# US 2009/0260296 A1 · Carved solid face doors having a raised panel design and methods of fabrication

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- Number: US 2009/0260296 A1
- Document ID: US20090260296A1
- Status: Published application
- Kind: A1
- Application number: 12/427,502
- Filed: 2009-04-21
- Published: 2009-10-22
- Earliest claimed: 2008-04-21
- Inventors: EDWARD FIMBEL, III; JEFFRY T. DEAL
- Web page: https://patentgrep.com/patent/US20090260296A1

## CPC

- E06B 3/485: {Sectional doors}
- E06B 3/7001: {Coverings therefor; Door leaves imitating traditional raised panel doors, e.g. engraved or embossed surfaces, with trim strips applied to the surfaces}
- E06B 3/721: {with panels on one lateral side of the frame only}
- E06B 2003/7044: {Garage doors}
- E06B 2003/7048: {with arcuate periphery; with openings having an arcuate periphery}
- E06B 2003/7051: {of layered construction involving different materials}
- 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)

## Abstract

Carved solid face doors having a raised panel design and methods of manufacture thereof are provided herein. In some embodiments, a carved, solid face door may include a solid base having a face and an opposing rear surface, wherein the face has a raised panel design carved into at least one section of the face, the raised panel design framed by flat portions carved into the face; and one or more overlays attached to the flat portions of the face and framing the raised panel to emulate the appearance of a floating raised panel construction.

## Claims

### Claim 1

A door, comprising:
a solid base having a face and an opposing rear surface, wherein the face has a raised panel design carved into at least one section of the face, the raised panel design framed by flat portions carved into the face; and
one or more overlays attached to the flat portions of the face and framing the raised panel to emulate the appearance of a floating raised panel construction.

### Claim 2 (depends on 1)

The door of claim 1, further comprising:
a plurality of locating pins disposed in respective pilot holes formed in the face and in the overlays to align of the overlays with respect to the face.

### Claim 3 (depends on 1)

The door of claim 1, wherein the solid base comprises a stable sheet material.

### Claim 4 (depends on 3)

The door of claim 3, wherein the stable sheet material comprises at least one of wood, medium density fiberboard, plastic, or cellular polyvinyl chloride.

### Claim 5 (depends on 1)

The door of claim 1, further comprising:
a backing coupled to the rear surface of the face.

### Claim 6 (depends on 5)

The door of claim 5, wherein the backing further comprises:
an outer frame.

### Claim 7 (depends on 6)

The door of claim 6, wherein the outer frame comprises at least one of wood, plastic, or metal.

### Claim 8 (depends on 6)

The door of claim 6, wherein the backing further comprises:
an inner core disposed within the outer frame.

### Claim 9 (depends on 5)

The door of claim 5, wherein the backing further comprises:
a skin covering at least one side of the backing.

### Claim 10 (depends on 9)

The door of claim 9, wherein the skin comprises at least one of plywood, wood, plastic, medium density fiberboard, or hardboard.

### Claim 11 (depends on 1)

The door of claim 1, wherein the face comprises a plurality of horizontal sections.

### Claim 12 (depends on 11)

The door of claim 11, wherein the raised panel is formed across the plurality of horizontal sections.

### Claim 13

A method for fabricating a door, comprising:
providing a solid base having a face and an opposing rear surface;
carving a raised panel design into the face, the raised panel design framed by flat portions carved into the face; and
attaching one or more overlay panels to the flat portions of the face, to emulate the appearance of a floating raised panel construction.

### Claim 14 (depends on 13)

The method of claim 13, wherein attaching the one or more overlays further comprises:
aligning the one or more overlays with the flat portions of the face with a plurality of locating pins disposed in corresponding pilot holes formed in each of the flat portions of the face and the one or more overlays.

### Claim 15 (depends on 13)

The method of claim 13, wherein carving further comprises:
carving the raised panel using computer-aided machinery.

### Claim 16 (depends on 15)

The method of claim 15, wherein the computer-aided machinery includes a computer numerical control milling machine.

### Claim 17 (depends on 13)

The method of claim 13, further comprising:
coupling a backing to the rear surface of the base.

### Claim 18 (depends on 13)

The method of claim 13, wherein the base comprises a plurality of sections.

### Claim 19 (depends on 18)

The method of claim 18, wherein the raised panel design is distributed across the plurality of sections of the base.

### Claim 20 (depends on 18)

The method of claim 18, wherein the base is separated into a plurality of sections after carving the raised panel design.