chart illustrating an exemplary method of making an exemplary door in accordance with some embodiments. 
         FIG.  4    is a perspective view illustrating an exemplary stile having a slot or groove in accordance with some embodiments. 
         FIG.  5    illustrates the exemplary stile of  FIG.  6 A , on which a piece of gas permeable membrane is being applied in accordance with some embodiments. 
         FIG.  6    illustrates the exemplary stile of  FIG.  6 A  with a piece of gas permeable membrane applied thereon and the groove ventable at the end of the stile in accordance with some embodiments. 
         FIG.  7    illustrates the exemplary stile of  FIG.  6 A  with a piece of gas permeable membrane applied thereon and a tube or straw inserted into the groove in accordance with some embodiments. 
         FIG.  8    is a cross-sectional view illustrating a portion of an exemplary foamed door having a vented stile and a gas permeable membrane, but not permeable to a foam material during the fabrication process, in accordance with some embodiments. 
         FIG.  9 A  illustrates a comparative door example without a ventable stile in some embodiments showing air pockets after cut open. 
         FIG.  9 B  illustrates an exemplary door with a vented stile in accordance with some embodiments, showing no air pocket after cut open. 
     
    
    
     DETAILED DESCRIPTION 
     This description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. 
     For purposes of the description hereinafter, it is to be understood that the embodiments described below may assume alternative variations and embodiments. It is also to be understood that the specific articles, compositions, and/or processes described herein are exemplary and should not be considered as limiting. 
     In the present disclosure the singular forms “a,” “an,” and “the” include the plural reference, and reference to a particular numerical value includes at least that particular value, unless the context clearly indicates otherwise. When values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. As used herein, “about X” (where X is a numerical value) preferably refers to ±10% of the recited value, inclusive. For example, the phrase “about 8” preferably refers to a value of 7.2 to 8.8, inclusive; as another example, the phrase “about 8%” preferably (but not always) refers to a value of 7.2% to 8.8%, inclusive. Where present, all ranges are inclusive and combinable. For example, when a range of “1 to 5” is recited, the recited range should be construed as including ranges “1 to 4”, “1 to 3”, “1-2”, “1-2 &amp; 4-5”, “1-3 &amp; 5”, “2-5”, and the like. In addition, when a list of alternatives is positively provided, such listing can be interpreted to mean that any of the alternatives may be excluded, e.g., by a negative limitation in the claims. For example, when a range of “1 to 5” is recited, the recited range may be construed as including situations whereby any of 1, 2, 3, 4, or 5 are negatively excluded; thus, a recitation of “1 to 5” may be construed as “1 and 3-5, but not 2”, or simply “wherein 2 is not included.” It is intended that any component, element, attribute, or step that is positively recited herein may be explicitly excluded in the claims, whether such components, elements, attributes, or steps are listed as alternatives or whether they are recited in isolation. 
     The present disclosure includes a door, a vented building component, a kit for making the door, and a method of making the door. In accordance with some embodiments, the present disclosure includes a door having at least one vented stile and an internal foam material. The vented stile advantageously enables the internal foam material to be formed without trapped air bubbles or pockets therein during the fabrication process. 
     Unless expressly indicated otherwise, references to “a vent” made herein are understood to encompass a structure as being formed as a groove, hole, recess, depression, channel, slot, or other suitable structure that permits the flow of air. References to “a gas permeable membrane” made herein are understood to encompass a thin sheet or film having a porous structure so that gas molecules can transport from one side to the other side of the membrane. One example is a tape. The gas permeable membrane is at least partially coated with adhesive on one side for bonding. 
     Referring to  FIGS.  1 A- 1 G and  2 A- 2 B , an exemplary door  10  in accordance with some embodiments comprises skins  12  comprising a first skin  12 - 1  and a second skin  12 - 2 . The first skin  12 - 1  provides a first outer door surface  13 - 1 . The second skin  12 - 2  provides a second outer door surface  13 - 2 . Both skins  12  form the front and back surfaces of the exemplary door  10 . 
     In some embodiments, the skins  12  may comprise a material of a glass fiber reinforced and mineral filled polymer composite, in which the polymer can be any suitable polymer, for example, cured from unsaturated polyester or polybutadiene. The skins  12  can be sheet molded from a sheet molding compound (CMC) in some embodiments. 
     The exemplary door  10  further comprises at least two stiles  14 , at least one core  16 , and at least two rails  18 . For example, in some embodiments, the stiles  14  include a stile  14 - 1  and a stile  14 - 2 . The rails  18  includes for a top rail  18 - 1  and a bottom rail  18 - 2 . The at least one core  16  is disposed between the first skin  12 - 1  and a second skin  12 - 2 . The at least one core  16  is also disposed between left and right stiles  14 - 1 ,  14 - 2 , and between top rail and bottom rails  18 - 1 ,  18 - 2 . 
     The two stiles  14  are aligned in parallel along a first direction, for example, a vertical direction as shown as “a” direction in  FIG.  1 A . The two stiles  14  are disposed at least partially between the first skin  12 - 1  and the second skin  12 - 2 . The door  10  further comprises two rails aligned in parallel along a second direction, which is perpendicular to the first direction. For example, the rails  12  are aligned in “b” direction (e.g., horizontally) as shown in  FIG.  1 A . The core  16  comprising a foam material is disposed between the first skin  12 - 1  and the second skin  12 - 2 . The two stiles  14  illustrated in  FIG.  1 A  includes a first stile  14 - 1  referred as a vented strike stile, and a second stile  14 - 2  referred as a hinge stile in some embodiments. 
     In some embodiments, the stiles  14  are made of laminated veneer lumber (LVL) or any other suitable material. The rails  18  comprise any suitable materials such as wood, a polymer, or a composite comprising wood and a polymer such as polyvinyl chloride. The rails  18  are made of a wood flour/PVC (polyvinyl chloride) composite in some embodiments. 
     Each core  16  may be in a shape of a rectangle or square in some embodiments, although the core  16  may have other geometric shapes. The core  16  may comprise a foam material such as polyurethane (PU) in some embodiments. The door  10  may have a rectangular shape. 
     Referring to  FIGS.  1 A and  1 C , in some embodiments, the middle portion  15  of the door  10 , which may be a depressed or recessed area, includes the skins  12  and the core  16 . The whole cavity  26  between the two skins  12  is also filled with the core  16 . The door  10  is a foamed door, for example, an insulation door. In some embodiments, the door  10  may include at least one glazing unit having glass panes (without skins) in the middle portion  15 . Such a door is a glazed door. 
     The at least one core  16 , includes one or more pieces of inner cores, which are encased by the skins  12 , stiles  14 , and rails  18 . The at least one core  16  comprises a polyurethane containing composition as described herein. 
     Referring to  FIGS.  1 C- 1 D and  2 B , in accordance with some embodiments, at least one stile  14  defines a vent such as a groove  20  therein. Although referred to as a “groove,” a person of ordinary skill in the art will understand that the groove may take any number of orientations or configurations. For example, the groove  20  may take the form of a recessed area, channel, or other structural element that may be covered by a gas permeable material to facilitate the egress of air in response to the injection of foam as discussed herein. The groove  20  may be located on a surface  14 - 3  facing the core  16 . The groove  20  may be oriented along a longitudinal direction of the at least one stile  14 - 1  defining the groove  20 . In  FIGS.  1 C- 1 D and  2 B , only the first stile  14 - 1  has the groove  20 . These drawings are for the purpose of illustration only. In some embodiments, both stiles may have a groove  20 . In addition, the stiles  14  and the rails  18  can be used interchangeably. For example, the groove  20  may exist in at least one rail  18 . 
     The groove  20  may have a suitable cross-sectional shape. In  FIGS.  1 C- 1 D and  2 B , the groove  20  has a rectangular shape in cross section. Examples of other suitable cross-sectional shape include, but are not limited to, a circle, a half-circle, a square, an oval, and an irregular shape. 
     The exemplary door  10  further comprises a gas permeable membrane  40  disposed on the at least one stile  14 - 1 . As illustrated in  FIG.  2 B , the gas permeable membrane  40  has a first side  40 - 1  facing and covering the groove  20 , and a second side  40 - 2  opposite to the first side  40 - 1 . The second side  40 - 2  contacts the foam material in the core  16 . The gas permeable membrane  40  is gas (e.g., air) permeable, but not permeable to the precursor of the foam material, or a glue, which includes oligomers or pre-polymer in a liquid or paste form. In some embodiments, the gas permeable membrane  40  such as a tape includes a non-woven polymer backing providing high gas permeability and meeting the outgassing requirements for foam-in-place insulation processes. The backing is conformable in some embodiments. The gas permeable membrane  40  such as a tape is selectively coated with an adhesive in areas contacting the at least one stile  14 - 1  on the first side  40 - 1  of the gas permeable membrane  40 . This selective strip coating is configured to provide good gas permeation during the fabrication of the exemplary door  10 . Adhesive is strip coated so uncoated areas have higher permeability to help minimize foaming voids. An exemplary tape used is available from 3M Company as 3M™ Venting Tape  3294 , which is a pink non-woven, synthetic backing with a strip coated low tack pressure sensitive acrylic adhesive. The tape may have any suitable dimension, for example, 2″×(5 mils). 005″. During the manufacturing process, the gas permeable membrane  40  allows air to pass through, but is not permeable for liquid and solid such as the PU foam and the precursors of the PU foam. The air pathway is not coated with adhesive, which is coated for the bonding needed. 
     Referring to  FIGS.  1 A- 1 B , the at least one  18 - 2  of the two rails  18  defines a first through hole  21  along the first direction. The first through hole  21  is aligned and connected to the groove  20 . In some embodiments, the at least one of the two rails  18  defines a second through hole  22  along the first direction. The second through hole  22  is connected to the core  16 . The at least one of the two rails  18  may also define a third through hole  24 . A tube  25  extends from the third through hole  24  into the foam material in the core  16 . Each of the first, second, and third through holes  21 ,  22 ,  24  are used during the fabrication, and may be filled with the same foam material or a sealant if needed. 
     Such a door  10  may be a door with an insulation core  16  embedded within a cavity defined by the stiles  14 , the rails  18 , and the skins  12  and extending the whole door. In some embodiments, the door may further comprise a glazing unit (not shown) having at least glass pane mechanically coupled with the first skin  12 - 1  and the second skin  12 - 2 . In some embodiments, the skins  12  may have ribs and flanges, and other fixtures (not shown) for fixing the glazing unit. For example, an exemplary configuration is described in U.S. application Ser. No. 16/104,455, filed on Aug. 17, 2018, which is incorporated by reference herein. As described in U.S. application Ser. No. 16/104,455, each of the first skin and the second skin includes a respective skin body portion providing an outer (e.g., exterior) door surface, and a respective flange portion connected with and extending inwardly from the skin body portion. Each skin body portion has a respective tip. The glazing unit has an edge disposed adjacent to, and between two tips. The end of a first flange portion and the end of a second flange portion have complementary shapes and sizes, and are interconnected to provide an interlocking structure. 
     Referring to  FIGS.  1 D- 1 E , each of the skins  12 - 1  and  12 - 2  may have interior ribs or studs  30  on the interior surfaces protruding into cavities  32  defining by the stiles  14 . The stiles  13  may include a stile cap  34 , which may be made of a metal or a plastic material. In some embodiments, the stile cap  34  is made of a PVC having wood grain patterns. 
     Referring to  FIGS.  1 F- 1 G , two exemplary rails  18  including a top rail and a bottom rail, respectively, may include notches  36  and  38  configured to be coupled with the skins  12  and the stiles  14 . 
     The present disclosure also provides a method for making a door as described above. Referring to  FIG.  3   , an exemplary method  100  comprises the following steps: 
     At step  102 , a first skin  12 - 1  and a second skin  12 - 2  are provided. The two skins  12  provides a first outer (i.e. exterior) door surface and a second outer door surface, respectively. 
     At step  104 , two stiles  14  and two rails  18  are provided. As described, at least one stile  14  defines a groove  20  therein. An exemplary stile  14  is illustrated in  FIG.  4   . 
     At step  106  of  FIG.  3   , referring to  FIG.  5   , a gas permeable membrane  40  is applied onto the at least one stile  14 . The gas permeable membrane  40  is gas permeable, but not permeable to the precursor of a foamable material, which is generally in the form of a liquid. The gas permeable membrane  40  has a first side  40 - 1  facing and covering the groove  20 , and a second side  40 - 2  opposite to the first side.  FIG.  6    illustrates a resulting stile structure after the gas permeable membrane  40  is applied thereon. The gas permeable membrane  40  may have one end folded and bonded onto one end of the stile  14 , while the groove  20  is maintained open at the end of the gas permeable membrane  40 . As illustrated in  FIG.  7   , a tubing  52  may be optionally used, is inserted into the groove  20  and extends outside in some embodiments. 
     At step  108  of  FIG.  3   , the first and second skins  12 , the two stiles  14 , the two rails  18 , are assembled together to define a cavity  26 . The two stiles  14  are aligned in parallel along a first direction and placed at least partially between the first skin  12 - 1  and the second skin  12 - 2 . The two rails  18  are aligned in parallel along a second direction, which may be normal to the first direction. In some embodiments, the two stiles  14  are aligned in a vertical direction along the vertical edges of the door and at least two rails  18  are aligned in a horizontal direction along the horizontal edges of the door, referring to a resulting door installed for use. 
     The stiles, the rails, and the skins may be optionally bonded using a glue. Such a glue can be an inorganic glue, a polymer hot melt adhesive (e.g., polyurethane or polyolefin based), or a thermosetting-based polymer adhesive (e.g., epoxy, urethane-based). References to an “inorganic glue” made herein are understood to encompass a chemical agent used for bonding the door core to the stiles and/or rails. 
     In some embodiments, an inorganic based glue, for example, comprising Na 2 SiO 3 , MgSiO 3 , and CaSiO 3  is used. In some embodiments, polyurethane reactive hot melt adhesive or a polyolefin-based adhesive is used for bonding, for example, a composite cap to the LVL or engineered wood. For example, a polyurethane reactive hot melt adhesive, DURAPRO UH-2125-1, is from IFS Industries, Inc. (Reading, Pa.). DURAPRO UH-2125-1 contains methylene bispenyl isocyanate and other polymer ingredients. 
     At step  110 , a foamable material as the precursor to the foam material is then injected so as to form a core  16  comprising such a foam material between the two skins  12 . The second side  40 - 2  of the gas permeable membrane  40  contacts the foam material in the core  16 . In some embodiments, the foamable material is injected into a cavity  26  defined by the two skins  12 , the two stiles  14 , and the two rails  18 . The foamable material may be a curable formulation including precursors of a foam material such as polyurethane (PU) in some embodiments. The air inside is pushed and passes through the gas permeable membrane  40 , and is released out from the door assembly through the groove  20  in the at least one stile  14 . A mix head might be used and fluidly connected with the second through hole  22 . The foam injection at Step  110  may take a period of time in the range of from 3 second to 10 seconds. The mix head is pulled out right after the injection and a plug can be inserted into the second through hole  22  to retain the foamable material with the cavity  26 . 
     As described in  FIGS.  1 A- 1 B , in some embodiments, at least one of the two rails  18  defines a first through hole  21  along the first direction. The first through hole  21  is fluidly connected to the groove  20  and configured to vent air and gas during the injecting step. The at least one of the two rails  18  also defines a second through hole  22  along the first direction, and the foamable material is injected from the second through hole  22 . In some embodiments, the at least one of the two rails  18  defines a third through hole  24 , and a tube  25  such as a plastic tube extends from the third through hole  24  into a gap or the cavity  26  between the first skin  12 - 1  and the second skin  12 - 2 . The third through hole  24  is used to vent air and gas in the middle of the cavity  26  during the injecting step  110 . In some embodiments, a tube such as a plastic tube is optionally inserted into each of the first through hole  21  and the second through hole  22 . Each tube may be pulled out, partially cut, or may be partially or fully sealed with the foaming material or an additional sealant. 
     The at least one stile  14  having a venting groove  20  also comprises a gas permeable membrane  40  applied onto a surface of the stile, i.e., the surface  14 - 3  of the stile  14  that faces the core. Such a gas permeable membrane  40  is gas permeable, but is not permeable by the foaming material. During the manufacturing process, the gas permeable membrane  40  allows air to pass through, but is not permeable for liquid and solid such as the PU foam and the precursors of the PU foam. So any air or gas generated from the foamable material are vented out through the gas permeable membrane  40  and the groove  20 . 
     At step  112  of  FIG.  2   , remaining holes on the at least one of the two rails  18  are optionally sealed with the foamable material or a sealant. The sealant may be a polymer formation the same as or different from the foamable material for the core  16 . The remaining holes may be one of the first, the second, and the third through holes  21 ,  22 ,  24 . During the injecting step  110 , the foamable material may fill the second and the third holes  22 ,  24 , and the tube  25 . In some embodiments, a portion of the groove  20 , the end of the groove  20 , or the whole groove  20  may be optionally sealed with a sealant. In some embodiments, the groove  20  or the end of groove  20  is sealed with a sealant. 
     In some embodiments, a rail  18  such as the bottom rail defines a hole  24 , and a tube  25 , such as plastic tube, is inserted into the hole  24  to the space between the two skins for injecting the foaming material into the space to form the core  16 . The tube  25 , or the tubing  52  to the groove may be pulled out of the hole  24  or groove  20 , or may be cut off such that a portion remains within the rail  18  and/or the core  16 . The hole or remainder of the tube may then be sealed with the foaming material or an additional sealant. In some embodiments, the tube  25  and the tubing  52  are made of an optically clear plastic material. 
     Referring to  FIG.  8   , a portion of a resulting exemplary door  10  is illustrated. Such a door  10  has a vented stile  14  and a gas permeable membrane  40  being gas permeable, but not permeable to a foam material during the fabrication process, in accordance with some embodiments. The resulting structure is the same as that described above, for example, in  FIG.  1 D . 
       FIG.  9 A  illustrates a comparative door example without a ventable stile and a gas permeable membrane in some embodiments. Such a comparative door includes air pockets after cut open.  FIG.  9 B  illustrates an exemplary door with a vented stile in accordance with some embodiments, showing no air pocket after cut open.  FIGS.  9 A- 9 B  were made based on photos taken from the samples made.  FIGS.  9 A- 9 B  illustrate a foamed door having a core  16  disposed inside the whole cavity  26  between the two skins  12 , including the middle depressed portion  15 . The method and the related structure provided in the present disclosure solve the problems of air bubble trapped inside a door. The resulting door as described has no air bubbles therein and provides high performance and durability. 
     The present disclosure also includes a vented building component. One example is the vented stile  14 - 1  as described. The vented stile  14 - 1  is described for the purpose of illustration only. Referring to  FIGS.  2 A- 2 B, and  4 - 7   , the vented building component  14 - 1  has a body extending from a first end  13 - 1  to a second end  13 - 2  and having a first side  14 - 3 . The first side  14 - 3  defines a vent  20  along at least a length thereof that extends to the first side  14 - 3 . The vented building component  14 - 1  has a gas permeable membrane  40  as described affixed to the first side  14 - 3  of the body such that the gas permeable membrane  40  covers the vent  20  along the first side of the body. In addition to a stile, the vented building component  14 - 1  can also be a vented rail for a door. As described, in some embodiments, the gas permeable membrane  40  includes a non-woven polymer backing providing gas permeability. One side of the gas permeable membrane  40  is selectively coated with an adhesive configured to be bonded with the body in area contacting the body. 
     The present disclosure also provides a kit or a product comprising the components described herein, and a resulting door assembly. In some embodiments, the kit or the door assembly comprises at least two skins  12  (outer skins), at least two stiles  14 , at least one core  16  (inner core) or a foaming material for the core  16 , at least two rails  18 , and the gas permeable membrane  40 . The skins  12  are fiberglass door skins, and the at least one core  16  may comprise polyurethane foam in some embodiments. The rails  18  comprise a wood flour/polyvinyl chloride composite material. The stiles  14  comprise polyvinyl chloride exterior cap  34  bonded to a laminated veneer or engineered structural lumber. The skins  12  comprise a match-molded high-compression unsaturated polyester and or poly-butadiene, glass-fiber-reinforced, mineral-filled composite material. At least one stile  14  has a venting groove as described. At least one rail may have the through holes as described. The holes can be also on the top rail or on another stile. 
     Although the subject matter has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments, which may be made by those skilled in the art.