Abstract: A door construction includes first and second door blanks each defining an L-shaped profile including: (i) a back member; (ii) a base member. The blanks are secured in opposed nesting relation to define first and second seams. The first and second seams. The first and second base members define edges of the door. The base member of the first blank defines a foot including a first contact surface and the back member of the first blank is folded upon itself to define a second contact surface. The base of the second blank defines a foot including a third contact surface and the back member of the second blank is folded upon itself to define a fourth contact surface. The first seam is defined at the abutment of the first and fourth contact surfaces, and the second seam is defined at the abutment of the second and third contact surfaces.

Abstract: 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.

Abstract: 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.