Systems and methods for making flush architectural doors using post-consumer materials

Abstract

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.

1 . A method for forming a flush architectural wooden door using at least one post-consumer material, the method comprising:
 collecting a previously-used door from a collection site, the previously-used door comprising a core having a first major surface, a second major surface opposite to the first major surface, and a perimeter around the opposing major surfaces;   extracting the core from the previously-used door;   applying rails and styles to the perimeter of the extracted core; and   applying a first skin over the first major surface of the extracted core and applied rails and styles;   wherein the extracted core, the rails, the styles, and the first skin have a collective weight, and wherein the extracted core forms over half of that collective weight.   
     
     
         2 . The method of  claim 1 , further comprising inspecting the extracted core for at least one of physical integrity, moisture, warpage, defects, damage, cutouts, or density prior to applying rails and styles to the perimeter of the extracted core. 
     
     
         3 . The method of  claim 1 , further comprising at least one of machining or refinishing the flush new architectural wooden door. 
     
     
         4 . The method of  claim 1 , wherein collecting the previously-used door from the collection site comprises collecting the previously-used door from one of a construction site or a demolition site. 
     
     
         5 . The method of  claim 1 , wherein extracting the core from the previously-used door comprises using a planer or an abrasive sander to remove at least one skin disposed over the core of the previously-used door. 
     
     
         6 . The method of  claim 1 , wherein extracting the core from the previously-used door comprises removing at least a portion of at least one style from the core of the previously-used door. 
     
     
         7 . The method of  claim 1 , further comprising establishing a chain of custody for the new flush architectural wooden door with the extracted core. 
     
     
         8 . The method of  claim 7 , wherein establishing the chain of custody for the new flush architectural wooden door with the extracted core comprises recording chain-of-custody information. 
     
     
         9 . The method of  claim 8 , wherein recording chain-of-custody information comprises recording the location of the collection site from where the previously-used door was collected. 
     
     
         10 . The method of  claim 8 , wherein establishing the chain of custody for the new flush architectural wooden door with the extracted core comprises stamping recorded chain-of-custody information onto the new flush architectural wooden door. 
     
     
         11 . The method of  claim 1 , further comprising applying a second skin over the second major surface of the core and applied rails and styles. 
     
     
         12 . A flush architectural door formed using at least one post-consumer material, the flush architectural door comprising:
 a recycled core extracted from a previously-used door, the recycled core having a first major surface, an opposing second major surface, a top end, an opposing bottom end, a first side, and an opposing second side;   a top rail disposed against the top end of the recycled core;   a bottom rail disposed against the bottom end of the recycled core;   a first style disposed against the first side of the recycled core;   a second style disposed against the second side of the recycled core; and   a first skin disposed over the first major surface of the recycled core;   wherein the recycled core, the rails, the styles, and the first skin have a collective weight, and wherein the recycled core forms over half of that collective weight.   
     
     
         13 . The flush architectural door of  claim 12 , further comprising a second skin disposed over the second major surface of the recycled core. 
     
     
         14 . The flush architectural door of  claim 12 , wherein the recycled core is formed substantially-entirely from post-consumer wood or wood-based products. 
     
     
         15 . The flush architectural door of  claim 12 , wherein the recycled core comprises at least one of woodchips, sawdust, wood shavings, particle board, plywood, resin, stud grade lumber, structural lumber, laminated strand lumber, or gypsum. 
     
     
         16 . The flush architectural door of  claim 12 , wherein the flush architectural door is a commercial-industrial door. 
     
     
         17 . The flush architectural door of  claim 12 , wherein the flush architectural door is a fire-rated door. 
     
     
         18 . The flush architectural door of  claim 12 , wherein the flush architectural door comprises chain-of-custody information disposed on the flush architectural door. 
     
     
         19 . The flush architectural door of  claim 12 , wherein at least a portion of the flush architectural door is refinished using at least one ultraviolet-light-cured material. 
     
     
         20 . The flush architectural door of  claim 12 , wherein the flush architectural door comprises at least one adhesive, the at least one adhesive comprising no added urea formaldehyde compounds.