A door panel comprising a body having front and rear door skins sandwiching, at least partially, two stiles, which together delimit an interior for injection of filling material. At least one of the stiles comprises a hollow structure with a partitioned hollow interior that extends along substantially the entire length of the body to offer mechanical strength to the door and to provide foundation for installing door fittings.

The present invention relates to a double backbone core for automated hollow door manufacture and a door comprising same. The double backbone core comprises an expandable core component comprising two backbones with relatively smaller cells running parallel to one another along the length dimension of the door, wherein the core is formed from a plurality of interconnected strips.

A structural panel includes a shell having spaced first and second exterior panels and frame members adjacent edges of the panels, and at least one polymeric sheet disposed between the exterior panels and bonded to an adjacent exterior panel. The polymeric sheet is made of a thermoplastic material and has a plurality of openings through its thickness spaced apart by flat wall portions of the polymeric sheet. Stiffeners are disposed between the polymeric sheets and are secured by polymeric end caps. The end caps are made of a thermoplastic material and have a plurality of openings through their thickness for receiving the stiffeners. A foam insulation material fills substantially all the space between the polymeric sheets, stiffeners, and frame members in the shell interior. At least one blast- or ballistic-resistant core layer may be disposed adjacent the at least one polymeric sheet.

A closure member of a preferred configuration and the method of making the same. The closure member has a board with a major axis and two panels to sandwich a hollow interior that is partitioned by a plurality of ribs positioned at intervals within the hollow interior, the hollow interior is delimited in a first direction by a pair of opposite end walls. The hollow interior is accessible in a second direction which is substantially traverse to the first direction, and at least one of the two panels is textured during the formation of the board to form a textured outer surface of the closure member, or the hollow interior is filled with a preferred reinforcement means.

A door pressing system for pressing interior passage doors, exterior entry doors, bi-fold doors, and/or closet doors features a multi-door pressing station including first and second presses, a loading device, and a discharging device. The pressing station is configured to alternatively move the first and second presses into operative alignment with the loading and discharging devices. The press in operative alignment delivers a pressed assembled door to the discharging device and receives an assembled door layup to be pressed from the loading device. The other press that is out of operatively alignment presses an assembled door received therein. Additional methods and systems are also provided.

Systems and methods for pressing a door assembly involve one or more die sections installed in a press, wherein the die sections each have a raised section that contacts and supports a recessed panel portion of a door skin of the assembly during the pressing operation to facilitate crushing of portions of a core of the door assembly that underlie the recessed panel portion of the door skin. The die sections may be made of plastic and readily changed out for different sizes or styles of doors.

A door pressing system for pressing interior passage doors, exterior entry doors, bi-fold doors, and/or closet doors features a multi-door pressing station including first and second presses, a loading device, and a discharging device. The pressing station is configured to alternatively move the first and second presses into operative alignment with the loading and discharging devices. The press in operative alignment delivers a pressed assembled door to the discharging device and receives an assembled door layup to be pressed from the loading device. The other press that is out of operatively alignment presses an assembled door received therein. Additional methods and systems are also provided.