Patent Description:
In a conventional manufacturing process, a door is typically made from a pair of door skins attached to opposite sides of a core and secured together. For example, one method of assembling doors involves applying adhesive to an inside surface of each of the two door skins, and then stacking an internal frame and lightweight core material between the door skins. The core and door skins are then pressed together to bring the adhesive into contact with the frame. Thereafter, the assembly is fed into a heated press for curing the adhesive to complete the process and prepare the door for final processing, which may include edge trimming, paint, or application of other surface treatments as desired. <CIT>, according to its abstract, relates to making a door having first and second door skins and an internal frame. The top and bottom surfaces of the frame are coated with an adhesive and the frame is placed on a first door skin. The second door skin is then placed on the opposite surface of the frame. The assembled components are then pressed to bond the first and second door skins to the frame with a pressed having platens. Movable shims may be used to vary the pressed force and pressing area. <CIT>, according to its abstract, relates to pressing a door assembly involving one or more die sections installed in a press, wherein the die sections each have a raised section that contacts and supports a recessed panel portion of a door skin of the assembly during the pressing operation to facilitate crushing of portions of a core of the door assembly that underlie the recessed panel portion of the door skin. The die sections may be made of plastic and readily changed out for different sizes or styles of doors.

In some embodiments, the door skins include a combination of flat panel portions and inwardly-contoured channels that simulate the sticking regions of a traditional solid wood door. In many conventional press configurations, pressure is applied to the door components (e.g., the door skins and core) to promote bonding. However, in many conventional pressing processes, the pressure is applied primarily to the flat panel portions of the door skins, but no direct pressure is applied to the inwardly-contoured channels. As a result, some doors may fail to bond properly during the pressing and curing processes, especially along the inwardly-contoured channels where no pressure is applied, which may lead to separation of the door skins and core and create overall performance issues.

Accordingly, the present inventors have identified a need for an improved system and method for manufacturing doors.

This is solved by the subject-matter of the independent claims; further embodiments are incorporated in the dependent claims.

According to an example, a system is provided for making a door assembly of the kind having an internal frame, a core, and first and second door skins attached to the frame on either side of the core, wherein each of the door skins has a planar portion bordering at least one recessed panel portion. The system comprises a scanning system operable to survey an outer surface of the first door skin and to obtain surface data therefrom identifying a location of the at least one recessed panel portion on the first door skin. The system also comprises a controller in communication with the scanning system, the controller receiving the surface data obtained by the scanning system. The system further comprises a press in operable communication with the controller, the press including a first set of actuators and a second set of actuators, each actuator in the first and second sets of actuators including a press member coupled thereto, wherein the first set and second set of actuators are operable to drive their corresponding press member toward each other for pressing the door assembly in a pressing operation. Based on the surface data from the controller indicating a location of the at least one recessed panel portion on the first door skin, the press selectably actuates a first group of actuators from the first set of actuators and a second group of actuators from the second set of actuators during the pressing operation, such that the corresponding press members of the selected first group of actuators directly contacts the at least one recessed panel portion of the first door skin and compresses a portion of the core underlying the at least one recessed panel portion of the first door skin, and the corresponding press members of the selected second group of actuators directly contacts the at least one recessed panel portion of the second door skin and compresses a portion of the core underlying the at least one recessed panel portion of the second door skin.

According to a <NUM>nd example of the system, the press simultaneously actuates the selected first group and second group of actuators during the pressing operation.

According to a <NUM>rd example of the system, each actuator in the selected first group of actuators is paired with a corresponding actuator in the selected second group of actuators, and the paired actuators are actuated simultaneously by the press during the pressing operation to compress the at least one recessed panel portion of both the first and second door skins.

According to a <NUM>th example of the system, the first and second door skins each further including a transition region extending between the at least one recessed panel and the planar portion, and the scanning system is further operable to identify a location of the transition region on the first door skin, and each of the first and second groups of actuators further includes at least one actuator directly contacting the respective transition region of the first and second door skins.

According to a <NUM>th example of the system, the press members of the first and second sets of actuators are separated by a gap forming a passageway through which the door assembly travels during the pressing operation.

According to a <NUM>th example of the system, the system further comprises a driver coupled to the door assembly. The driver is operable to move the door assembly through the passageway between the press members during the pressing operation.

According to a <NUM>th example of the system, the press members are rollers operable to rotate as the driver moves the door assembly through the press.

According to an <NUM>th example of the system, the press members each include non-marring contact surfaces that directly contact the at least one recessed panel portion of the first and second door skins during the pressing operation.

According to a <NUM>th example of the system, the scanning system includes one or more two-dimensional lasers.

According to a <NUM>th example of the system, the system further comprises an alignment mechanism operable to align the door assembly prior to entry into the press for the pressing operation.

According to an example, a method is provided for making a door assembly of the kind having an internal frame, a core, and first and second door skins attached to the frame on either side of the core, wherein each of the door skins has a planar portion bordering at least one recessed panel portion, said method comprising:.

According to a <NUM>nd example of the method, the press simultaneously actuates the selected first group and second group of actuators during the pressing operation.

According to a <NUM>rd example of the method, provided as an option to the second example, each actuator in the selected first group of actuators is paired with a corresponding actuator in the selected second group of actuators, and the steps of actuating the first and second groups of actuators via the press are performed simultaneously during the pressing operation to compress the at least one recessed panel portion of both the first and second door skins.

According to a <NUM>th example of the method, the first and second door skins each further include a transition region extending between the at least one recessed panel and the planar portion, and the method further comprises:.

According to a <NUM>th example of the method, the press members of the first and second sets of actuators are separated by a gap forming a passageway through which the door assembly travels during the pressing operation.

According to a <NUM>th example of the method, provided as option for the fifth example of the method, the method further comprises driving, via a driver, the door assembly through the passageway between the press members during the pressing operation.

According to a <NUM>th example of the method, the press members are rollers operable to rotate as the driver moves the door assembly through the press.

According to a <NUM>th example of the method, the press members each include non-marring contact surfaces that directly contact the at least one recessed panel portion of the first and second door skins during the pressing operation.

According to an <NUM>th example of the method, the scanning system includes one or more two-dimensional lasers.

According to a <NUM>th example of the method, the method comprises aligning the door assembly prior to entry into the press for the pressing operation.

Additional aspects and advantages will be apparent from the following detailed description of preferred embodiments, which proceeds with reference to the accompanying drawings.

With reference to the drawings, this section describes embodiments of a drop roller press system and methods for using the same in making recessed panel doors. Throughout the specification, reference to "one embodiment," "an embodiment," or "some embodiments" means that a described feature, structure, or characteristic may be included in at least one embodiment of the systems and methods described herein. Thus, appearances of the phrases "in one embodiment," "in an embodiment," or "in some embodiments" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the described features, structures, and characteristics may be combined in any suitable manner in one or more embodiments. In view of the disclosure herein, those skilled in the art will recognize that the various embodiments can be practiced without one or more of the specific details or with other methods, components, materials, or the like. In some instances, well-known structures, materials, or operations are not shown or not described in detail to avoid obscuring aspects of the embodiments.

<FIG> collectively illustrate embodiments of a drop roller press system <NUM> and related methods for making recessed panel doors <NUM>. Briefly, a typical panel door <NUM> includes a frame <NUM> extending along the perimeter of the door <NUM> and defining an internal compartment filled by a core <NUM> of any suitable material. The door <NUM> further includes a pair of door skins <NUM>, <NUM> surrounding the core <NUM> and adhesively coupled to the frame <NUM>. In some embodiments, the door skins <NUM>, <NUM> may be preformed with recessed panel regions <NUM>, <NUM> that provide desirable contours to the outer profile of the door <NUM>. During assembly, the door skins <NUM>, <NUM> and core <NUM> are compressed together to facilitate the bonding process. However, as noted previously, many conventional press systems fail to apply direct pressure to the recessed areas and to the transition regions <NUM>, <NUM> extending between the recessed panel regions <NUM>, <NUM> and the flat, planar regions <NUM>, <NUM> of the door skins <NUM>, <NUM>. Accordingly, the components of the door <NUM> may fail to bond properly, thereby potentially leading to separation of the door skins <NUM>, <NUM> from the core <NUM> and/or frame <NUM>.

With particular reference to <FIG>, the disclosed system includes a scanning system <NUM> designed to survey the door <NUM> and to identify the location of any surface features on the door <NUM>, such as the recessed panel regions <NUM>, <NUM> and the transition regions <NUM>, <NUM>, relative to a reference point on the door <NUM> (such as the top border or side edge borders of the door <NUM>). The surface data obtained by the scanning system <NUM> is processed and stored in a programmable logic controller <NUM>. Thereafter, the door <NUM> is transported to a drop roller press <NUM> that includes a plurality of actuatable top and bottom actuators <NUM>, <NUM> (e.g., pneumatic cylinders) and press members <NUM>, <NUM> (e.g., rollers) that are controllable based on the stored surface data and instructions from the programmable logic controller <NUM>. The drop roller press <NUM> is designed to actuate a targeted subset of actuators <NUM>, <NUM> and press members <NUM>, <NUM> to apply direct pressure to the recessed panel regions <NUM>, <NUM> and the transition regions <NUM>, <NUM> (or other surface areas of interest) identified by the scanning system <NUM>. As noted previously, these areas typically would not receive direct application of pressure in conventional presses. Subsequent to this roll pressing process, the door <NUM> may be transferred to a cold rolling press <NUM> for further pressing, then trimmed, finished, and packaged for shipment or sale. Additional details of each of these and other embodiments of the scanning system <NUM> and drop roller press <NUM> are described in further detail below with reference to the figures.

<FIG> and <FIG> illustrate a door <NUM>, made by the method and system disclosed herein, in accordance with one embodiment. With reference to <FIG>, door <NUM> includes an internal frame <NUM> that extends around a perimeter of door <NUM> to define a cavity filled by a core <NUM>. A first (or front) door skin <NUM> overlays a front surface of frame <NUM> and core <NUM>. A second (or rear) door skin <NUM> (<FIG>) overlays a rear surface of frame <NUM> and core <NUM> opposite the front surface. First door skin <NUM> includes an inner surface <NUM> facing core <NUM> and frame <NUM>, and an outer surface <NUM> forming the front surface of door <NUM>. Inner surface <NUM> is coupled to the front surface of frame <NUM> by an adhesive or other suitable means. First door skin <NUM> preferably has a first planar portion <NUM> lying in a first plane. First planar portion <NUM> generally surrounds one or more recessed panel portions <NUM> (or panel regions) formed in first door skin <NUM>, and may present the appearance of conventional stiles and rails.

Recessed panel portions <NUM> appear as shallow, indented regions in the outer surface <NUM> of first door skin <NUM>, where the panel portions <NUM> are recessed relative to first planar portion <NUM>. In some embodiments, recessed panel portions <NUM> may have a rectangular shape and planar surface as shown, or may have other regular or irregular shapes and contours contributing to the overall aesthetic design of door <NUM>. Each recessed panel portion <NUM> may have a depth in the range of about <NUM>-<NUM> inwardly from first planar portion <NUM>, for example, and may have width W in the range of about <NUM> to <NUM> (or more typically in the range of about <NUM> to <NUM>) and a height H in the range of about <NUM> to <NUM> (or more typically in the range of about <NUM> to <NUM>). Transition regions <NUM>, known in the art as "sticking" or simulated sticking, extend between and connect first planar portion <NUM> to recessed panel portions <NUM>. First planar portion <NUM>, panel portions <NUM>, and transition regions <NUM> are preferably formed in a unitary sheet of material, such as molded high-density fiberboard, for example, that has a substantially uniform thickness throughout (but may be somewhat thinner at transition regions <NUM>). One suitable door skin is made of a fiber composite material having a thickness in the range of about <NUM> to <NUM>, or <NUM> to <NUM>, or <NUM> to <NUM>. When first door skin <NUM> includes multiple recessed panel portions <NUM>, they are typically substantially co-planar in a second plane that is parallel to and spaced inwardly from the first plane of first planar portion <NUM>. The recessed panel portions <NUM> characterize door <NUM> as a recessed-panel door.

Similarly, second door skin <NUM> includes an inner surface <NUM> facing core <NUM> and frame <NUM> and an outer surface <NUM> forming a rear surface of door <NUM>. Second door skin <NUM> is coupled to the rear surface of frame <NUM> by an adhesive. In second door skin <NUM>, simulated stiles and rails comprise a second planar portion <NUM> lying in a third plane spaced apart from the first and second planes of first door skin <NUM>. Second planar portion <NUM> surrounds one or more recessed panel portions (or panel regions) <NUM> that are recessed relative to second planar portion <NUM>. Transition regions <NUM> (sticking), extend between and connect second planar portion <NUM> to recessed panel portions <NUM>. When second door skin <NUM> includes multiple panel portions <NUM>, they are typically substantially co-planar in a fourth plane parallel to and spaced inwardly from the third plane of second planar portion <NUM>. Preferably, recessed panel portions <NUM> have similar dimensions in width, height, and depth as recessed panel portions <NUM> of first door skin <NUM>. In an alternative embodiment (not shown), one of the first or second door skins <NUM>, <NUM> may have a different ornamental design, different contours, different sticking, or panel regions that are not recessed, or may be entirely flat (flush) and lacking simulated sticking entirely.

In one example embodiment, core <NUM> comprises an expanded paper honeycomb material, which has a relatively high strength to weight ratio, but which is crushable by the press systems and methods described below. For example, the expanded paper honeycomb material of core <NUM> may have a compressive strength in the range of about <NUM> force per square cm (kgf/cm<NUM>) to about <NUM> kgf/cm<NUM> (<NUM> kPa to <NUM> kPa) or more typically in the range of about <NUM> kgf/cm<NUM> to about <NUM> kgf/cm<NUM> (<NUM> kPa to <NUM> kPa). Other structural materials that can be crushed or compressed under sufficient pressure may also be used for core <NUM>, for example, expanded plastic film honeycomb material, corrugated cardboard, low density foam board, and others.

As noted previously, in a conventional press system, the components of the recessed panel door are compressed together to promote adhesive bonding. For example, in one conventional press system, an upper platen and a lower platen are designed to move toward one another to press the door skins <NUM>, <NUM> together. Briefly, the door skins <NUM>, <NUM> may be pre-formed in a door skin press process, including preforming recessed panel portions <NUM>, <NUM> and transition regions <NUM>, <NUM>. Adhesive (not illustrated) is applied between first door skin <NUM> and frame <NUM> and between second door skin <NUM> and frame <NUM> to bond the door skins <NUM>, <NUM> to frame <NUM>. Frame <NUM> may be coated with adhesive before being stacked together with door skins <NUM>, <NUM>. Alternatively, door skins <NUM>, <NUM> may be coated in the region of frame <NUM> or over their entire surface so they also adhere to core <NUM>. Once the door skins <NUM>, <NUM> are ready for pressing, the upper and lower platen contact the outer surfaces <NUM>, <NUM> of the door skins <NUM>, <NUM> along the respective first and second planar portions <NUM>, <NUM>, and press together the components of the door <NUM>, so as to ensure positive contact between adhesive-coated surfaces of the internal frame <NUM> and door skins <NUM>, <NUM>. Once the door <NUM> has been pressed, the door <NUM> is ejected from the press and then may be transported for further processing via any suitable conveying means, such as a belt conveyor, powered rollers, or other transport system (not shown). In other embodiments, the door skins <NUM>, <NUM> and core <NUM> may be pressed together in other suitable methods, such as via a roller press system or other suitable systems.

As noted previously, however, many conventional press systems and methods fail to apply direct pressure to the recessed panel regions <NUM>, <NUM> and to most, if not all, of the transition regions <NUM>, <NUM>. With reference to <FIG>, the following describes example systems and methods of a drop roller press system <NUM> designed to remedy the deficiencies of conventional systems by applying direct pressure to the recessed panel regions <NUM>, <NUM> and to the transition regions <NUM>, <NUM> to ensure positive contact and promote proper bonding between the door skins <NUM>, <NUM> and core <NUM>. The pressing operation may also compress the core <NUM> between the recessed panel regions <NUM>, <NUM> of door skins <NUM>, <NUM>, as is further described below. Example methods of assembling door <NUM> will now be described with collective reference to <FIG>.

<FIG> is a block diagram illustrating the overall concept of a manufacturing process for the recessed panel door <NUM> in accordance with one example embodiment. With reference to <FIG>, the following discussion provides a brief overview of certain aspects of the manufacturing process for making the recessed panel door <NUM>, followed by a more detailed description focusing primarily on the scanning system <NUM> of <FIG> and the drop roller press <NUM> of <FIG> and <FIG>.

With reference to <FIG>, the door <NUM> is pressed using any suitable pressing method and system <NUM>, such as the cold rolling pressing system described above with opposing platen. Once the door <NUM> has been pressed, the door <NUM> is transported from the press system <NUM> to a scanning system <NUM>. In some embodiments, the scanning system <NUM> may be integrated with the press system <NUM>, wherein both units sharing a common housing structure. In other embodiments, the systems <NUM>, <NUM> may be standalone structures that are preferably operatively connected to one another via a suitable transport system to optimize the overall process.

As further described below with reference to <FIG>, the scanning system <NUM> is designed to survey the outer surfaces <NUM>, <NUM> of the door skins <NUM>, <NUM> to identify any regions of the door <NUM> where a transition or recessed area, such as recessed panel regions <NUM>, <NUM> or sticking regions <NUM>, <NUM>, is present. The surface data of the panel door <NUM> is communicated from the scanning system <NUM> to a programmable logic controller <NUM>. After passing through the scanning system <NUM>, the door <NUM> is transported to a drop roller press <NUM> having a plurality of actuators <NUM>, <NUM> each bearing a press member <NUM>, <NUM>. The controller <NUM> is in operative communication with the drop roller press <NUM> and controls (or sends instructions to another controller to control) operation of the actuators <NUM>, <NUM>. In accordance with the surface data obtained by the scanning system <NUM>, an appropriate subset of actuators is selectably actuated to apply direct pressure to the recessed panels <NUM>, <NUM> and the sticking regions <NUM>, <NUM> of the door <NUM> as it moves through the drop roller press <NUM>. The cylinders <NUM>, <NUM> and rollers <NUM>, <NUM> cooperate to ensure that positive pressure is applied to the recessed panels <NUM>, <NUM> and the sticking regions <NUM>, <NUM> to promote effective bonding. Subsequently, the door <NUM> may be transported to a cold rolling press <NUM> (or other suitable press) for further pressing, then finished as desired and packaged for shipment or sale. As noted previously, the following sections provide additional details of the scanning system <NUM> and the drop roller press <NUM> with reference to <FIG>, respectively.

<FIG> is a schematic view of a scanning system <NUM> in accordance with one embodiment. With reference to <FIG>, the scanning system <NUM> includes a frame <NUM> supporting one or more scanning subsystems <NUM> arranged along the frame <NUM> so as to cover a sufficiently wide field and ensure full coverage of a target area for properly evaluating the outer surfaces <NUM>, <NUM> of the door <NUM>. In one embodiment, the scanning subsystems <NUM> may include two-dimensional lasers arranged along the frame <NUM> at spaced out intervals such that the lasers collectively capture the entire outer surfaces <NUM>, <NUM> of the door <NUM>. It should be understood that while the illustrated and described embodiment of the scanning subsystems <NUM> mentions the use of two-dimensional lasers, other suitable subsystem designs capable of identifying surface features on the door <NUM> may be used. For example, the scanning system <NUM> may instead incorporate imagers, cameras, or other suitable devices capable of obtaining the target surface data from the outer surfaces <NUM>, <NUM> of the door <NUM>.

With reference to <FIG>, in one embodiment, the scanning subsystems <NUM> may be positioned on the frame <NUM> above the door <NUM> such that when the door <NUM> is transported (via a belt conveyor, rollers, or any other suitable transport mechanism) underneath, the scanning subsystems <NUM> collectively obtain the surface data from the outer (front) surface <NUM>, where the surface data indicates a position of the recessed panel portions <NUM>, <NUM> and the sticking regions <NUM>, <NUM>, and their respective depth relative to the flat planar regions <NUM>, <NUM> of the door skins <NUM>, <NUM> as noted previously. In this embodiment, although the surface data from the outer (bottom) surface <NUM> is not obtained directly by the scanning subsystems <NUM>, the surface data from the outer (front) surface <NUM> can be used to suitably approximate the corresponding location of the surface features on the outer (bottom) surface <NUM> since the door skins <NUM>, <NUM> are substantially identical and include the same arrangement of surface features (within acceptable tolerances). Accordingly, the surface data from the outer (front) surface <NUM> alone can be used to indicate a position of the recessed panel portions <NUM>, <NUM> and the sticking regions <NUM>, <NUM> on both outer surfaces <NUM>, <NUM> of the door <NUM> without requiring reprocessing of the door <NUM> to obtain data from the outer (bottom) surface <NUM> or a more complex scanning subsystem <NUM> designed to simultaneously read both surfaces of the door <NUM> as it passes through the scanning system <NUM>. That being said, in other embodiments, the scanning system <NUM> may obtain surface data from both door skins <NUM>, <NUM> either simultaneously or consecutively (e.g., the door may be flipped and transported again through the scanning system <NUM>).

The surface data obtained by the scanning system <NUM> may be further processed via a processor (not shown) or programmable logic controller <NUM> to translate the information and develop an appropriate mapping of the location and depth of the recessed panel portions <NUM>, <NUM> and the sticking regions <NUM>, <NUM> on the door <NUM>. With this mapping information, the controller <NUM> can direct appropriate actuation of specific pairs of cylinders <NUM>, <NUM> of the drop roller press <NUM> as further discussed below with reference to <FIG>.

In some embodiments, the scanning system <NUM> may incorporate a sensor (not shown) or other suitable means to detect a presence of the door <NUM> and ensure the scanning system <NUM> is operating when the door <NUM> is within the field of view of the scanning subsystems <NUM>. Data from the sensor may also be used to ensure the accuracy of the surface data mapping when the door <NUM> reaches the drop roller press <NUM> for further pressing. In other embodiments, the scanning system <NUM> (or the door transport mechanism) may further include one or more alignment mechanisms (not shown), such as bumpers, guides, or other suitable mechanisms designed to push against one or more side edges of the door <NUM> to align the door <NUM> as desired prior to entry into the scanning system <NUM>.

<FIG> are schematic views of one embodiment of a drop roller press system <NUM> designed for applying direct pressure to the recessed areas of the panel door <NUM> as identified by the scanning system <NUM> discussed previously. With reference to <FIG>, the drop roller press system <NUM> includes a first (upper) frame structure <NUM> supporting a plurality of upper cylinders <NUM>, each cylinder supporting a corresponding press member <NUM> (e.g., a roller or other suitable member) along an end thereof. Similarly, a second (lower) frame structure <NUM> supports a plurality of lower cylinders <NUM>, each cylinder supporting a corresponding press member <NUM> (e.g., a roller or other suitable member) along an end thereof. The press members <NUM>, <NUM> are preferably made of a relatively soft, low-friction material, such as white polytetrafluoroethylene (PTFE) or another plastic material or a resilient or elastomeric material such as hard non-marking rubber. The press members <NUM>, <NUM> are preferably non-marring by being made of or coated with relatively soft, low friction materials that tend not to scratch or damage door skins <NUM>, <NUM> during pressing.

As illustrated in the figures, the plurality of upper and lower cylinders <NUM>, <NUM>, and their corresponding press members <NUM>, <NUM> are arranged in a paired relationship relative to one another such that each upper cylinder <NUM> and press member <NUM> is paired with and faces a corresponding lower cylinder <NUM> and press member <NUM>. A small gap <NUM> extends between the press members <NUM>, <NUM> of the upper and lower cylinders <NUM>, <NUM> to form a passageway for the door <NUM> as further described below. In the embodiment illustrated, a transport subsystem (e.g., a conveyor other suitable system) feeds the door <NUM> through the roller press system <NUM> via the gap <NUM>, such that the door passes between the press members <NUM>, <NUM>. In some embodiments, a clamp <NUM> or other suitable guiding mechanism may be used to apply a pulling force on the door <NUM> to guide the door <NUM> through the roller press system <NUM> as needed to avoid potential jams and ensure the door <NUM> continues moving along at a desired rate.

In the illustrated configuration, the upper and lower cylinders <NUM>, <NUM> are arranged such that they move along an axis generally orthogonal (or angled slightly from a strictly orthogonal relationship) to the horizontal axis along which the door <NUM> travels to drive the press members <NUM>, <NUM> toward the outer surfaces <NUM>, <NUM> of the door skins <NUM>, <NUM> respectively. When the cylinders <NUM>, <NUM> are actuated, the press members <NUM>, <NUM> are moved toward and contact the outer surface <NUM>, <NUM> of the door skins <NUM>, <NUM>. As further described in detail below, a specific subset of cylinders <NUM>, <NUM> is actuated to drive the corresponding press members <NUM>, <NUM> toward the door <NUM> along a location of the recessed panel portions <NUM>, <NUM> of the door skins <NUM>, <NUM> based on the surface data of the door <NUM> as acquired by the scanning system <NUM>. As further described in detail below, the specific subset of cylinders <NUM>, <NUM> are actuated simultaneously in pairs to apply pressure evenly to the recessed panel portions <NUM>, <NUM> during pressing by drop roller press <NUM>. This process also helps ensure that the door skins <NUM>, <NUM> do not fracture or bow outwardly during the pressing operation as further described in detail below.

With particular reference to <FIG>, the following section discusses details of a pressing procedure in accordance with one example embodiment. As noted previously with reference to <FIG>, the surface data identifying the location of the recessed panel portions <NUM>, <NUM> and the sticking regions <NUM>, <NUM> is obtained by the scanning system <NUM> and transmitted to the controller <NUM>. Thereafter, as the door <NUM> moves through the gap <NUM> of the drop roller press <NUM>, the controller <NUM> (or other controller) actuates a specific subset of cylinders <NUM>, <NUM> such that the corresponding members <NUM>, <NUM> contact and apply direct pressure to the door <NUM> at the location of the recessed panel regions <NUM>, <NUM> and transition regions <NUM>, <NUM> as identified by the scanning system <NUM>. As noted previously, the selected subset of upper and lower cylinders <NUM>, <NUM> operate as a pair, so both upper and lower cylinders <NUM>, <NUM> are actuated simultaneously to apply pressure to both the outer surfaces <NUM>, <NUM> of the door skins <NUM>, <NUM>. The pressure applied by the cylinders <NUM>, <NUM> and the press members <NUM>, <NUM> against the panel portions <NUM>, <NUM> may both crush (or compress or deform) the core <NUM> and ensure positive adhesive contact between door skins <NUM>, <NUM>, frame <NUM>, and the adhesive layer applied therebetween.

In some embodiments, the drop roller press <NUM> may further include an alignment mechanism (not shown) to align the door <NUM> relative to the drop roller press <NUM> prior to entry. The alignment mechanism may help improve the accuracy of the pressing procedure to ensure that the press members <NUM>, <NUM> are applying pressure to the target regions of the door <NUM>.

After the door components are pressed, the clamp mechanism <NUM> may guide the door <NUM> away from the drop roller press <NUM>. Thereafter, the door <NUM> may be fed to a separate heated press station (not shown) for curing the adhesive bonds between door skins <NUM>, <NUM> and frame <NUM>.

Claim 1:
A system for making a door assembly of the kind having an internal frame, a core, and first and second door skins attached to the frame on either side of the core, wherein each of the door skins has a planar portion bordering at least one recessed panel portion, said system comprising:
a scanning system (<NUM>) configured to survey an outer surface of the first door skin and to obtain surface data therefrom identifying a location of the at least one recessed panel portion (<NUM>, <NUM>) on the first door skin;
a controller (<NUM>) in communication with the scanning system, the controller configured to receive the surface data obtained by the scanning system; and
a press (<NUM>) in operable communication with the controller, the press including a first set of actuators (<NUM>) and a second set of actuators (<NUM>), each actuator in the first and second sets of actuators including a press member (<NUM>, <NUM>) coupled thereto, wherein the first set and second set of actuators are configured to drive their corresponding press member toward each other for pressing the door assembly in a pressing operation, and
wherein the press, based on the surface data from the controller indicating a location of the at least one recessed panel portion on the first door skin, is configured to selectably actuate a first group of actuators from the first set of actuators and a second group of actuators from the second set of actuators during the pressing operation, such that the corresponding press members of the selected first group of actuators directly contact the at least one recessed panel portion of the first door skin and compress a portion of the core underlying the at least one recessed panel portion of the first door skin, and the corresponding press members of the selected second group of actuators directly contact the at least one recessed panel portion of the second door skin and compresses a portion of the core underlying the at least one recessed panel portion of the second door skin.