Expandable spacer cores for panel doors and the method of making same

摘要

A door is provided that has a first outer skin and a second outer skin. A first and second outer skins are separated by frame to form a hollow core between the frame and the outer skins. An expandable spacer is connected to the first and second skins to hold the first and second skins a predetermined distance apart. The expandable spacer has a plurality of elongated members having a width. The elongated members are each oriented substantially perpendicular to the first and second outer skins. The expandable spacer has a plurality of expandable core liners extending between the elongated members. The expandable core liners orient the elongated members with respect to the first and second outer skins in a perpendicular direction. The elongated members having a reduced width portion formed therein that corresponds to the molded portion of the first skin. A reinforcement layer may be applied to the elongated members at the narrowed portion to support the narrowed portion.