Note: Descriptions are shown in the official language in which they were submitted.
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MET~OD ~ ~AKING A DOOR WITX RAISED PANEL~
Backqround and Summary of the Invention
This invention relates to a raised panel door and more
particularly to a method of manufacturing such a door wherein the
door is prepared from a continuous core or core panel extending
within the door and serving to strengthen the door and impart other
characteristics, such as improved resistance to break in, fire
resistance, lessened sound transmission, and increase durability.
A conventional panel door comprises what is known as
stiles and rails extending vertically and horizontally in the door.
The rectangular spaces which are bounded by these stiles and rails
are filled with panels, and these normally have tapered marginal
edges that seat within grooves presented by the stiles and rails.
A panel door of this description typically may be made of
decorative wood, such as oak, etc., and because of its
aesthetically pleasing appearance is widely sold.
While a conventional door has a pleasing appearance,
because of its material content and structure, the door suffers
durability, security, and safety problems that detract from its
utility. Further explaining, under the stress of normal usage and
the passage of time, the stiles and rails tend to sag, warp, and
split or separate from each other with loosening of the panels
which they encompass. The panels themselves are relatively easily
broken out for the purpose of breaking through the door. The door
provides a relatively poor barrier to the transmission of sound and
offers little resistance to fire. Furthermore, the construction
of the door is such that it is difficult to produce with a venear
overlay covering less expensive construction materials within the
interior of the door.
The door of this invention is related to the door of the
earlier filed applications above referred to in that such may be
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manufactured from a continuous core. However, features are
incorporated into the door of this invention promoting economies
in manufacture, and savings made in the materials used in
constructing the door.
Accordingly, an object of the invention is to provide an
improved method of making a panel-style door where such is prepared
from a continuous core which forms the interior of the door as
completed.
Another object is to provide a method of constructing a
raised panel-style door which comprising: providing a core panel
havin~ a substantially planar surface extending over one side
thereof, forming an elongate channel which extends in a rectangular
course over the surface of the core panel and which is bottomed b~
bottom surfaces recessed inwardly from the surface of the core
panel, said channel encompassing a rectangular region of the
surface of the core panel, applying a veneer overlay over said
region and bottom surfaces adjacant said region, and inlaying the
channel with decorative inlay strips and by such inlaying,
positioning margins of the inlay strips flush with ~he core panel
surface where the panel surface extends laterally outwardly of the
channel, the inlay strips further covering the veneer overlay where
the overlay extends over bottom surfaces of said ~hannel.
The door is producible with very little wastage of
material. The core panel from which the door is built may be made
of plywood or a composite material, such as particle board, or of
a material selected for fire resistance, such as a treated panel
or a panel having extending within it a fire resistant or fire
retardant layer. The particular make up of the core panel is
dependent to a great extent on the intended use of the door,
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the fire retardant qualities desired, the resistance to breakage
desired, etc.
These and other objects and advantages are obtained
by the invention, which will become more fully apparent from the
following description which is to be taken in conjunction with
the accompanying drawings, wherein:
Fig. 1 is a perspective view illustrating a panel,
such as may be utilized as the core of a door;
Fig. 2 is a perspective view illustrating the panel
after the preparation on the face thereoE of multiple channels,
each extending in a rectangular course as does a picture frame;
Fig. 3 is a cross-sectional view on a somewhat
enlarged scale, taken generally along the line 3-3 in Fig~ 2;
Fig. 4 is a view illustratin~ in cross section the
upper right hand portion of the panel shown in Fi~. ~ aEter the
application of veneer overlays and the inlaying of inlay strips
within a channel;
Fig. 5 is a cross-sectional view, taken generally
along the line 5-5 in Fig. 4; and
Fig. 6 is a perspective view of a completed door.
Describing now the invention in more detail, in the
manufacture of a door, a core panel is selected which has a
rectangular outline, and length and width dimensions
substantially corresponding to those of the final door. In Fig.
1, such a panel is illustrated at 10, and is surfaced by surace
12. As earlier described, the panel may conveniently be made o
plywood, o a composite material, such as particle board, or of
a material selected for fire resistance, such as a treated
panel, etc., with the particular make up of the core panel being
dictated through the use intended for the final door, cost
considerations, etc.
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As a first step in the manufacture of the do~r,
multiple channels are prepared in the face of the panel, each
extending in a rectangular course as does a picture rame. Each
channel encompasses a rectangular region which, in the completed
door and when properly overlaid, simulates a panel in a
panel-style door. The channels are prepared by cutting or
routing out material from the core panel. In Fig. 2, six of
such channels are illustra-ted, these being indicated at 14, 16,
18, 20, 22, and 24. The channels are distributed with two to a
row and the rows of channels being spaced from each other
longitudinally along the core panel. In Fig. 2, only one side
or face of the core panel is illustrated. It sho~ld be
understood that ordinarily a duplicate set of channels would be
prepared on the opposite side of the door, each channel on one
side of the door lying directly opposite a similar channel on
the opposite side o the door.
After removing of material to form the channelsrwhat
is referred to herein as a support panel is produced. A similar
support panel may be produced as the product of a one-step
molding operation from moldable material processed with suitably
configured molding dies. With this procedure, channels are
formed without the removal of material, but as the direct result
of the molding operation.
As earlier described, each channel encompasses a
rectangular region of the surface of panel core 10, depicted in
the case of channel 14 by the rectangular region 28. As
illustrated in Fig. 3, the surfaces shown at 14a, 14b that
bottom channel 14 incline or slope inwardly into the panel core
progressing laterally outwardly of the rectangular region which
the channel encompasses.
With channels present as described, it is convenient
at the next step in the door manufacture to apply a veneer
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overlay to the rectangular region encompassed by each channel
and to the surfaces bottoming the channel which encompass each
rectangular region. This is illustrated in Figs. 4 and 5
wherein a veneer overlay 30 is shown which covers central region
28 encompassed by channel 14, as well as bottom surfaces 14c and
14b of the channel encompassing region 28. The grain of the
veneer in this overlay is shown at 32, the grain direction being
generally vertical, as would be the case of the grain direction
in a panel of a conventional panel-style door.
To cover up margins of each overlay 30 applied to the
floor of a channel and the region that it encompasses r inlay
strips may be secured in place, as exemplified by strips 36, 3B
shown in Fig. 4, one of which extends along the length of each
o the legs in a channel. Each inlay strip has an outer margin,
shown at 40 for strip 38, which lies flush with surface 12 of
the panel where such surface extends laterally outwardly of a
channel. Each inlay strip further abuts against the outer side
of the leg of the channel which receives the inlay strip.
The inlay strips or molding strips provide a sloping
transition between the surface of the panel core where such
extends outwardly of a channel and the overlay surfaces which
bottom the channel receiving the strips.
In the applying of a veneer overlay and other
overlays to be described, the usual adhesive is employed to bond
the overlay in place. The inlay strips are also secured in
place through appropriate means as through use of a conventional
adhesive.
Edges of the door extending along opposite sides and
the top and bottom of the door are finished off by applying
decorative wood strips, such as those shown at 44~ 46. These
again may be secured in place as by using an adhesive. Opposite
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margins of these edge strips lie flush with opposite sides of
the core panel.
To finally complete a side of the door, a veneer
overlay is applied in covering relation over the surEace o~ the
core panel in regions disposed outwardly oE the various channels
described. Preferably, this veneer overlay comprises veneer
strips, such as the one shown at 50 in Fig. ~, which extend
along vertical expanses of the surface 12 of the panel, as found
at opposite side margins of the door with grain of these strips
extending vertically. In horiæontal expanses of the panel's
surface, such as are ~ound at top and bottom margins of the
door, veneer strips 52 are used in the overlay, these strips
havinq grain extending in a horizontal direction. The veneer of
this overlay extends over and covers the side margins of edge
strips 44, 46 which bound panel core 10 in the completed door
and also extends over and covers those margins of the inlay
strips which earlier have been described as lying Elush with the
surface of the panel and as exemplified by margin 40.
In the manufacture of an oak door, oa~ is the wood
ordinarily selected for the edge strips which bound the core
panel and the wood of the veneer forming veneer strips 50, 52.
A completed door constructed as descri~ed, and as
shown in Fi~. 6 at 5~, has an appearance very closely resembling
the appearance of a conventional stile and rail door produced
using traditional procedures. The entire face of the door is
covered with the decorative wood selected. Each rectangular
region encompassed by a channel and, in most instances, a major
portion of the surfaces bottoming the channel encompassing this
rectangular region are exposed in the door, thus to simulate a
panel, and have graining in the veneer applied thereover which
extends in a uniform direction, normally, vertically when
simulating a door of a conventional type.
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Joints 56 appear, for instance, at the four co.rners
of the door where horizontally and vertically extending veneer
strip overlays meet. These joints impart the visual appearance
of the usual joints found between stile and rail members of a
conventional door. In fact r however, there are no joints in the
core panel at these locations, the joints extending only as deep
as the thickness of the veneer strip overlays.
While a preferred embodiment has been described in
connection with the door in its manufacture, it should be
obvious that variations and modifications are possible without
departing from the invention.
