Recycled Door Core Reuse in Flush Architectural Doors
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Solution Overview
Problem
The high cost and environmental impact of constructing new buildings are exacerbated by the destruction of flush architectural wooden doors during demolition, as they are typically made from newly harvested wood, leading to waste and the need for additional materials.
Innovation Solution
The use of post-consumer materials, specifically recycled cores from previously-used doors, to form new flush architectural doors, which reduces the demand for new wood and minimizes waste by reusing existing materials, and can earn environmental credits through certifications like LEED.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If new wood is harvested to manufacture flush architectural doors, then the supply of new wood is ensured, but the environmental impact and cost increase
Solution Approach 1:
The patent applies the discarding and recovering principle by collecting and reusing door cores from demolished buildings that would otherwise be discarded as waste. These recovered cores are cleaned, inspected, and reused in new door assemblies, thereby reducing the need to harvest new wood and minimizing environmental impact while maintaining material supply
Solution Approach 2:
The patent changes the source parameter of the wood material from newly harvested to post-consumer recycled. By altering the origin parameter of the material while maintaining its functional properties through cleaning and inspection processes, the invention reduces environmental impact without compromising the availability of sufficient wood material for door manufacturing
2Quantity of substance
If new wood is harvested to manufacture flush architectural doors, then the supply of new wood is ensured, but the cost increases
Solution Approach 1:
The patent recovers valuable door cores from demolished buildings, transforming them from waste into reusable materials. This recovery process eliminates the need to purchase and process new wood, thereby reducing material costs while ensuring sufficient quantity of wood-like material is available for new door production
Solution Approach 2:
The patent converts the harmful waste generated from demolished doors into a beneficial reusable resource. By transforming discarded door cores into valuable manufacturing materials, the invention reduces both the cost of acquiring new wood and the environmental harm of waste disposal, creating economic and ecological benefits simultaneously
3Quantity of substance
If flush architectural wooden doors are destroyed during demolition, then space is cleared for new construction, but waste is generated and materials are lost
Solution Approach 1:
The patent implements a systematic recovery process that intercepts door cores before they become waste. During or after demolition, these cores are collected, cleaned of attachments, inspected for damage, and sorted for reuse. This process ensures material availability for new construction while preventing loss of valuable wooden materials that would otherwise be discarded
Solution Approach 2:
The patent performs preliminary cleaning and inspection of door cores immediately after recovery from demolition sites. By preparing these materials in advance through removing attachments, drying, and assessing their condition, the invention ensures they are ready for reuse, thereby maintaining material availability while preventing waste generation
Data Source
AI summary
A method for forming a flush architectural wooden door using at least one post-consumer material includes collecting a previously-used door from a collection site. The previously-used door includes a core having a first major surface, a second major surface opposite to the first major surface, and a perimeter extending around the opposing major surfaces. The core is extracted from the previously-used door. Rails and styles are applied to a perimeter of the extracted core. A first skin is applied over the first major surface of the extracted core and applied rails and styles. The extracted core, rails, styles, and first skin have a collective weight. The extracted core forms over half of that collective weight.