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US 11,920,405 B2Granted
Shaker doors with solid core and methods for making thereof
AssigneeMasonite Corporation
InventorsJohn Robinson, Steven B. Swartzmiller, Steven Gutkowski, Robert C. Allen, Roland Karsch, Michael Macdonald
Life of this patent
Estimating the term…
Abstract
The present invention relates to shaker doors with solid cores and methods for making the same. The shaker doors contain different core materials at the recessed panel than the raise peripheral region to provide dimensional stability and reduced distortion when the doors are exposed to high humidity. The devices and methods also provide for easy assembly of solid core shaker doors, including fire rated doors.
Claims17
A shaker door, comprising:
- a) a rectangular peripheral frame;
- b) two door facings attached to opposite sides of the rectangular frame, wherein each of the door facings is made from a wood composite and contains a raised peripheral region, a transition surrounded by and immediately adjacent to and contiguous with the raised peripheral region, and a planar recessed panel that is surrounded by, immediately adjacent to, and contiguous with the transition, the recessed panel being recessed from the raised peripheral region, the two door facings and the rectangular frame define a cavity therebetween, wherein a first distance between the two door facings at the peripheral region is greater than a second distance between the two door facings at the panel;
- and
- c) a core filling the cavity, wherein the core comprises one of:
- i) a first core having a first portion at the panel with a first density and second portion with a second density less than the first density, the second portion disposed between the raised peripheral regions,
- ii) a second core having a first portion having a thickness sufficient to fill the cavity between the panels, the first portion being sandwiched between two filler layers located at the raised peripheral regions, or
- iii) a third core having a first portion filling a portion of the cavity at the recessed panels and extending beyond the recessed panels, and a second portion filling the remaining cavity at the raised peripheral regions.
4 more elements
A method for making a shaker door, comprising the steps of:
- a) providing a rectangular frame;
- b) attaching a first door facing to one side of the rectangular frame, wherein the first door facing is made from a wood composite and contains a raised peripheral region, a transition surrounded by and immediately adjacent to and contiguous with the raised peripheral region, and a planar recessed panel that is surrounded by, immediately adjacent to, and contiguous with the transition, the recessed panel being recessed from the raised peripheral region;
- c) laying a core on to an inner side of the first door facing;
- and
- d) attaching a second door facing formed from a wood composite to a second side of the rectangular frame and on top of the core, wherein the second door facing is identical to the first door facing, wherein a first distance between the first and second door skins at the peripheral region is greater than a second distance between the first and second door skins at the panel, wherein the laying step comprises:
- i) placing a first portion, having a first density, on an inner surface of the recessed panel, and
- ii) placing a second portion, having a second density, on the inner surface of the raised peripheral region, wherein the second density is less than the first density and the second portion is thicker than the first portion, or
- i) placing a first filler layer at an inner surface of the raised peripheral region,
- ii) placing a first portion, which spans substantially the entire area within the frame, on the first filler layer and an inner surface of the recessed panel, and
- iii) placing a second filler layer on the middle layer at the raised peripheral region, or
- i) placing a first portion filling on an inner surface of the recessed panel, wherein the first portion extends beyond an area covered by the recessed panel, and
- ii) placing a second portion at the raised peripheral region, wherein sections of the first portion that extends beyond the area covered by the recessed panel interlocks with the second portion.
9 more elements
Dependencies are inferred from the claim text.