DOOR CONSTRUCTION AND METHOD

摘要

A new and improved door construction and method of manufacturing same are advantageously provided. The door includes first and second formed door panels, each having an identical or substantially similar L-shaped profile defined by an elongated back portion and a relatively shorter base portion. The first and second formed door panels are placed in opposed nesting relation so that the back portions and the base portions are arranged in opposed facing relation to each other. A hollow region is thus defined by and between the first and second formed door panels. The panels are temporarily held in alignment to each other in this relationship by an adhesive, preferably through use of a suitable internal core material secured between the panels by the adhesive. The panels are thereafter permanently joined by laser welding performed along first and second seams. In particular, the first seam is formed at the abutment of the base of the first panel with the back of the second panel, and the second seam is formed at the abutment of the base of the second panel with the back of the first panel. The first seam is disposed along a first lateral edge of the door construction immediately adjacent the back portion of the second panel. The second seam is disposed along a second lateral edge of the door construction immediately adjacent the back portion of the first panel. This arrangement results in substantially uninterrupted first and second door edges defined by the base portions of the first and second L-shaped door panels.