Door comprising vented stile, and method of making the same

A method for making a door, comprising steps of:

• providing a first skin providing a first outer door surface and a second skin providing a second outer door surface;
• providing two stiles and two rails, wherein at least one stile defines a vent therein;
• applying a gas permeable membrane onto the at least one stile to cover the vent;
• assembling the two stiles, the two rails, and the first and second skins;
• and
• injecting a foamable material so as to form a core comprising a foam material between the first skin and the second skin, the gas permeable membrane contacting the foam material in the core,
• wherein the gas permeable membrane is permeable to gas, but not liquids or solids,
• wherein at least one of the two rails defines a first through hole along a first direction, which is connected to the vent and configured to vent air and gas during the injecting step,
• wherein the at least one of the two rails defines a second through hole along the first direction, and the foamable material is injected from the second through hole, and
• wherein the at least one of the two rails defines a third through hole, and a tube extends from the third through hole into a gap between the first skin and the second skin.

A door comprising:

• a first skin providing a first outer door surface;
• a second skin providing a second outer door surface;
• two stiles aligned in parallel along a first direction and disposed at least partially between the first skin and the second skin, wherein at least one stile defines a vent therein;
• two rails aligned in parallel along a second direction, the second direction is perpendicular to the first direction;
• and
• a gas permeable membrane disposed on the at least one stile, the gas permeable membrane covering the vent,
• wherein at least one of the two rails defines a first through hole along the first direction, which is connected to the vent,
• the at least one of the two rails defines a second through hole along the first direction, which is connected to a core, and
• the at least one of the two rails defines a third through hole, and a tube extending from the third through hole into the foam material in the core.

A kit for a door, comprising:

• a first skin configured to provide a first outer door surface;
• a second skin configured to provide a second outer door surface;
• two stiles configured to be aligned in parallel along a first direction and disposed at least partially between the first skin and the second skin, wherein at least one stile defines a vent therein;
• two rails configured to be aligned in parallel along a second direction, the second direction is perpendicular to the first direction;
• and
• a gas permeable membrane disposed on the at least one stile, the gas permeable membrane covering the vent,
• wherein at least one of the two rails defines a first through hole along the first direction, which is connected to the vent,
• wherein the at least one of the two rails defines a second through hole along the first direction, which is connected to a core, and
• wherein the at least one of the two rails defines a third through hole, and a tube extending from the third through hole into the foam material in the core.