Patent Abstract:
The present invention relates to a modular door having at least one door panel, premanufactured stiles and at least two rails, and is held together using rods optionally having at least one stabilizer; a modular door kit containing said components; and a method of assembling a modular door having said components without requiring adhesives or any extra fasteners.

Full Description:
RELATED APPLICATIONS 
     The present application is a Continuation-in-Part of U.S. application Ser. No. 13/713,723 filed on Dec. 13, 2012, whose contents are expressly incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     The current invention pertains to new and useful improvements to a door assembly process utilizing mortises, tenons and dowels as well as use of dowels for locking door stiles and rails. 
     BACKGROUND OF THE INVENTION 
     Millions of doors are assembled, installed and renovated every year. The process of manufacturing and assembling door is long and complicated; usually it takes several hours to assemble and install a door. Generally, the door is supplied as fully assembled with or without a frame. If the door is supplied without a frame, then prior to installation, the hinges and locks have to be drilled, cut and attached to the door and the frame. Generally, most of the doors have to be prepped for hardware prior to installations; this procedure requires a manipulation of a heavy door. 
     The manufacturing process requires that the door assembly be glued to keep the parts together, and during the gluing process the door has to be locked in special clamps to keep its integrity. The glue requires an extensive curing time before the rest of the door assembly can be completed. Following the gluing process, the door stiles have to be beveled in order to allow smooth closure of the door. The beveling process is known in the art and involves a removal of some layer(s) of material from the stiles on the hinge and/or lock side, thus creating a vertical plane with a slope of approximately 2-3 Degrees. Only after beveling can the whole door be sanded, prepped and painted or covered by protective layers known in the art. 
     This lengthy and involved door manufacturing process allows delivery of fully assembled doors. Delivery of doors in a disassembled state is not possible as the gluing and beveling process can only be performed on the manufacturing site. Furthermore, in the current process if a part or parts of the door are damaged during transportation, the entire door is considered broken and must be replaced. 
     In the case of a modular door, only the damaged part needs to be replaced. 
     The delivery of disassembled doors has the following benefits: they take less space, the risk of breakage is reduced, and if there are broken parts, they can be easily replaced by spare parts. However, disassembled doors need to be assembled on-site by the end user. Therefore, a kit for door assembly is required in which the stiles are beveled prior to the assembly. The assembly kit does not require any complicated tools and ordinarily does not require use of glue. 
     One of the technologies used in door building and manufacturing is the use of mortise and tenon. This technology is well-known and described for example, in U.S. Pat. No. 541,450. This patent teaches a door comprising styles and rails, which are suitably mortised and tenoned together while dowel pins are inserted into the long side of the stiles and pass through both tenons while remaining invisible. This locking means is generally used to improve sturdiness of the final product but does not eliminate the use of glue during the door assembly. There is a further technology of mortise and tenon with protruding dowel also disclosed in the U.S. Pat. No. 5,086,601. This patent teaches a construction of frames for windows and doors while utilizing a joint structure with mortise and tenon. 
     The present invention addresses the deficiencies in prior art by providing an improved method of door assembly by reducing or virtually eliminating a use of glue. The invention also provides a kit for self-assembly of a modular door and method of manufacturing such kit. 
     SUMMARY OF THE INVENTION 
     The current invention pertains to new and useful improvements to a door assembly and an assembly process utilizing mortises, tenons and dowels as well as use of dowels (rods) for locking door stiles and rails. 
     In one aspect of the invention there is provided a modular door comprising:
         a. at least one door panel having a top, a bottom and two sides;   b. a first pre-manufactured stile having a first end, a second end and two sides; one of said sides further comprising at least one mortise, preferably a plurality of mortises,   c. a second pre-manufactured stile having a first end, a second end and two sides; one of said sides further comprising at least one mortise, preferably a plurality of mortises,   d. wherein each stile further comprises a first passageway having a diameter for receiving at least one rod, preferably a plurality of rods, wherein said first passageway extends from the first end of the stile to the second end of the stile passing through at least one of said mortise of the stile;   e. a first pre-manufactured rail having two sides, a first end defining a first tenon and a second end defining a second tenon, wherein each tenon has an aperture having a diameter to matingly receive at least one rod, preferably a plurality of rods;   f. a second pre-manufactured rail having two sides, a first end defining a first tenon and a second end defining a second tenon, wherein each tenon has an aperture to matingly receive at least one rod, preferably a plurality of rods; preferably each of said first passageway and said aperture are substantially of the same diameter; each of said stiles and rails for use in enclosing said at least one door panel;   g. optionally, at least one intermediate pre-manufactured rail having two sides, a first end defining a first tenon and a second end defining a second tenon, wherein each tenon has an aperture to matingly receive at least one rod, preferably a plurality of rods, and positioned between said first rail and said second rail and enclosing said at least one door panel;   h. each of said rails being attachable to the first and second stiles by said mortise of said stile engaging with said tenon of said rail, further affixed in place by at least one rod, preferably a plurality of rods; and   i. wherein at least one rod, preferably two of the plurality of rods locks a single rail, preferably a plurality of rails inside the corresponding stile, wherein upon the insertion of said tenon into said mortise of each stile, the first passageway and apertures are positioned offset one to another, wherein upon insertion of at least one rod, preferably a plurality of rods, into said first passageway and apertures, each tenon is tightly locked into its corresponding mortise;
 
wherein the at least one of said rods further comprises at least one stabilizer.
       

     Another aspect of the invention is to bevel and prep the hardware during the manufacturing process in such a way as to give the end user the ability to assemble a door without the use of glue or a door clamp press. The elimination of glue allows disassembly of the door if needed. 
     The glue-less construction of the door creates multiple advantages and options of improving the design, style, workability, integrity, reuse, and repair if needed as the process allows the end user to take the door apart after it has been assembled, resulting in a considerable savings in time and money by placing the customization factor into the users&#39; hands. 
     In one embodiment, the assembly is carried out using a traditional mortise and tenon joint in the door assembly. In its preferred embodiment, an aperture is created within the tenons on the rails at both ends while a passageway is created along the entire body of the stile. This passageway stops short of the mortises at the top and bottom of the stile. Thereafter, an oversized hole is preferably drilled in the stile for accommodating a bushing. The bushing completes the passageway, by retaining integrity of the stile and enabling rods to be pre-inserted without added friction. This function is useful during assembling or disassembling multiple rail configurations. 
     Preferably, the corresponding apertures in the tenons and passageway are slightly off-set to one another. In this way, when assembled the stiles and rails in combination with the rod/bushings being driven into their final resting position create an opposing force so all mortise and tenons are pressed and locked together for all stiles and rails simultaneously. 
     Finally, driving a screw through the bushing into the stile locks the bushings and rods in place. 
     In another embodiment, the at least one door panel is friction-fitted by the stiles and rails. Preferably, the at least one door panel is fitted within a pre-formed channel disposed along the sides of the stiles and rails. 
     The current invention eliminates the use of glue and the use of a door clamp press, which has a direct result of eliminating the curing time, beveling and prepping for hardware after the assembly for the end user. 
     Beveling and prepping for hardware is done during the stile manufacturing process. The manufacturing process dictates the use of a clamp press with two parallel surfaces in order to prevent buckling and deformation of the door under force. 
     If needed, the stile can be matched to an existing opening, transcribing the original hardware placement to the new door or in this case stile. Since the single stile can be handled, the marking of the hardware makes this a much easier task to handle in place of a fully assembled door. After prepping the stile, the door can be assembled and immediately installed without a wait for glue curing and other door preparations utilized in prior art. 
     Another aspect of the invention is the use of one or more extensions to the rails of the door. These extensions can be used on the top and/or bottom rails. The end user&#39;s choice of different materials such as wood, metal, Plexiglas™, plastic or composite material extension will give the door a unique look. In addition, use of extensions can make it more resilient to the elements. Using a rubber or silicon cover on the extension may, for example, assist in reduction of water damage to the door. Furthermore, use of extensions would allow replacement of the extension only if it became soiled or broken, without need to replace the whole door. 
     In a preferred embodiment, the at least one rod, preferably a plurality of rods comprises pushing rods, locking rods, and locking/pushing rods. The pushing rods are provided to deliver the locking rods into the tenons of the intermediate rail, while the locking/pushing rods are provided to lock one rail as well as to push another locking or pushing rod through the rod receiving channel of the stile. 
     According to yet another aspect of the invention, the set of rods further comprises an unlocking rod having the length equal to the height of the tenon of the corresponding rail to be unlocked. These unlocking rods are positioned between the pushing rods and the locking rods, and can be pushed into the tenon of the rail while removing the locking rod from the tenon to release the intermediate rail from the stile. 
     According to yet another aspect of the invention, the at least one of said rods, preferably said locking rods, further comprises at least one stabilizer, preferably an o-ring, positioned on said rod, to minimize movement of said rod in said passageway and/or aperture. Preferably, said stabilizer is substantially the same diameter as the diameter of the passageway and/or aperture. In a preferred embodiment, the o-ring may be made of any material known in the art for making O-rings including, but not limited to, polymeric elastomer, natural rubber, synthetic rubber, and combinations thereof. The function of the o-ring is to ensure a snug fit of the locking rod in the passageway and/or aperture whilst minimizing the locking rod from moving around in the passageway of the stiles and aperture of the rails. 
     According to another embodiment, the at least one stabilizer is integral with at least one of said rods. The integral at least one stabilizer is, in one embodiment, made from the same material as the rod and may be in a shape conforming to a shape of the passageway and/or aperture. In another embodiment, the at least one stabilizer is moveable along a length of at least one of said rods. In another embodiment, the stabilizer may be in the form of a collar, for example, and also serving to join at least two of said rods. Preferably the collar has a diameter substantially the same as the diameter of the passageway and/or aperture. 
     According to yet another aspect of the invention the top and/or bottom rails include a receiving member to receive an extension to the door with a corresponding mating member. This extension to the door can be decorative or functional and can be easily replaced upon wear or change in utility. 
     According to one additional aspect of the invention, there is a kit for assembling a modular door comprising:
         a. at least one door panel;   b. at least two pre-manufactured stiles each having two ends and two sides, provided with mortises along one of the sides and a first passageway having a diameter and passing through said mortises;   c. at least two pre-manufactured rails each having two sides and two ends with tenons provided at each end while each tenon has a predrilled aperture to receive at least one rod, preferably a plurality of rods; and   d. at least one rod, preferably a plurality of rods to lock the rails to the stiles via said predrilled aperture and said first passageway,
 
wherein the at least one of said rods further comprises at least one stabilizer.
       

     The at least one rod, preferably a plurality of rods, can include two short locking rods of sufficient length to lock one rail to the stile and two long locking rods of sufficient length to lock at least two rails to the stile. More preferably, the plurality of rods has at least six locking rods to lock at least three rails to the stiles, and at least two pushing rods to deliver the locking rods into the distant mortises of the stile. Still more preferably, each stile has at least one locking rod, one pushing rod pre-inserted into a first passageway proximate mortise, distant from one of the ends of the stile. 
     In yet another embodiment there can be an unlocking rod further positioned between the pre-inserted locking rod and pushing rod and a filler rod holding these rods in place during storage and delivery. 
     According to yet another aspect of the invention, the at least one of said rods of the kit, preferably said locking rods, further comprise at least one stabilizer, preferably at least one o-ring, positioned on said rod, to minimize movement of said rod in said passageway and/or aperture. Preferably, said stabilizer is substantially the same diameter as a diameter of the passageway and/or aperture. In a preferred embodiment, the o-ring may be made of any material known in the art for making o-rings including, but not limited to, polymeric elastomer, natural rubber, synthetic rubber and the like. The function of the o-ring is to ensure a snug fit of the locking rod in the passageway and/or aperture whilst minimizing the locking rod from moving around in the passageway of the stiles and aperture of the rails. 
     According to another embodiment, the at least one stabilizer is integral with at least one of said rods of the kit. The integral at least one stabilizer is, in one embodiment, made from the same material as the rod and may be in a shape conforming to a shape of the passageway and/or aperture. In another embodiment, the at least one stabilizer is moveable along a length of at least one of said rods. In another embodiment, the stabilizer may be in the form of a collar, for example, and also serving to join at least two of said rods. Preferably the collar has a diameter substantially the same as the diameter of the passageway and/or aperture. 
     Preferably the kit also has at least one door extension member capable of being attached to at least one of the rails. 
     According to yet another aspect of the invention, there is provided a method of assembling a modular door said door comprising at least one door panel having a top, a bottom and two sides; a first pre-manufactured stile having a first end, a second end and two sides; one of said sides further comprising at least one mortise, preferably a plurality of mortises; a second pre-manufactured stile having a first end, a second end and two sides; one of said sides further comprising at least one mortise, preferably a plurality of mortises, wherein each stile further comprises a first passageway for receiving at least one rod, preferably a plurality of rods, wherein said first passageway extends from the first end of the stile to the second end of the stile passing through at least one of said mortise of the stile; a first pre-manufactured rail having two sides, a first end defining a first tenon and a second end defining a second tenon, wherein each tenon has an aperture to matingly receive at least one rod, preferably a plurality of rods, a second pre-manufactured rail having two sides, a first end defining a first tenon and a second end defining a second tenon, wherein each tenon has an aperture to matingly receive at least one rod, preferably a plurality of rods, preferably each of said first passageway and said aperture are substantially of the same diameter; each of said stiles and rails for use in enclosing said at least one door panel; optionally, at least one intermediate pre-manufactured rail having two sides, a first end defining a first tenon and a second end defining a second tenon, wherein each tenon has an aperture to matingly receive at least one rod, preferably a plurality of rods, and positioned between said first rail and said second rail and enclosing said at least one door panel, each of said rails being attachable to the first and second stiles by said mortise of said stile engaging with said tenon of said rail, further affixed in place by at least one rod, preferably a plurality of rods, and wherein at least one rod, preferably two of the plurality of rods lock a single rail, preferably a plurality of rails inside the corresponding stile, wherein upon the insertion of said tenon into said mortise of each stile, the first passageway and apertures are positioned offset one to another, comprising the following steps of:
         1. Inserting the first tenon of the first rail into a first mortise of the first stile;   2. Locking said first tenon in said first mortise with a first rod;   3. Positioning the at least one door panel adjoining said first rail and first stile;   4. Inserting the first tenon of the second rail in to a second mortise of the first stile while locking the first door panel in place;   5. Positioning a second stile on the side of the rails distant from the first stile, wherein the second tenons of each of the first rail, the second rail and the optionally at least one intermediate rail are inserted into the corresponding mortises of the second stile and the first and second door panels are also locked in place; and   6. Locking the second tenons of the rails in the second stile using a second rod;
 
wherein the first and second rods further comprise at least one stabilizer.
       

     In a preferred embodiment, the method of assembling the door further comprises the steps of:
         1. positioning a second door panel adjoining said second rail and the first stile;   2. inserting the first tenon of the at least one intermediate rail into a third mortise of the first stile while locking the second door panel in place; and   3. locking the First tenon of the second rail and the first tenon of the optionally at least one intermediate rail in corresponding mortises oldie first stile using a third rod;       

     In another preferred embodiment, the method of assembling the door further comprises the steps of:
         1. Inserting a bushing in an opening of the first passageway; and   2. Inserting a screw into said bushing to secure the rods to the stiles.       

     According to yet another aspect of the invention, the rods used in the assembling of the door comprise at least one stabilizer, preferably at least one o-ring, positioned on the rods, to minimize movement of the rods in said passageway and/or aperture. Preferably, said stabilizer is substantially the same diameter as a diameter of the passageway and/or aperture. In a preferred embodiment, the o-ring may be made of any material known in the art for making o-rings including, but not limited to, polymeric elastomer, natural rubber, synthetic rubber and the like. The function of the o-ring is to ensure a snug fit of the rods in the passageway and/or aperture whilst minimizing the rods from moving around in the passageway of the stiles and aperture of the rails. 
     According to another embodiment, the at least one stabilizer is integral with at least one of said rods used in the assembly of the door. The integral at least one stabilizer is, in one embodiment, made from the same material as the rod and may be in a shape conforming to a shape of the passageway and/or aperture. In another embodiment, the at least one stabilizer is moveable along a length of at least one of said rods. In another embodiment, the stabilizer may be in the form of a collar, for example, and also serving to join at least two of said rods. Preferably the collar has a diameter substantially the same as the diameter of the passageway and/or aperture. 
     The assembled door does not require a use of glue or additional bonding agents during the assembly process. 
     The rods locking the rails inside each stile comprise at least one rod, and preferably more than two rods. The rods are selected from locking rods, pushing rods, filler rods, unlocking rods and combination thereof. Preferably, a set of bushings further locks the rods inside the stiles. 
     Additionally, the use of Plexiglas™ gives an even broader choice of uniqueness by shining light directly on to the Plexiglas™ and using it as a light conductor through the door body to shine out the other end without the use of wires. 
     Another aspect of the invention is the ability to take the door apart. Disassembly of the door brings a unique factor into effect. If a door is to be disassembled due to the size being increased, design change, and/or a damaged component in the door that needs replacing, these tasks may be done easily. 
     The end user can accomplish the above-named tasks by removing the screw penetrating the rail and bushing and, using the same screw, drive into the center of the bushing through the rod leaving half the screw outside of the bushing. This will lock the bushing to the rod. Using this as a clamping point, the rods that hold the tenons can be unlocked by simply removing the bushing/rod at either ends of the door. Once completed, a rod of smaller diameter may be inserted. The length is determined by the following formula:
 
width of the tenon+plus length of bushing/rod that was removed+one inch
 
     The rod of smaller diameter is then inserted into the door with force needed until the tip is flush with the door. Remove the rod and repeat this procedure for all the locks. The rails are unlocked from the stiles; the door can now be disassembled. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is an exploded view of the modular door. 
         FIG. 2  is a see-through view of an assembled modular door. 
         FIG. 3  is an elevated see-through view of a rail of the modular door. 
         FIG. 4  is an elevated view of a stile. 
         FIG. 5  is a cut view of  FIG. 4  through line A-A. 
         FIG. 6  is an enlarged top view of area B of  FIG. 5 . 
         FIG. 7  is an elevated view of the extension insert into the rails. 
         FIG. 8  is a see through partial view of the bottom part of the assembled door. 
         FIG. 9  is an elevated view of the bushing. 
         FIG. 10  is a cut view of  FIG. 9  through line C-C. 
         FIGS. 11-15  illustrate the process of disassembly of the modular door. 
         FIG. 16  is an illustration of stile with pre-inserted rods. 
         FIGS. 17A and 17B  demonstrate the interaction of the rail and stile in locked and unlocked state. 
         FIG. 18  shows another embodiment of the locking rod. 
         FIG. 19  shows another embodiment of the locking rod. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  illustrates an exploded view of the modular door  10 . This modular door comprises a first stile  20 , a second stile  21  and a top rail  30  and a bottom rail  32 . The door also comprises at least one intermediate rail  31 . Depending on the design requirements, the door may include additional horizontal rails between the top and bottom rails  30  and  32 . Locked between the stiles and the rails, there are panels  11  and  12 . The panels can be manufactured any way and from any material known to a person skilled in the art of door manufacturing, and the number of panels may vary according to the number of rails. 
     Each stile comprises a plurality of mortises corresponding to a set of tenons positioned on the rails, best illustrated in  FIG. 2 , and there are a plurality of rods ( 40 - 44  and  46 ), which retain the tenons inside the mortises of each stile. 
       FIG. 2  illustrates rail  31  with tenon  34  positioned proximate to its corresponding mortise  26  in stile  21 , and rail  32  with tenon  34  positioned proximate to its corresponding mortise  25  in stile  21  prior to the assembly process. 
       FIG. 2  illustrates the assembled door with tenon  34  of rail  31  completely inserted into mortise  26  of stile  20  and locked in this position by the means of rod  40 . Tenon  34  of rail  32  is fully inserted into mortise  25  of stile  20  and locked in this position by the means of rod  44 . Finally, tenon  34  of rail  30  is fully inserted into mortise  27  of stile  20  and locked in its position by rod  46 . Rails  30 ,  31  and  32  are fixed to stile  21  on the opposite side of the door, in the same manner as they are fixed to stile  20 . 
     As illustrated in  FIG. 2 , panel  11  is locked between rails  30  and  31  and by stiles  20  and  21 , while panel  12  is locked between stiles  20  and  21  and rails  31  and  32 . 
     Rail Manufacturing Process: See  FIG. 3   
     
         
         
           
             1. Rail  30  is squared. 
             2. Groove  36  is cut vertically on one side of rail  32  down the center of the rail so panel  11  can be inserted into this groove during the door assembly. 
             3. A pair of tenons  34  is created on each end of rail  32 . 
             4. Apertures  35  are drilled in each tenon. These holes receive the rods locking the mortises of the stiles. 
             5. In one of the embodiments, first rail  30  and/or second rail  32  may have an extra mortise  33  on a side opposite groove  36  in order to receive an extension  37 . In yet another alternative embodiment second rail  32  can also have a mortise  33  to receive a bottom extension  37 . All intermediate rails  31  have two grooves  36  to receive panels on both sides. 
             6. In a preferred embodiment, a chamfer (not shown) is applied to the tenon for better seating on assembly of the door. 
           
         
       
    
     In one embodiment, second rail  32  and first rail  30  are identical and can be used interchangeably to reduce the number of manufactured pieces of the door. In yet another embodiment (not shown), rails  30 ,  31  and  32  may be identical thus groove  36  on both sides of the rails can be used to receive a panel  12  or extension  37 . 
     Referring to  FIG. 7 , extension  37  can be added to first rail  30 , second rail  32  or both by the means of insertion a mating member  38  into receiving member  33  of the rails. Mating member  38  can be of any type known in the art such a ridge, tenon, and a plurality of pins, etc. 
     The extensions can vary in height, preferably from ¾″ to 10″ depending on the manufacturing materials and design. Extension  37  can be constructed from various materials such as metals, wood, plastics and composite materials. Each extension  37  can be rubberized, painted or coated to protect the insert from elements and wear. 
     Stile Manufacturing Process ( FIGS. 4-6 ): 
     The manufacturing process of stile  20  is similar to the manufacturing process of stile  21 . The only difference is the preparation and positioning of the hardware on these stiles.
         1. Stile  20  is squared and beveled.   2. A plurality of mortises  25 ,  26 ,  27  are cut into stile  20  according to design.   3. Channel  22  is cut down the center of stile  20  (opposite the bevel) so panels  11  and  12  can be inserted during an assembly process.   4. First passageway  23  is provided down the center of the stile just short of the top and bottom keeping the integrity intact. This passageway receives rods locking the tenons of the rails in the mortises of the stile. Passageway  23  can be lined (not shown) with a plastic or metal sleeve in lieu of wood. Passageway  23  is placed a few millimeters behind groove  22  that holds panels  11  and  12  in place in order not to lose the integrity of groove  22 .   5. Bushing holes  28  are drilled at the top and bottom of stile  20  continuing where the passageways left off to accept a wood, plastic, Plexiglas™ or metal bushing/rod.   6. In a preferred embodiment as illustrated in  FIG. 16 , at least some of the plurality of rods  40 ,  41 ,  42  and  43  are strategically pre-inserted into first passageway  23  to save on assembly time of the finished door for the end user.   7. With reference to  FIG. 16 , rod  40  (referred to as a “locking rod”) can be placed at the very edge of mortise  26 . It can enter from the bottom or top of the stile from which a hole was created to accept a bushing (depending on the design of the mortises). Once rod  40  has entered the passageway, a small amount of force can be applied in order to set it into place.   8. Rod  41  (referred to as an “unlocking rod”) can enter from the following mortise and be placed behind the first rod. Little to no force is needed to position this rod, as this rod has a smaller diameter than rod  40 . Rod  42  can also use the same path as rod  40  and can be placed directly against rod  41 . Little to no force is needed to position rod  42 , as it too has a smaller diameter than the rod  40 . Rod  43  can be placed against rod  42  and enter from the mortise like rod  41  (short in length). Rod  43  is provided in order to keep rods  40 ,  41  and  42  in place during the transportation. A small amount of force is need to position rod  43 . This may all be repeated depending on the design chosen.       

     The plurality of rods have varied lengths, at least two of which are of smaller diameter and can be made of wood, plastic, Plexiglas™, metal or other material known in the art. The length of rod  40  preferably corresponds to the width of tenon  34  plus two inches. 
     Rod  41  has a length preferably corresponding to the width of tenon  34  and has a smaller diameter than rod  40 . 
     Rod  42  is preferably a few inches short of the following mortise, as well as being of a smaller diameter. 
     Rod  43  fills the remaining gap to the edge of the mortise and preferably has the same diameter as the passageway. 
     The lengths of the rods are determined by the design. If using multiple rails  31  and if locking from one side top or bottom, approximately 2 inches or the width of the tenon should be added to rod  41  for every rail added. 
     Rods  40 ,  41 ,  42 ,  43 ,  44 ,  46  are provided to lock the tenons inside the mortises, and to move the neighboring rods into correct positions. The rods can vary in diameter from about ¼″ to about 1″. The material of the rod can vary according to the design, size and weight of the door. The material can be selected from metals (such as steel or metal alloys), wood species, Plexiglas™, plastics, etc. 
     According to yet another aspect of the invention, one long rod may replace all rods  40 - 44 , and this long rod may lock both rails  31  and  32  to stile  20 . 
       FIG. 9  provides an illustration of bushing  45 . Bushing  45  (as well as corresponding bushing  47  in  FIG. 1 ) is provided to lock the rods in their position and to prevent movement of the rods away from first passageway  23 . 
     Bushing size can vary in length and diameter in lengths of about 1″ to about 3″ and diameters of about ½″ to about 1⅝″. The material of the bushing can be selected from metals such as steel or metal alloys, wood species, clear Or colored Plexiglas™, plastics, etc. In one preferred embodiment, bushing  45  is coupled with bottom rail rod  44 . This rod can be locked in seat  55  (see  FIG. 10 ) by any means known in the art. In addition, bushing  45  has a tapered screw hole  48  allowing the bushing to be locked both to stile  20  and rail  30 . 
     In the same manner bushing  47  may be coupled with the top rod  46 . 
       FIGS. 17A and 17  B 
     In a preferred embodiment, aperture  35  in tenon  34  is created in an offset from the center line of first passageway  23  of stile  20 , thus creating a pre-tensioned joint. This is done in order to create a pulling force on tenon  34  into their corresponding mortises when the rods are inserted. This force therefore, closes the gap G between the two components (the gap  60  in  FIG. 17B  is smaller than the gap  60  in  FIG. 17A ). This force causes a tight attachment between the components and therefore eliminates the need of using a clamp press for gluing the door. Further, it virtually eliminates the use of glue in the door assembly process, making the process simpler, faster and economically effective. 
     
       FIGS. 18 and 19 
     
     With reference to  FIGS. 18 and 19 , rod  40  further comprises at least one o-ring  70  positioned on the rod and having substantially the same diameter as the diameter of the first passageway  23  and the aperture  35 . The o-ring is made of any material known in the art for making o-rings including, but not limited to, polymeric elastomer, natural rubber, synthetic rubber and the like. The function of the o-ring is to ensure a snug fit of the rod in the passageway and aperture and preventing the rod from moving around in the stiles and rails. In this embodiment, the resilient nature of the o-ring material allows the rod to fit snuggly within the aperture and the first passageway to prevent lateral and longitudinal movement within the aperture and the first passageway. 
     Process of Assembly: See  FIG. 1 . 
     An example of the modular door assembly process is provided below. 
     In one of the embodiments, the mortises, tenons, channels and rods can be sprayed or covered with substances known in the art, to allow smooth insertions of tenons and rods.
         1. Stile  20  is positioned on a flat surface.   2. First rail  30  is attached to the top of stile  20  with tenon  34  inserted into mortise  27 .   3. Rod  46  comprising an o-ring is inserted with appropriate force into its final resting position generating a force from the offset created in the manufacturing process to close gap  60  between stile  20  and rail  30  and locking it into position.   4. Bushing  47  locks rod  46  followed by driving a screw  48  in an angle through bushing  47  into rail  30 , locking the bushing to stile  20  and rail  34  simultaneously. In a preferred embodiment, bushing  47  is coupled with rod  46  prior to insertion into first passageway  28  to make the process of assembly more convenient and reducing the chance of damaging the dowel.   5. Panel  11  (or panels if required by design) is inserted into panel channels  36  and  22 .   6. Intermediate rail  31  (or multiple rails) is inserted into stile  20  by insertion of tenon  34  into mortise  26 .   7. Panel  12  (or panels if required by design) is inserted into panel channels  36  and  22 .   8. Second rail  32  is inserted into stile  20  by insertion of tenon  34  into mortise  25 .   9. Rod  44  comprising an o-ring is inserted with the appropriate force into its position, while at the same time pushing pre-inserted rods  40 ,  41 ,  42  and  43  into their final resting position. This will generate force from the offset closing the gap between stile  20  and both middle rail  31  and bottom rail  32  simultaneously.
           A screw  48  is driven into bushing  45 , locking the bushing to rail  32  and stile  20 .   
           10. Stile  21  is placed in a corresponding position and force is applied bringing the stile down to its final seating, mating tenon  34  of rail  30  with mortise  27 , tenon  34  of rail  32  with mortise  26  and tenon  34  of rail  32  with mortise  25 .   11. Rod  46  comprising an o-ring is inserted with the appropriate force into its final resting position generating force from the offset created in the manufacturing process to close the gap  60  between stile  21  and rail  30  and locking it into position. Rod  46  is locked with bushing  47 , then a screw  48  is driven into bushing  47  to connect it to rail  30  and stile  21 . (Preferably bushing  47  is coupled with rod  46  as explained above.)   12. Finally, rod  44  comprising o-ring  70  is installed with the appropriate force into its final resting position, while at the same time pushing the pre-inserted rods  40 ,  41 ,  42  and  43  into their final resting position, which will generate force from the offset to close the gap between both stile  21  and mid and bottom rails  31  and  32  (and/or multiple rails) simultaneously.       

     Rod  44  is locked with bushing  45  and screw  48  is driven into bushing  45  ultimately to lock rail  32  to stile  21 . (Preferably bushing  45  is coupled with rod  44  as mentioned above.) 
     Alternatively, in a further embodiment of the invention, glue or another bonding agent can be added to all mortises and tenons to add strength to the door, if the door will not be disassembled. However, this addition of glue prior to assembly does not extend the assembly time since there is no need to wait for the glue to dry. 
     Disassembly Process ( FIGS. 11-15 ) 
     There may come a time when a modular door may need to be disassembled to replace worn or damaged parts. If glue was not utilized during the assembly, disassembly is relatively easy. 
     Steps for the full disassembly of the modular door are provided below; but in most ases, a partial disassembly of the door will suffice.
         1. Remove screw  48  locking the bushings to rail and stile. (See  FIG. 11 .)   2. Drive a screw through the center of the bushing into the rod, locking the rod and bushing together. A good portion of the screw should be left protruding so that it can be used as an anchoring point for the bushing and rod to be removed (See  FIG. 12 .)   3. Use a claw end of a hammer or other tool known in the art; remove the hushing and rod attached by the screw, using a technique known to a person skilled in the art.   4. Repeat the above procedure with all bushings.   5. Using a rod  50 , (preferably made of steel, with a substantially smaller diameter and having sufficient length to push the rod  41  into tenon  34  of rail  31 ) remove rod  40  from tenon  34  of rail  31  by placing rod  50  into the hole and drive it forward until the tip is flush with the edge of the door (see  FIG. 15 ).   6. Rod  50  is then removed from the first passageway using tools known in the art. Rod  50  used to push the rods  40 ,  41 ,  42  and  43  may vary in length due to design.   7. The door can now be taken apart. The mortise and tenons are unlocked.
 
Advantages of the Modular Door Kit
   1. Before assembly the stile can be machined for hardware installations such as hinges and or locks. A single stile simplifies handling, unlike manipulating the entire assembled door.   2. Shipping the components in a disassembled state makes the process of loading/unloading from dock level, truck, or condo elevator much easier to manage.   3. This novel process gives the customer on-the-spot flexibility in design, dimensions and integrity with multiple choices of materials and designs that can be used. For example, pre-manufactured parts of the door (such as the door panels) can be constructed from different materials to fit the custom design selected by the end user at the store.   4. This vast customization factor eliminates delays and reduces material and labour costs that are incurred as a matter of course when manufacturing custom doors.   5. After assembly is complete, the door can be installed immediately whether an end user chooses to assemble it with or without glue.   6. Do-it-yourself end users have the opportunity to assemble the door themselves, thus furthering labour cost savings.   7. The pockets  36  created on the top and bottom of the door rails provide the customer with an option of extending the height of a door to match high door openings, allowing an existing door to be reused rather than replaced. Depending on the chosen material, inserts  37  can make the door more resistant to the elements, increase its integrity or simply bring about a design change.   8. In a preferred embodiment, when the door is assembled without a bonding agent, the end user has the advantage of greater flexibility in design, dimensions, replacement of damaged components, or even disassembly that was not previously available.       

     In one of the alternative embodiments, by using a Plexiglas™ or other transparent material in bushing/dowel and rods the door can be illuminated. A light source can be placed on either the top or bottom of the door and, using the Plexiglas™ as a conductor to carry light through the door can create a unique look without the need to run any wires through the door. 
     Design options may include choosing transparent, semi-transparent, or light scattering features on selected parts of the door. For example, an illumination from the sill of the door can be transferred through hard transparent dowels to similarly constructed top and/or bottom rails, providing such a door with a unique illuminating feature. The transparent or otherwise light scattering inserts can be positioned in the rails, panels and even stiles. 
     The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

Technology Classification (CPC): 4