Patent ID: 8394219

Claim:
A method of manufacturing a hollow core door, the method comprising the steps of: providing a solid wood composite flat blank having a density of at least about 550 kg/m 3 ; moisturizing the flat blank to raise its moisture content; applying a liquid conditioning thermal curable resin to at least one major surface of the flat blank; pre-heating at least a surface of the flat blank to a temperature of at least about 80° C.; after said pre-heating step has been performed, positioning the flat blank into a press between first and second platens, at least one of the platens being heated; reforming the flat blank into a molded door skin including a plurality of panels defined therein by closing the press; and affixing at least a first molded door skin to a first side of a door frame and affixing a door skin to an opposite second side of the door frame.