Hollow core door for preventing pressure build up having a prefabricated center panel and method of making the door

Abstract

A hollow core door for preventing pressure build up in a room having a forced air system includes an outer stile and rail frame, an inside skin having an opening secured to the outer frame, an outer skin having an opening secured to the outer frame, and a core assembly, which may be prefabricated, including a core assembly frame, a center panel disposed within the core assembly frame, openings extending through the center panel adjacent to the core assembly frame, spacers adjacent to the core frame to space the core assembly apart from the inside and outside skins, and the core assembly is disposed within the outer frame, whereby air flows through the opening in the inside skin, along the center panel, through the openings in the center panel, along the center panel and outwardly through the opening in the outside skin in a non-linear manner to prevent pressure build up in a room in which the door is installed to comply with the Department of Energy maximum recommended pressure of three pascals or less. Different types of spacers are disclosed. A method for making the hollow core door is disclosed.