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US 2022/0178196 A1Published application
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
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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.
Claims20
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 contains at least one rectangular recessed panel and a raised peripheral region surrounding the recessed panel, the two door facings and the rectangular frame define a cavity therebetween;
- 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 spanning substantially the entire area within the frame and 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 contains at least one rectangular recessed panel and a raised peripheral region surrounding the recessed panel;
- c) laying a core on to an inner side of the first door facing;
- and
- d) attaching a second door facing 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.
2 more elements
Dependencies are inferred from the claim text.