Solid Face Door Raised Panel Design via CNC Milling
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Solution Overview
Problem
Existing door manufacturing methods, such as stamped metal and multiple-piece construction, face challenges in design flexibility, cost, and quality control, particularly for large or intricate designs, due to tooling expenses and time-consuming assembly processes.
Innovation Solution
The use of computer-aided machinery, like CNC milling machines, to carve designs directly into a solid base of the door, allowing for flexible and efficient creation of raised panel designs with overlays that emulate traditional constructions, reducing production time and costs while maintaining high precision and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stamped metal or vinyl exterior is used, then manufacturing cost is reduced, but design flexibility is limited
Solution Approach 1:
The door face is segmented into multiple panels with distinct raised panel designs, allowing each panel to be independently designed and manufactured. This segmentation enables design flexibility while maintaining cost-effective manufacturing through modular construction.
Solution Approach 2:
The patent transitions from two-dimensional stamped or molded surfaces to three-dimensional raised panel constructions. By adding the vertical dimension through raised panels, the design achieves greater complexity and flexibility without proportionally increasing manufacturing cost.
2Adaptability or versatility
If multiple-piece construction is used, then design flexibility is improved, but manufacturing time and complexity increase
Solution Approach 1:
Multiple door panels are merged into a single integrated construction unit with unified raised panel designs. This merging reduces the number of separate components that need to be fabricated, aligned, and assembled, thereby reducing manufacturing time while preserving design flexibility.
Solution Approach 2:
The raised panel designs are pre-carved and prepared on each panel before final assembly. This preliminary action of pre-forming the decorative elements eliminates time-consuming on-site construction activities and streamlines the overall manufacturing process.
3Adaptability or versatility
If multiple-piece construction is used, then design flexibility is improved, but quality control issues increase
Solution Approach 1:
By merging multiple panels into a single integrated construction, the patent reduces the interfaces and joints between components. This merging minimizes potential quality control issues such as misalignment, gaps, and variations in assembly, while maintaining the design flexibility of multi-panel constructions.
Solution Approach 2:
The patent uses standardized raised panel designs that can be replicated across multiple panels. This standardization ensures consistent quality control and reduces variations in appearance and dimensions, while still allowing for flexible design configurations through the arrangement of standardized elements.
Data Source
AI summary
Carved solid face doors having a raised panel design and methods of manufacture thereof are provided herein. In some embodiments, a carved, solid face door may include a solid base having a face and an opposing rear surface, wherein the face has a raised panel design carved into at least one section of the face, the raised panel design framed by flat portions carved into the face; and one or more overlays attached to the flat portions of the face and framing the raised panel to emulate the appearance of a floating raised panel construction.