A method for manufacturing a three-dimensionally deformed plate made of a wood fiber material comprises providing a prefabricated, flat wood fiber material plate as the original plate, preheating the original plate in sections, wetting the preheated section of the original plate with an atomized liquid mixture of water and a separating agent, introducing a section of the original plate that is preheated and wetted with a liquid mixture of water and a separating agent between two rollers of a molding station, wherein the rollers respectively provide a corrugated profile in the peripheral direction of the external surface, such that the original plate is being deformed in sections into a plate with a wave shape, wherein rollers are being used, the respective profiling of which has half-waves which follow one another in the peripheral direction and which at least partially have a different extension in the peripheral direction.

A fire rated door includes a core, a first decorative panel and a second decorative panel. The core includes: (a) a fire resistant center panel having a bottom, a top, a first side, a second side, a first end and a second end, wherein the fire resistant center panel is made of a first fire resistant material, and (b) an extruded fire resistant border attached to the first side, the second side, the first end and the second end of the fire resistant center panel, wherein the extruded fire resistant border is made of a second fire resistant material having a higher density than the first fire resistant material. The first decorative panel is attached to the top of the fire resistant center panel and the extruded fire resistant border. The second decorative panel is attached to the bottom of the fire resistant center panel and the extruded fire resistant border.

A core layer suitable for a multilayer composite including at least one surface layer and one core layer, the surface layer arranged to at least partially cover the core layer and be fixedly connected thereto, wherein the core layer has elements composed of wood, which elements have plate-like regions arranged in zig-zag-shaped fashion, wherein a plate-like zig region of an element with an adjoining plate-like zag region of the element form a common edge between them, in such a way that the wood element of zig-zag-shaped form is formed, wherein elements of zig-zag-shaped form are arranged in the core layer such that two such edges of two different elements cross one another at a non-zero angle, and wherein the two elements are fixedly connected to one another at the crossing point. In one embodiment, a wood element of zig-zag-shaped form may be adhesively bonded to a planar wood element.

A system for manufacturing a three-dimensionally deformed plate made of a wood fiber material comprises a preheating station, a wetting device, and a molding station including two rollers spaced apart for receipt of a preheated and wetted flat wood fiber material plate therebetween. The rollers respectively include an external surface including a wave-shaped profiling in the peripheral direction, wherein the respective profiling has half-waves which follow one another in the peripheral direction, and which have a different extension in the peripheral direction

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.

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.

A system and method for making a door having first and second door skins and an internal frame. The top and bottom surfaces of the frame are coated with an adhesive and the frame is placed on a first door skin. The second door skin is then placed on the opposite surface of the frame. The assembled components are then pressed to bond the first and second door skins to the frame with a pressed having platens. Movable shims may be used to vary the pressed force and pressing area.

Aspects of the present disclosure describe a rechargeable door that includes at least one internal rechargeable battery and at least one further DC component powered by such rechargeable battery, wherein the at least one internal rechargeable battery is configured to be recharged via a physical connection, such as wired connections, or other contacts such as magnetic contacts or pogo pins or spring contacts, in the door via a second rechargeable battery or via wireless recharging, for example magnetic inductive or resonance charging, via placement of the second rechargeable battery on or within the door.

A core layer suitable for a multilayer composite including at least one surface layer and one core layer, the surface layer arranged to at least partially cover the core layer and be fixedly connected thereto, wherein the core layer has elements composed of wood, which elements have plate-like regions arranged in zig-zag-shaped fashion, wherein a plate-like zig region of an element with an adjoining plate-like zag region of the element form a common edge between them, in such a way that the wood element of zig-zag-shaped form is formed, wherein elements of zig-zag-shaped form are arranged in the core layer such that two such edges of two different elements cross one another at a non-zero angle, and wherein the two elements are fixedly connected to one another at the crossing point. In one embodiment, a wood element of zig-zag-shaped form may be adhesively bonded to a planar wood element.

The present disclosure provides an acoustic hollow core door comprising a door slab including an inner door frame, a first facing secured to a first side of the inner door frame, and a second facing secured to a second, opposite side of the inner door frame. The inner door frame and the first and second facings define an at least partially hollow air cavity, and at least one of the first or second facings has a thickness between about 0.150 and 0.320 inches and a nominal density of between about 0.80 and 1.1 grams per cubic centimeter. The hollow core door may include internal sticks or core inserts positioned within the hollow air cavity between the first and second facings. Acoustically absorptive material may be positioned within the hollow air cavity to reduce resonance effects around 250-315 Hz frequency range. The acoustic hollow core door achieves STC ratings of between about 25 and 31, while maintaining weight reduction compared to solid core doors with comparable acoustic performance.