Automated door assembly, press, and adhesive therefor

Abstract

Provided is a system and method of 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 press having upper and lower dies configured to impart a larger compression force toward a central area of the door skins. Wear resistant belts or membranes are provided to protect the door skins from being marred by the upper and lower dies during the pressing process.

1 - 10 . (canceled) 
     
     
         11 . A door press, comprising:
 an upper die having an upper surface, wherein the upper surface contains a membrane fixed thereto, the first membrane providing a center portion that is thicker than a peripheral portion; and   a lower die having a lower surface, the upper and lower surfaces facing one another to define a mold cavity in which a door assembly is received for pressing therein.   
     
     
         12 . The door press of  claim 11 , wherein the membrane is made of silicone or rubber 
     
     
         13 . The door press of  claim 11 , wherein the membrane is removably attached to the upper die. 
     
     
         14 . The door press of  claim 11 , wherein the membrane is configured for imparting a concave shape to the central region of the door during pressing operation. 
     
     
         15 . The door press of  claim 11 , wherein the membrane is expandable. 
     
     
         16 . The door press of  claim 15 , wherein the first membrane comprising a center portion having an upper chamber formed therein and a peripheral portion attached to the upper surface, the upper chamber spaces the center portion from the upper surface and is configured to accept gas to inflate the center portion to a raised position relative to the peripheral portion. 
     
     
         17 . The door press of  claim 16 , wherein the door assembly comprises a door frame having stiles and rails forming a perimeter of the door frame, a first door skin and a second door skin, the door skins being adhesively secured on opposite sides of the door frame; and
 wherein the upper surface is shaped to compress a central portion of the first door skin to a greater extent than a peripheral portions disposed about a perimeter of the door skins, so that the surface of the central portion and the peripheral portion of the first door skin are coplanar with each other upon completion of the pressing operation.   
     
     
         18 . The door press of  claim 11 , wherein the lower surface contains a second membrane fixed thereto, the second membrane providing a center portion that is thicker than a peripheral portion. 
     
     
         19 . A door pressing station comprising one or more door presses of  claim 11 . 
     
     
         20 . The door pressing station of  claim 19 , wherein the first membrane is expandable. 
     
     
         21 . The door pressing station of  claim 20 , wherein the first membrane comprising a center portion having an upper chamber formed therein and a peripheral portion attached to the upper surface, the upper chamber spaces the center portion from the upper surface and is configured to accept gas to inflate the center portion to a raised position relative to the peripheral portion. 
     
     
         22 . The door pressing station of  claim 19 , wherein the door assembly comprises a door frame having stiles and rails forming a perimeter of the door frame, a first door skin and a second door skin, the door skins being adhesively secured on opposite sides of the door frame; and
 wherein the upper and lower surfaces are shaped to compress central portions of the door skins to a greater extent than peripheral portions disposed about a perimeter of the door skins, so that surfaces of the central portions and the peripheral portions of the door skins are coplanar with each other upon completion of the pressing operation.   
     
     
         23 . A method for pressing an assembled door, comprising:
 providing the press of claim  1 ; and   pressing the assembled door in the press.   
     
     
         24 . The method of  claim 23 , wherein the membrane is made of silicone or rubber. 
     
     
         25 . The method of  claim 23 , wherein the membrane is removably attached to the upper die. 
     
     
         26 . The method of  claim 23 , wherein the membrane is configured for imparting a concave shape to the central region of the door during pressing operation. 
     
     
         27 . The method of  claim 23 , further comprising the step of expanding the membrane. 
     
     
         28 . The method of  claim 27 , wherein the first membrane comprises a center portion having an upper chamber formed therein and a peripheral portion attached to the upper surface, the upper chamber spaces the center portion from the upper surface and is configured to accept gas to inflate the center portion to a raised position relative to the peripheral portion. 
     
     
         29 . The method of  claim 23 , wherein the door assembly comprises a door frame having stiles and rails forming a perimeter of the door frame, a first door skin and a second door skin, the door skins being adhesively secured on opposite sides of the door frame; and
 wherein the upper and lower surfaces are shaped to compress central portions of the door skins to a greater extent than peripheral portions disposed about a perimeter of the door skins, so that surfaces of the central portions and the peripheral portions of the door skins are coplanar with each other upon completion of the pressing operation.   
     
     
         30 . The method of  claim 23 , wherein the lower surface contains a second membrane fixed thereto, the second membrane providing a center portion that is thicker than a peripheral portion.