Patent ID: 12252929

DETAILED DESCRIPTION

A manufactured door is disclosed as it may include at least one mid panel with openings formed therethrough to reduce weight while maintaining structural integrity of the finished door product. In an example, the manufactured door includes a first mid panel and a second mid panel. At least one of the first mid panel and/or the second mid panel has a plurality of openings formed therethrough.

To reduce the weight of the door, the example manufactured door is manufactured by creating lightening holes in the solid mid panel(s). These lightening holes are carefully engineered in the door structure to make the door lighter, while retaining the integrity of a full solid door of similar dimensions.

A front outer panel is assembled over the mid panel(s) to form a front door side, and a back outer panel is assembled over the mid panel(s) to form a back door side. A first structural edge forms a first door edge, and a second structural edge forms a second door edge. The structural edges provide a mounting location for hinges and/or the door handle. The manufactured door is finished by laminating a door skin over the front outer panel and the back outer panel. In an example, the manufactured door can be prefinished with any of a variety of finished appearances.

In an example, at least several of the plurality of openings in the first mid panel align with at least several of the plurality of openings in the second mid panel. In another example, at least several of the plurality of openings in the first mid panel do not align with at least several of the plurality of openings in the second mid panel.

An example manufactured door is manufactured of medium-density fiberboard (MDF) or other suitable material (including but not limited to wood, plastic, metal, etc.). In an example, the manufactured door weighs less than a similar door made of solid MDF (e.g., the weight of a 80″×32″ door is about 60 pounds).

The example manufactured door produced according to the techniques described herein exhibit little or no cracking, have a high-quality finish, reduce sound transmission for increased privacy, do not shrink, and are more stable and durable than comparable traditional solid wood doors. The finishes can include texture details, and show crisp and clean lines.

In an example, the manufactured door can be custom made of MDF routed with a 3DL finish, with engineered components to resist warp. The manufacturing process enables a fast turn-around time to produce doors that are pre-finished and ready to install. The customer can choose from a selection of contemporary designs, finishes and colors, with optional hardware and jambs. The example manufactured door can be sold directly to the tradesman or homeowner. Due to the weight savings, the manufactured door can be shipped cost-effectively nationwide to homes and construction sites.

Before continuing, it is noted that as used herein, the terms “includes” and “including” mean, but is not limited to, “includes” or “including” and “includes at least” or “including at least.” The term “based on” means “based on” and “based at least in part on.”

It is also noted that the examples described herein are provided for purposes of illustration, and are not intended to be limiting. Other devices and/or device configurations may be utilized to carry out the operations described herein.

FIG.1is a partial cutaway view of an example manufactured door10illustrating various components. An example manufactured door10includes a first mid panel12and a second mid panel14(see, e.g., top view inFIG.3). At least one of the first mid panel12and the second mid panel14have a plurality of openings16formed therethrough. In an example, the manufactured door10may include a single mid panel. In another example, the manufactured door10may include more than two mid panels. The plurality of openings16reduce weight of a finished door product while maintaining structural integrity of the finished door product.

In an example, the manufactured door10is made from a highly refined MDF and/or low density fiberboard (LDF). MDF and LDF are stable and abundant wood fiber material.

In an example, at least several of the plurality of openings16in the first mid panel12align with at least several of the plurality of openings16in the second mid panel14. In another example, at least several of the plurality of openings16in the first mid panel12do not align with at least several of the plurality of openings16in the second mid panel14.

In an example, a front outer panel18is assembled over the mid panel(s)12and14to form a front door side. A back outer panel20(see, e.g., top view inFIG.2) is assembled over the mid panel(s)12and14to form a back door side.

In an example, a first structural edge22forms a first door edge24, and a second structural edge26forms a second door edge28. The structural edges22and26provide support for door hardware, such as a door handle1and/or hinges2a-c.

FIG.2are top edge views32and34of the example manufactured door10taken along lines2-2inFIG.1. The top edge view32shows an example of the manufactured door10having a single edge24and26on each side. The top edge view34shows an example of the manufactured door10having double edges24a-band26a-b. Staples3can be seen inFIG.3as these may be used to hold the door components together at least temporarily during assembly (e.g., for alignment during gluing).

The manufactured door10may be finished with a door skin30(e.g., laminated over the front outer panel18and the back outer panel20). In an example, the door skin30is a thermally fused foil finish. The door skin30may be any suitable finishing product. For example, the door skin30may be a Thermofoil or other vinyl.

An example finish is made via 3DL (three dimensional laminate) technology. There are multiple color and finishes options, from wood texture to solid colors and finishes. This blend of materials and technology delivers architecturally-true, ready to install finished doors to fit any interior style.

The finished manufactured door10is superior to a standard painted door. The finished manufactured door10is much less likely to chip as compared to paint. The door skin30is available in solid colors, in addition to wood grain, stone, and metallic appearance finishes. The door skin30is made to last. The door skin30is more consistent and smoother than a painted door. The door skin30is easy to clean using standard household cleaning products. Various finishes are available for the door skin30to cater to both budget-conscious shoppers and those looking for a high-end product.

FIG.3is an exploded partial view of the example manufactured door10illustrating various components. An example manufactured door10includes at least one mid panel12and14having a plurality of openings16formed therethrough. In an example, two mid panels12and14are provided (e.g., a front and rear mid panel12and14). In another example, more than two mid panels may be provided. The mid panels12and14may be glued and/or otherwise connected together (e.g., via staples13shown inFIG.3).

In an example, a front outer panel18is assembled over the mid pane(s)12and14to form a front door side. A back outer panel20is assembled over the mid panel(s)12and14to form a back door side. The manufactured door10may be finished with a door skin30laminated on or over the front outer panel18and the back outer panel20.

The manufactured door10may have at least one structural edge. In an example, a first structural edge22forms a first door edge24, and a second structural edge26forms a second door edge28. The structural edges22and26may be manufactured of solid wood or any other material configured to provide structural support for the manufactured door edges (e.g., for mounting hinges, door handles and/or other door hardware).

In an example, at least one door panel32covers at least some of the plurality of openings formed through the at least one mid panel12or14. The door panel(s)32may be assembled between an opening34formed in the front outer panel18or the back outer panel20and the at least one mid panel12or14. In an example, the door panel(s)32may be solid panel(s).

In an example, the plurality of openings16formed through at least one mid panel12,14form a pattern (see, e.g.,FIG.4). The pattern may be provided to provide additional structural support (e.g., for panels and/or door hardware), while maintaining an overall desired weight of the finished door product. For example, there may be no openings formed through one or more of the mid panel(s) within a predetermined surface area designated to mount a door handle, as seen inFIG.4. Other patterns may also be provided, e.g., for sound deadening or other desired characteristics of the finished door product.

In an example, the manufactured door10may have unique shapes and/or finishes. For example, different types of door panels (solid, multi-paneled, square panels, rounded top, etc.). Regardless of the underlying door shape, a thermally fused foil finish enables the door to have soft, seamless edges that do not trap dirt or bacteria, are durable, and feature a “cleaner” look (e.g., as a single component finish). The manufactured door1is easy to clean and maintain. The thermally fused foil finish is cost-effective for manufacturing, and can even have the appearance of natural wood without the added cost of real wood. The manufactured door10can be made available in a wide variety of styles, e.g., from classic to contemporary. Many rich, textured colors may also be available to the consumer.

In an example, the manufactured door includes hinges2a-cthat are no-mortise. No-mortise hinges2a-crefers to hardware that does not require cuts in the wood for hinges to be attached. No-mortise hardware is a quick and easy option for installing hinges. No-mortise hinges2a-cdo not require cuts to be made in the manufactured door10to install the hinges2a-c. No-mortise hinges2a-care thinner than standard hinges, which limits the gap on the doors. No-mortise hinges2a-cleave only a small space between the adjacent doors or the door and frame. These hinges2a-cmay be provided in a variety of profiles and interior mounted varieties. Example no-mortise hinges can be designed specifically for full inlay doors. These hinges may have a leaf that provides extra support by wrapping around the door.

In an example, the manufactured door10also enables optional pre-hanging of the doors. A pre-hung door includes a door10hung on hinges2a-cand assembled in a MDF, wood, or other material frame (the frame is also called the door “jamb”), with a door stop. Full MDF, hardwood or other inserts and jambs may be provided. For pre-hanging the door10, the jambs are fully finished in the factory based on the color and finish of choice.

A pre-hung door10is ready to install in the door opening, with no on-site assembly required. This reduces construction time (and scheduling) and lowers project cost. Factory pre-hanging ensures that hinge pockets are mortised square and precise, and that hinges are always flush on the door and frame.

Boring and latch/deadbolt mortising may also be provided with factory pre-hanging. This prepares the door10for hardware installation. A choice of single or double bore options can be available in different “backset” positions (e.g., the placement of the handle or lockset from the door edge). Factory pre-hanging also ensures that the “reveal” (the small gap between the door and the jamb when the door is closed) is always correct.

In an example, the manufactured door10provides a solution to an otherwise heavy MDF door. That is, the manufactured door includes full size MDF panels which can be routed and/or carved to create different designs and shapes and finished using a thermally fused foil finish. This process provides a manufactured door10that is extremely simple and fast to produce, less expensive, and has a good quality finish and appearance.

FIGS.4-7illustrate assembly of the example manufactured door10.FIG.8shows a fully assembled view of the first and second sides of the example manufactured door10. The operations shown and described herein are provided to illustrate example implementations. It is noted that the operations are not limited to the ordering shown. Still other operations may also be implemented.

Example operations for producing a manufactured door10may include forming a plurality of openings16through at least one mid panel12,14to reduce weight of the manufactured door10. In an example, other areas of the manufactured door remain solid to provide strength for the finished door product.

By way of further illustration, operations may include hollowing LDF boards via CNC Routing. In an example, the LDF board is routed in specific areas to form openings at least partly therethrough to reduce overall weight of the finished door product. Other areas of the LDF boards remain solid, e.g., providing a surface for application of the thermally fused foil finish.

Example operations may also include assembling a front outer panel18over the at least one mid panel to form a front door side of the manufactured door10. Example operations may also include assembling a back outer panel20over the at least one mid panel12,14to form a back door side of the manufactured door10.

Example operations may also include adding one or more decorative inlay panels36a-c. These panels36a-care positioned between the mid panel(s)12,14and the outer panels18,20, e.g., to cover the openings16. Additional top trim40a-band side trim38a-bmay be provided adjacent to the decorative inlay panels36a-cto eliminate any gaps, e.g., as shown inFIG.5.

Example operations may also include assembling a first structural edge22adjacent the at least one mid panel12,14to form a first door edge24of the manufactured door10. In an example, the first structural edge22may provide support for a door handle.

Example operations may also include assembling a second structural edge26adjacent the at least one mid panel12,14to form a second door edge28of the manufactured door10. The second door edge26may provide support for door hinges2a-c.

In an example, supports22and26(e.g., poplar hardwood strips) are positioned along the edges of the panel12,14to increase strength for hinges2a-c, screws, handles1and/or other door hardware.

The process may be repeated for both the front and back door segments, and then the front and back door segments may be glued together to form the overall structure of the manufactured door10. A finished door10is shown both the front side11aand the back side11binFIG.8. By way of illustration, a routed MDF outer panel may be positioned on top of the routed LDF mid panel(s). Using a press, the panels and then the front and back door segments can be glued together. Both segments or “sides” of the door are glued together and pressed to form the finished door product.

After the door sides are glued together, the finish of choice may be applied. Example operations may also include laminating a door skin on the front outer panel and the back outer panel to finish the manufactured door.FIG.9illustrates application of an example door skin30to the manufactured door10. By way of further illustration, a thermally fused foil finish may be applied with a Thermafoil press as a 3DL (three dimensional laminate) finish. In an example, the 3DL finish is made by fusing a layer of a special vinyl to an MDF core using air pressure, suction and heat. The vinyl is formed to the routed surface by heat. Then positive air pressure is applied to create a vacuum. The thermally fused foil finish is adhered using a water-based glue or other suitable adhesive. The result is an extremely durable surface that is more resistant and smoother than paint.

It is noted that the examples shown and described are provided for purposes of illustration and are not intended to be limiting. Still other examples are also contemplated.