Composite door and method of manufacture

摘要

A composite door includes a solid core 10 formed from a wood-based material 11. A first recess 20 is formed in a first side 12 of the solid core, and a skin (116, Fig 2A) is formed over the first side of the solid core and the first recess. An insulating material, such as polyurethane foam 130, is provided in a cavity defined by the solid core and the first skin. A second recess 24 may be formed in a second side 14 of the door with optional apertures 21 allowing passage of insulating material between the two sides of the core. An associated method comprises machining the first recess in a first side of the solid core; providing a skin over the first side of the solid core and the first recess to create the cavity; and injecting or flowing an insulating material into the cavity.