Shaker doors with solid core and methods for making thereof
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.
1. A shaker door, comprising:
a) a rectangular frame;
b) first and second molded door facings attached to opposite sides of the rectangular frame, the first and second door facings respectively comprising first and second raised peripheral regions opposite to one another, first and second transitions opposite to one another and surrounded by, immediately adjacent and perpendicular to, and contiguous with the first and second raised peripheral regions, and first and second recessed panels opposite to one another and terminating at opposite sides and opposite ends thereof at continuous planar outer perimeters that are surrounded by, immediately adjacent and perpendicular to, and contiguous with the first and second transitions, an entirety of the first and second recessed panels within the continuous planar outer perimeters being planar and recessed from the raised peripheral regions, the first and second door facings and the rectangular frame defining a cavity; and
c) a core contained in the cavity, the core comprising:
i) a first core comprising a first member and a second member, the first member of the first core having a first density and being disposed between the first and second recessed panels but not extending beyond the continuous planar outer perimeters of the first and second recessed panels, the second member of the first core having a second density less than the first density and being disposed between the first and second raised peripheral regions but not within the continuous planar outer perimeters of the first and second recessed panels; or
ii) a second core comprising a first member and a second member, the first member of the second core spanning substantially an entire length and width of the cavity and having a thickness sufficient to fill an area of the cavity between the first and second recessed panels, the second member of the second core comprising first and second layers on opposite sides of the first member of the second core and being disposed between the first and second raised peripheral regions but not within the continuous planar outer perimeters of the first and second recessed panels; or
iii) a third core comprising a first member and a second member, the first member of the third core being disposed between the first and second recessed panels and comprising an overhang extending beyond the continuous planar outer perimeters of the first and second recessed panels, the second member of the third core being disposed between the first and second raised peripheral regions but not within the continuous planar outer perimeters of the first and second recessed panels, the second member of the third core having a channel receiving the overhang of the first member of the third core; or
iv) a fourth core comprising a first member and a second member, the first member of the fourth core being disposed between the first and second recessed panels and comprising an overhang with opposite overhang surfaces extending beyond the continuous planar outer perimeters of the first and second recessed panels, the second member of the fourth core being disposed between the first and second raised peripheral regions but not within the continuous planar outer perimeters of the first and second recessed panels, the second member of the fourth core having an L-shaped cross section with a ledge contacting one of the overhang surfaces and providing a void at the other of the overhang surfaces.
2. The shaker door of claim 1 , wherein the core contained in the cavity comprises the first core c)i).
3. The shaker door of claim 2 , wherein the first density of the first core is 120% to 250% greater than the second density of the first core.
4. The shaker door of claim 2 , wherein the first density of the first core is 25 to 35 lbs/ft 3 , and the second density of the first core is 13 to 23 lbs/ft 3 .
5. The shaker door of claim 2 , wherein the first member and the second member of the first core are made of different materials.
6. The shaker door of claim 2 , wherein the first member of the first core has first opposite surfaces adhered directly to the first and second recessed panels, respectively, and wherein the second member of the first core has second opposite surfaces adhered directly to the first and second raised peripheral regions, respectively.
7. The shaker door of claim 1 , wherein the core contained in the cavity comprises the third core c)iii).
8. The shaker door of claim 7 , wherein the overhang extends 25% to 50% of a distance between the first and second recessed panels and the rectangular frame.
9. The shaker door of claim 7 , wherein the first member of the third core has first opposite surfaces adhered directly to the first and second recessed panels, respectively, and wherein the second member of the third core has second opposite surfaces adhered directly to the first and second raised peripheral regions, respectively.
10. The shaker door of claim 7 , wherein the first member and the second member of the third core are made of different materials.
11. The shaker door of claim 1 , wherein the core contained in the cavity comprises the fourth core c)iv).
12. The shaker door of claim 11 , wherein the overhang extends 25% to 50% of a distance between the first and second recessed panels and the rectangular frame.
13. The shaker door of claim 11 , wherein the first member of the fourth core has first opposite surfaces adhered directly to the first and second recessed panels, respectively, and wherein the second member of the fourth core has second opposite surfaces adhered directly to the first and second raised peripheral regions, respectively.
14. The shaker door of claim 11 , wherein the first member and the second member of the fourth core are made of different materials.
15. The shaker door of claim 1 , wherein the core contained in the cavity comprises the second core c)ii).
16. The shaker door of claim 15 , wherein the thickness of the first member of the second core is a first thickness, and wherein the first and second members of the second core have a combined second thickness that is about three times the first thickness.
17. The shaker door of claim 15 , wherein the first and second layers of the second member of the second core each comprise a plurality of strips.
18. The shaker door of claim 15 , wherein the first member and the second member of the second core are made of different materials.
19. The shaker door of claim 15 , wherein the first member of the second core has first opposite surfaces adhered directly to the first and second recessed panels, respectively, and wherein the second member of the second core has second opposite surfaces adhered directly to the first and second raised peripheral regions, respectively.
20. The shaker door of claim 15 , wherein the second member of the second core is made of a compressible material.