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 soundproof door assembly for use in reduction of sound transmitted from one side of the door to the other side, having an STC number at least STC 36 determined in accordance with ASTM E413-10 and E90-09, comprising a soundproof door having a thickness of 30-80 mm, which comprising two door skins, one formed as a front door skin and the other formed as a rear door skin for the soundproof door respectively; a quadrilateral frame, constituted by a top rail member, a bottom rail member, a left stile member and a right stile member to seal the perimeter of the door skins; and a multiple-layered core, to form a concrete inner portion of the door, which comprising three layers of a hard-soundproof material that blocks sound with high frequency over 500 Hz, wherein each of the door skins includes an aperture aligned and devoid of any soundproofing core thereby forms a window of the soundproof door for accommodation of a glass pane.

Barriers may utilize cores that may be pre-assembled and dropped into a barrier or may be formed within the barriers. The cores may include traditional core materials, biomass materials, graphite polystyrene (GPS) material, or other types of materials. The core may be formed from one or more layers, such as one or more stiffener layers (e.g., stiffener panel, stiffener rods, or the like), one or more matrix layers (e.g., with apertures extending therein), one or more solid layers (e.g., wood, plastic, composite, foam, fiber, or the like), one or more fluid sealed layers (e.g., air, argon, nitrogen, or other like), and/or other types of layers. The barrier edge members, the faces, and/or the core layers described herein may be assembled to each other in traditional ways, such as welding, and/or may be assembled to each other in a way that reduces the amount of welding and/or use of steel.

A soundproof door assembly for use in reduction of sound transmitted from one side of the door to the other side, having an STC number at least STC 36 determined in accordance with ASTM E413-10 and E90-09, comprising a soundproof door having a thickness of 30-80 mm, which comprising two door skins, one formed as a front door skin and the other formed as a rear door skin for the soundproof door respectively; a quadrilateral frame, constituted by a top rail member, a bottom rail member, a left stile member and a right stile member to seal the perimeter of the door skins; and a multiple-layered core, to form a concrete inner portion of the door, which comprising three layers of a hard-soundproof material that blocks sound with high frequency over 500 Hz, wherein each of the door skins includes an aperture aligned and devoid of any soundproofing core thereby forms a window of the soundproof door for accommodation of a glass pane.

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 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 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.

A manufactured door is disclosed having at least one mid panel having a plurality of openings formed therethrough. In an example, two mid panels are assembled back-to-back with one another. The example manufactured door also includes a front outer panel assembled over the at least one mid panel to form a front door side. A back outer panel is assembled over the at least one mid panel to form a back door side. A door skin is laminated on the front outer panel and the back outer panel for a finished appearance to the manufactured door.

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.