Abstract: An expandable, low-elasticity spacer made of two-sided corrugated material having a topsheet, a bottomsheet, and a corrugated sheet therebetween forming flutes. The spacer comprises two strips of the corrugated material, joined together to form a polygon having inside and outside corners. Each outside corner of the polygon has a slit parallel to the flutes that severs the continuity of the sheet in which it is made, eliminating the ability of the discontinuous portions to pull against each other, thereby eliminating potential spring back. The spacer is perforated, scored or crimped parallel to the flutes in one or more of the inside corners to make it easier to bend the spacer at the desired fold line. Because the spacer avoids springing back to its collapsed position, it can be sized to fill a cavity with no excess material and leave no unintended gaps. The corrugated material is preferably fiberboard or plastic.

Abstract: This spacer for paneled hollow-core doors has an H-beam configuration, with a first flange connected along its length to a second flange along its length by a web. The web is perpendicular to both the first and second flanges. A hollow-core door is assembled by placing the spacer between two door skins. Once the door is assembled, the web is parallel to the door skins. To accommodate the variation in distance between the bottom and top skins that is created by the raised panels, the bottom edge of each flange has one or more bottom notches that fits closely over the raised portion of the panel in the bottom skin and one or more top notches that fits closely over the raised portion of the panel in the top skin. Preferably only two or three spacers are used in a paneled door, each spacer extending the length of the door.

Abstract: This spacer for paneled hollow-core doors has an H-beam configuration, with a first flange connected along its length to a second flange along its length by a web. The web is perpendicular to both the first and second flanges. A hollow-core door is assembled by placing the spacer between two door skins. Once the door is assembled, the web is parallel to the door skins. To accommodate the variation in distance between the bottom and top skins that is created by the raised panels, the bottom edge of each flange has one or more bottom notches that fits closely over the raised portion of the panel in the bottom skin and one or more top notches that fits closely over the raised portion of the panel in the top skin. Preferably only two or three spacers are used in a paneled door, each spacer extending the length of the door.

Abstract: This spacer for paneled hollow-core doors has an H-beam configuration, with a first flange connected along its length to a second flange along its length by a web. The web is perpendicular to both the first and second flanges. A hollow-core door is assembled by placing the spacer between two door skins. Once the door is assembled, the web is parallel to the door skins. To accommodate the variation in distance between the bottom and top skins that is created by the raised panels, the bottom edge of each flange has one or more bottom notches that fits closely over the raised portion of the panel in the bottom skin and one or more top notches that fits closely over the raised portion of the panel in the top skin. Preferably only two or three spacers are used in a paneled door, each spacer extending the length of the door.

Abstract: A door has an outer skin and an inner skin with a frame along the edges of the outer skin and inner skin to hold the door skins apart to form a hollow space therebetween. A rigid space core filler or spacer is used in the hollow portion to provide structural support between the pair of outer skins. The spacer has a first and second elongated members each oriented perpendicular to the outer skins and a plurality of rigid cross-spacers coupled to an extending between the first elongated member and the second elongated member. The rigid space cores are formed by gluing strips of flexible material between layers of rigid materials so that the rigid materials are held together and separated the length of the flexible material to form a first assembly. The first assembly formed is cut across the layers of material and through the rigid layers. An adhesive is applied to the top edges of this assembly and is placed between a pair of rigid layers to form a second assembly.

Abstract: A door is provided that has a first outer skin and a second outer skin. A first and second outer skins are separated by a frame to form a hollow core between the frame and the outer skins. The outer skins have molded potions that extend into the space between 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 support the elongated members with respect to the first and second outer skins in a perpendicular direction. The elongated members and the expandable core liners have a reduced width portion formed therein that corresponds to the molded portion of the outer skins.

Abstract: A door has a pair of outer skins separated by a frame to form a hollow space therebetween. An expandable spacer core is connected between the pair of skins. The expandable spacer core has a plurality of elongated members each oriented perpendicular to both outer skins. A plurality of expandable core liners extend between elongated members to position the elongated members with respect to each other and to the outer skin. The expandable spacer cores are formed by gluing strips of expandable core liners between corrugated layers so that the corrugated layers are held together by the expandable core liners. The corrugated layers are cut in a direction across the expandable core liners. Once the expandable spacer cores are formed, an adhesive is placed on the edges of the expandable spacer core and the expandable spacer core is affixed to the inner side of the outer skins of the door.

Abstract: 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.

Abstract: An exterior door comprises a frame having a pair of vertical stiles joined by horizontal rails. The outer surface of each of the stiles and rails is provided with a groove extending the full length thereof. The frame has a core. A pair of exterior panels are adhesively secured to the faces of the frame, with the upper, lower and side edges of the panels each being provided with a bevel surface having a predetermined angle. A closure molding is provided for each of the outer surfaces of the rails and stiles forming the frame. Each molding in its free state has a generally elongated rigid strip having a slightly curved web and an elongated ledge on the inner surface of the web which is perpendicular thereto. The web's outer edges are inclined, with the inner inclined surfaces thereon being on an angle equal to the angle of the bevel surfaces. The molding strips flatten out when applied to the frame, with the ledges fitting tightly into the grooves.