# US 12,110,738 B2 · Panel doors and related method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,110,738 B2 - Document ID: US12110738B2 - Status: Granted - Kind: B2 - Application number: 18/197,293 - Filed: 2023-05-15 - Published: 2023-09-07 - Granted: 2024-10-08 - Earliest claimed: 2018-03-29 - Assignees: Masonite Corporation - Applicants: Masonite Corporation - Inventors: Jan H. Ettrich; Hubert Breton - Web page: https://patentgrep.com/patent/US12110738B2 ## CPC - E06B 7/14: Measures for draining-off condensed water or water leaking-in {frame members for draining off condensation water, throats at the bottom of a sash} - E06B 3/5409: {Means for locally spacing the pane from the surrounding frame} - E06B 3/5454: {inside U-shaped section members} - E06B 3/66304: {Discrete spacing elements, e.g. for evacuated glazing units} - E06B 3/74: with wooden panels {or frame (E06B3/721, E06B3/725 and E06B3/76 take precedence)} - B32B 21/14: comprising wood board or veneer - E06B 3/5892: {Fixing of window panes in openings in door leaves} - E06B: FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES (shades or blinds for greenhouses A01G9/22; curtains A47H; lids for car boots or bonnets B62D25/10; skylights E04B7/18; sunshades, awnings E04F10/00) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## Abstract A door is provided that includes a door panel having a periphery and opposite first and second panel surfaces, stiles and rails collectively surrounding the panel, and sealant. The stiles have channeled stile surfaces extending across a thickness of the stiles and facing one another. The rails have channeled rail surfaces extending across a thickness of the rails and facing one another. The channeled stile surfaces and the channeled rail surfaces include channels with open ends that receive the periphery of the panel, first grooves positioned at first interfaces of the first panel surface and first edges of the open ends of the channels, and second grooves positioned at second interfaces of the second panel surface and second edges of the open ends of the channels. The sealant is received in the first and second grooves, preferably forming a water-proof seal. ## Claims ### Claim 1 A door, comprising: a door panel having a periphery and opposite first and second panel surfaces; stiles and rails collectively surrounding the panel, the stiles having channeled stile surfaces extending across a thickness of the stiles and facing one another, the rails having channeled rail surfaces extending across a thickness of the rails and facing one another, the channeled stile surfaces and the channeled rail surfaces comprising channels with open ends that receive the periphery of the panel, first sealant-receiving grooves positioned at first interfaces of the first panel surface and first edges of the open ends of the channels, the first sealant-receiving grooves having a first unobstructed, open groove area configured to receive a first continuous bead of sealant applied therethrough, and second sealant-receiving grooves positioned at second interfaces of the second panel surface and second edges of the open ends of the channels, the second sealant-receiving grooves having a second unobstructed, open groove area configured to receive a second continuous bead of sealant applied therethrough; and said sealant received in the first and second sealant-receiving grooves. ### Claim 2 (depends on 1) The door of claim 1, wherein the door panel comprises an insulated glazing unit. ### Claim 3 (depends on 1) The door of claim 1, wherein the door panel comprises laminated veneer lumber. ### Claim 4 (depends on 1) The door of claim 1, wherein the stiles and the rails are solid members extending between opposite surfaces of the door. ### Claim 5 (depends on 1) The door of claim 1, wherein the sealant comprises an acrylic latex polymer. ### Claim 6 (depends on 1) The door of claim 1, wherein the channeled stile surfaces and the channeled rail surfaces slope at an oblique angle toward outer edges of the door. ### Claim 7 (depends on 1) The door of claim 1, further comprising foam spacers positioned in the channels between the periphery of the door panel and bottoms of the channels. ### Claim 8 (depends on 1) The door of claim 1, wherein the channels have bottom surfaces with empty recesses. ### Claim 9 (depends on 1) The door of claim 1, further comprising a compressed elastomeric film received in the channels and positioned about the periphery of the door panel to contact the first and second panel surfaces. ### Claim 10 (depends on 1) The door of claim 1, wherein the sealant has a joint movement capability of at least 25% of a width of the sealant to permit limited movement of the door panel relative to the stiles and the rails at the first and second interfaces. ### Claim 11 (depends on 10) The door of claim 10, wherein the sealant provides a waterproof seal at the first and second interfaces. ### Claim 12 A door, comprising: a door panel having a periphery and opposite first and second panel surfaces, the door panel having a multi-ply construction comprising a medium density fiberboard ply and first and second solid wood plies on opposite sides of the medium density fiberboard ply; stiles and rails collectively surrounding the panel, the stiles having channeled stile surfaces extending across a thickness of the stiles and facing one another, the rails having channeled rail surfaces extending across a thickness of the rails and facing one another, the channeled stile surfaces and the channeled rail surfaces comprising channels with open ends that receive the periphery of the panel, first sealant-receiving grooves positioned at first interfaces of the first panel surface and first edges of the open ends of the channels, the first sealant-receiving grooves having a first unobstructed, open groove area configured to receive a first continuous bead of sealant applied therethrough, and second sealant-receiving grooves positioned at second interfaces of the second panel surface and second edges of the open ends of the channels, the second sealant-receiving grooves having a second unobstructed, open groove area configured to receive a second continuous bead of sealant applied therethrough; and said sealant received in the first and second sealant-receiving grooves configured to establish water-proof seals at the first and second interfaces. ### Claim 13 (depends on 12) The door of claim 12, wherein the stiles and the rails are solid members extending between opposite surfaces of the door. ### Claim 14 (depends on 12) The door of claim 12, wherein the channeled stile surfaces and the channeled rail surfaces slope at an oblique angle toward outer edges of the door. ### Claim 15 (depends on 12) The door of claim 12, further comprising foam spacers positioned in the channels between the periphery of the door panel and bottoms of the channels. ### Claim 16 (depends on 12) The door of claim 12, wherein the channels have bottom surfaces with empty recesses. ### Claim 17 (depends on 12) The door of claim 12, further comprising a compressed elastomeric film received in the channels and positioned about the periphery of the door panel to contact the first and second panel surfaces. ### Claim 18 (depends on 12) The door of claim 12, wherein the sealant has a joint movement capability of at least 25% of a width of the sealant to permit limited movement of the door panel relative to the stiles and the rails at the first and second interfaces. ### Claim 19 (depends on 18) The door of claim 18, wherein the sealant comprises an acrylic latex polymer. ### Claim 20 (depends on 1) A method of making the door of claim 1, comprising: providing a door panel having a periphery and opposite first and second panel surfaces; securing stiles and rails to the panels to collectively surrounding the panel, the stiles having channeled stile surfaces extending across a thickness of the stiles and facing one another, the rails having channeled rail surfaces extending across a thickness of the rails and facing one another, the channeled stile surfaces and the channeled rail surfaces comprising channels with open ends that receive the periphery of the panel, first unobstructed, open sealant-receiving grooves positioned at first interfaces of the first panel surface and first edges of the open ends of the channels, and second unobstructed, open sealant-receiving grooves positioned at second interfaces of the second panel surface and second edges of the open ends of the channels; and applying sealant in the first and second sealant-receiving grooves.