MXPA00007228A - Flat-skinned door the simulates a three-dimensional molded skin door and corresponding method - Google Patents

Abstract

A method of making a flat-skinned door (1) which simulates a three-dimensional molded skin door, and corresponding product, are disclosed. The method includes the steps of applying a basecoat(s) to the door skin, applying a woodgrain puff-ink to the skin over the basecoat in order to simulate woodgrain patterning, utilizing a printing roll(s) to print a photographic image on the door which simulates a three-dimensionmolded door skin, and forming a hardened non-stainable polymerized coating over the image applied by the printing roll(s). In such a manner, a flat-skinned door (1) may be made which simulates a three-dimensional molded skin door.

Description

FLAT OUTER PLATE DOOR THAT SIMULATES A TRIDIMENSIONAL MOLDED OUTER PLATE DOOR AND METHOD FOR ITS MANUFACTURE FIELD OF THE INVENTION This invention relates to the hollow core door, and to the corresponding method for the manufacture thereof. More particularly, this invention relates to a hollow core door made from flat, door plates that simulate a three-dimensional molded door.

BACKGROUND OF THE INVENTION Hollow core doors are known in the art. For example, see U.S. Patent No. 5,560,168, the description of which is incorporated by reference herein. A typical hollow core door includes a frame or perimeter structure with vertically extending uprights and upper and lower rails, with a pair of opposite door outer plates secured to the perimeter of the frame. REF.121640 Hollow core, molded, three-dimensional doors are also known. For example, hollow-core, molded, three-dimensional doors are described in the aforementioned '168 patent. Molded hollow core doors include at least one outer door plate which is molded, for example, to define a plurality of recessed panels and adjacent flat portions. Such doors are seen by many in the trade as aesthetically attractive in certain scenarios. Unfortunately, hollow-core doors, while molded, are attractive, suffer from at least the following problems. First of all, these are more expensive to process than hollow-core doors, of flat outer plate, due to the increased cost of a molded outer plate, relative to a flat outer plate. Secondly, problems may arise in the manufacture of molded outer door plates when the molds are not in register. Third, the "molding requirements limit the types of material (which are often expensive) from which the outer plate of the base door can be made.

It is apparent from the foregoing that there is a need in the art for a door that has the aesthetically pleasing qualities of a hollow core, molded door (or carved wood door), that is economically viable and economical, of a hollow core door with a flat outer plate. One purpose of this invention is to meet the needs previously described in the art, as well as other needs that will become apparent to the person skilled in the art from the following detailed description of this invention.

BRIEF DESCRIPTION OF THE INVENTION Generally speaking, this invention meets the need previously described in the art by providing a hollow core door comprising: a door frame including first and second vertical posts that are oriented substantially parallel to each other, a top rail member, and a lower rail member; first and second outer door plates, each of the outer door plates is substantially planar; the first outer door panel, fixed to a first side of the door frame, and the second outer door panel, fixed to a second side of the door frame; at least one of the first and second door plates includes the following layers formed thereon: a) a base coat layer of a first color placed substantially over a complete surface of the at least one door plate; b) a layer in wood grain pattern that forms a wood grain pattern that is substantially placed on the entire surface of at least one door plate; c) a layer of ink for panel placed solely on a first portion of the surface of the at least one door plate, for the purpose of simulating the hollow panels on at least one door plate; d) a layer of shadow ink placed only on a second portion of the surface of the at least one door plate, wherein the second portion is mainly located on the substrate at sites that do not include the first portion, so that the layer Shade ink is formed where the ink layer of the panel is not present; and e) a protective, substantially transparent, poly-coated top coat layer. In the preferred embodiments, each of the first and second plates each have the same layers a) -e) placed thereon, so that each plate simulates a three-dimensional molded or carved door plate. A further objective of this invention is to provide a method for manufacturing a flat plate door that aesthetically simulates a three-dimensional molded or carved door. This invention will now be described with reference to certain embodiments thereof, as illustrated in the following drawings.

IN THE DRAWINGS Figure 1 is a front elevation view of a flat plate door simulating a molded plate door, according to one embodiment of this invention. Figure 2 is an exploded cross-sectional view of a flat door plate used on one side of the door frame of Figure 1. Figure 3 is a schematic illustration according to one embodiment of the present invention, which describes a mounting line for manufacturing hollow-core, flat-plate doors according to this invention. Figure 4 is a cross-sectional, partial, lateral view of the three-roll printing process used in the manufacturing process of Figure 3, according to certain embodiments of this invention. Figure 5 (a) is a plan view of a flat plate door that simulates a plate door molded according to yet another embodiment of this invention. Figure 5 (b) is a plan view of a flat plate door that simulates a plate door molded according to yet another embodiment of this invention.

Figure 5 (c) is a plan view of a flat plate door that simulates a plate door molded according to yet another embodiment of this invention.

DETAILED DESCRIPTION OF CERTAIN MODALITIES OF THIS INVENTION Referring now more particularly to the accompanying drawings, in which similar reference numerals indicate similar parts throughout the various views. Figure 1 is a front elevation view of a hollow core door 1 according to an embodiment of this invention. The door 1 includes a pair of flat plates 3, substantially flat, opposite, secured to a frame or door structure on opposite sides thereof, to form the hollow core door. The door frame includes vertical, elongated, opposite vertically extending uprights 5, and upper and lower rails 7, 9 respectively. The outer peripheries of the vertical posts 5 and the rails 7, 9 define the outer periphery of the frame for the door 1, while the internal edges of these frame members are shown in Figure 1 in dashed lines, since these are low. the faceplate 3. The faceplate 3 of the door is secured to one side of the frame members 5, 7, 9 by adhesive such as polyvinyl acetate, and a similar, rear door plate is correspondingly secured to the other side of the door. these frame members. The plates define a hollow area between them, which may include a foam core in certain embodiments. The plates 3 of the door 1 are manufactured to simulate three-dimensional molded door plates, although the plates 3 are substantially flat or flat and are not molded. While it is preferred that each of the plates simulate a molded door plate, it is only necessary that one of the plates facing away from the door have that appearance. In this way, the plates 3 are aesthetically pleasing due to their simulation of molded plates, and - at the same time they are economically feasible because they are not molded. Each flat plate 3 is made to appear to include panels 11 molded, or recessed by carving, and / or adjacent flat portions 13, as well as connection areas 15, angled, shaded. With reference to Figure 2, each door plate 3 includes the following layers: the substrate 17 (e.g., of a composite wood material such as compressed board, medium density fiber board, or similar dimensionally stable material) including the porous composite layer 19 and possibly the reinforcing layer 21, the sealant 23 applied to the porous surface 25 of the substrate, to create a uniformly impermeable surface on which to apply the subsequent materials, the first colored viscous basecoat 27 and the second coating viscous base 29 of the same color (both applied by roller) applied to the sealed surface, with the color of the base coat, selected to reflect the color of the general background environment of the wood, which is simulated by the door, grain pattern or wood grain 31, printed, of an acrylic printing ink or the like, the printed ink layer 33 to form the linear features on each plate 3 that simulate the panels 11 and the flat portions 13, the printed ink layer 35 to form the linear features on the outside of each plate 3, which simulate the shaded portions angled 15, and finally the protective coating 37 which preferably does not accept the spots. The protective coating 37 is applied to protect the grain or wood grain pattern and is transparent, so that the printed wood grain 31 and the printed mold simulations 33 and 35 are visible through the coating 37. The coating 37 it is hard enough to allow the door and / or the plate to be stacked and shipped horizontally, without substantial degradation to the outer surface. As will be described below, each of the layers 33 and 35 (and optionally the layer 31) is discontinuous through the substrate / door plate, to form and define different discrete portions that stimulate the panels 11 and the flat portions 13. A method of manufacturing the door 1 according to one embodiment of this invention can be understood by reference in Figures 3 through 5. It should be understood that these figures are for illustrative purposes only and the placement and size of each element. It is not intended to be limiting.

For purposes of simplicity, the manufacturing method will be described with reference to the door plates using a composite wood substrate 17, but it should be understood that the substrate 17 may be made of other materials such as a non-porous material, fiber material of glass, or similar. The substrate 17 enters a horizontal conveyor system (see Figure 3) in the cleaning station 41 of multiple brushes, with the surface 25 facing the brushes. The surface 25 of the substrate 17 is cleaned using multi-rotating brushes, which clean the surface; the adhesion of the subsequent layers can be adversely affected if the surface 25 is not cleaned. The conveyor portion 43 conveys the clean substrate 17 to direct the roller coating station 45, where the liquid sealant 23 is applied to the surface 25. The sealant 23 is an acrylic sealer, such as that available from Akzo Coatings, Inc., under its product number 641-Y029-42. The conveyor system then transports the sealed substrate 17 to an infrared oven 47 which cures and hardens the sealer 23. While it is preferred that the sealant 23 be cured, other non-cure sealants may be used in the practice of this invention. If the substrate 17 is non-porous (for example, because it is metallic), then a sealant is not required. The substrate 17 having the dry sealer 23 on it then enters a first coating station 49, direct roller, where the first liquid base coat 27 is applied. The base coat 27 can be a water based vinyl acrylic copolymer with a low volatile organic solvent (VOC) content having a viscosity of about 38 seconds on a Zahn # 2 layer in certain embodiments, as is available from Akzo under the product number 651-W029-12. The conveyor 50 then transports the substrate having the wet base coat 27 to the second direct roll coating station 51, where the second layer 29 of the base coat is applied over the first base coat. The second base coat layer 29 is applied, and each base coat layer 27, 29 has a thickness of approximately 76.2 micrometers (0.003 mils) in certain embodiments. The second basecoat 29 is allowed to level while being transported on the conveyor. The controlled viscosity of the basecoat layers results in tactile qualities, when dry, of the raw wood. Multiple layers of basecoat are preferred in order to ensure surface coverage while minimizing the thickness of each such layer. The conveyor 52 then transports the substrate having two wet base coatings to two double, sequential, high speed, 53 and 55 furnaces. The operation of ovens 53 and 55, and other elements described herein are described in U.S. Patent No. 5,597,620, the disclosure of which is incorporated by reference herein. The furnace 53 is adjusted to approximately 121 ° C (250 ° F) in order to prevent the base coat from forming a layer, and the furnace 55 is adjusted to approximately 191 ° C (375 ° F). The residence time of the substrate in the furnaces 53 and 55 is about 25 seconds, with the surface temperature when it leaves the furnace 55 which is about 55 ° C (131 ° F). Furnaces 53 and 55 can be convection ovens, which cause the solvent to be moved relatively quickly away from the substrate. The ovens 53 and 55 dry and harden the basecoat layers 27 and 29. The conveyor portion 57 then transports the substrate to the brush station 59. The base coat layers 27 and 29 are allowed to cool to ambient air during transport due to the residence time achieved. Base coatings must be dry and hard, so that the base coatings are not malleable at station 59. At station 59, the outer surface of the base coat layer 29 is polished with high speed rotating brushes, which remove scratches on the base coat surface and any fibers or the like that lie on the surface of the basecoat. The conveyor portion 61 then transports the brushed substrate to the rotogravure printing station 63, of three platforms. While on conveyor 61, the polished surface of basecoat 29 is cooled to remove heat from polishing. The three-deck printing station 63 is shown in more detail in Figure 4. The printing station 63 includes the wood grain printing roller 65 which applies the ink layer 31 which simulates wood grain to the substrate, the transfer roller 67 for wood grain printing, the panel printing roller 69 which applies the ink layer 33 which simulates the recessed panel 11, and the shadow printing roller 71 which applies the ink layer 35 which simulates the shade 15. As shown in Figure 4, the substrate 17 having layers 24, 27 and 29 on it enters the printing station 63 of three platforms. Roller 65 prints a layer 31 in wood grain pattern, simulating a grain or grain of wood such as teak, oak, or mahogany, on the substrate over basecoat layers 27 and 29. This wood grain pattern can to be printed in certain embodiments with an acrylic printing ink 73 such as that which is available from Akzo under the product number 699-C029-37 OA. The printing ink may also be a "swelling" ink, which is one that expands after the thermal actuation. The swelling ink thus helps to give the plate the feeling of a three-dimensional wood grain, also increasing its attractiveness. The reservoir 75 houses printing ink 73 of wood grains, and the rotating ink transfer roller 7 is immersed within the ink 73 during rotation, and thereby transfers the ink 73 to the printing roller 65 of wood grain, rotating, which includes a wood grain pattern, inverted, raised, engraved, molded, or otherwise formed on its rotating surface. In this way, the roller 65 applies the layer 31 of the wood grain pattern to the substrate 17 on the basecoat layers. Exemplary wood grain patterns are shown by reference numbers 78 in Figures 1 and 5 (b) -5 (c). In certain embodiments, the wood grain layer 31 is applied substantially over the entire surface of the substrate. The conveyor of the printing station then transports the substrate having the wood grain layer 31 on it towards the rotary printing transfer station 79 which includes the transfer roller 67. During this transport close to 5-15 seconds, layer 31 of wood grain begins to dry, and becomes sticky. The high pressure rubber roller 67, when rotating the substrate on the sticky wood grain layer, picks up part of the sticky layer 31 and transfers it to a circumferentially spaced site on the substrate, where the sticky portion is reapplied on the substrate. base coating. Thus, the pattern 31 of the wood grain can have empty spaces and / or gaps defined therein to improve the unique appearance of the layer 31. After the layer 31 has been laminated with the transfer roller 67, the layer 31 simulates wood grain without tension. Still with reference to Figure 4, after the substrate with the wood grain layer 31 comes out of the transfer roller 67, it proceeds towards the panel printing roller 69. In certain embodiments, the layer 31 is allowed to dry substantially (e.g., to prevent scuffing or rubbing) before the substrate 17 reaches the roll 69. The substrate is registered by means known in the art before reaching the roll 69, in order to ensure that the layers 33 and 35 are applied to each substrate 37 that leaves the same site relative to each other and to the edges of the substrate. As the substrate 17 is transported past the roller 69, this panel printing roller 69 contacts the substrate, and applies or prints the ink layer 33 on it, on the wood grain layer 31, with the layer 33. of forming / printing the lines 81 (see Figures 1 and 5 (a) -5 (c)) on the substrate in order to stimulate the three-dimensional molded panels 11 and the flat portions 13. In this way, the layer 33 is constituted of lines 81 that are applied to the substrate. The ink 83 of the panel, maintained in the reservoir 85, is transferred to the roller 69 by the rotating transfer roller 87, so that the roller 69 comes into rotatable contact with the substrate in order to apply the simulation layer 33 of the panel to this one, on the wood grain pattern 31. After the lines 81 (for example, the panel simulation layer 33) have been applied to the substrate by the roller 69, the substrate 17 is conveyed to the shadow application roller 71. In certain embodiments, the ink layer 33 is allowed to dry during transportation between the rollers 69 and 71. When the substrate 17 reaches the shadow printing roller 71, this roller applies the shade layer 35 to the substrate 17 on the top of the basecoat layers and after the panel 33 layer has dried. The shadow layer 35 defines lines / shadow patterns 89 [see Figures 1 and 5 (a) -5 (c)] which simulate angled portions 15 connecting the substantially planar bottom portions of the panels 11 to the planar portions 13. In certain embodiments, the shadow layer 35 (and thus the shadows 89) is only applied to the areas that simulate these angled portions, and thus is mainly applied directly on the wood grain layer where the panel layer 33 He is not present. Shadows 89 give the resulting image an appearance of depth, thus improving the simulated three-dimensional appearance. In this way, the roller 71 has a defined pattern on its outer roller surface which represents the inverse of the shades 89 to be printed on the substrate. The shade ink 91, held in the tank 93, is transferred to the printing roller 71 by the transfer roller 95, so that the roller 71 applies the layer 35 of the shade 89 to the substrate on the base coat layers according to roller 61 makes contact with the substrate in a rotating manner. Again, it is important that the substrate 17 be placed on register in the printing station, so that the rollers are aligned, and the ink applied in the correct places (for example, so that the shade layer 35 can always be applied at least in the angle simulation areas 15 between the lines 81 formed by the roller 69). The inks 73, 83, 91, as well as the base coat color, may all be of different colors according to certain embodiments of this invention. Thus, when these are all of different colors, the process described herein is akin to a four-color printing process that can achieve superior visual results and be aesthetically pleasing to those who observe the finished product. In other words, the base coat may be of a first color, the wood grain of a second color, the panels of a third color, and the shades of a four color. The printed image formed by various layers is preferably formed from a high-quality photograph, a molded plate to be simulated, with the photograph being separated by means known in the art, and printing plates (e.g. , the rolls) prepared. It is therefore high quality printing.

After the substrate 17 has passed through the roller 71, and thus the layers 23-35 have been applied thereto, the conveyor portion 93 transports the substrate away from the printing station 63 and into the direct roller coater 95. as shown in Figure 3. While on conveyor 93, the ink in layer 35 dries. The direct roller coater 95 applies a first layer of a protective coating 37. The coating 37 may be, for example, a polymerizable, non-tacky protective coating. The first coating layer 37 can be approximately 76.2 micrometers (0.003 thousandths of an inch) thick in certain modalities. The carrier portion 99 then transports the substrate to the second direct roller coater 101 (which is optional) which applies a second coating layer 37. Two layers are preferred. The conveyor portion 103 then transports the substrate 17 to the double speed, high speed ovens 105 and 107. Before reaching the ovens, the substrate remains on the conveyor portion 103 for about 3 seconds to allow the protective coating 37 to level out. The double high speed ovens 105 and 107 harden the coating 37 and remove the low volatile organic solvents therefrom. The oven 105 can be adjusted to approximately 135 ° C (275 ° F) and the oven 107 to approximately 149 ° C (300 ° F). Alternatively, the protective coating may be one that does not require thermal polymerization. A conveyor then transports the substrate to the infrared oven 109. The furnace 109 can be adjusted to approximately 927 ° C (1700 ° F) so that complete polymerization of the coating 37 can be achieved. The complete polymerization is achieved for example at about 149 ° C (300 ° F), and occurs on the surface of the coating 37 at a transport speed of approximately 61 meters per minute (approximately 200 feet per minute). Successful polymerization can be achieved at a surface temperature of approximately 104 ° C (220 ° F). The polymerization of the protective coating 37 occurs while the substrate 17 is in the furnace 109. The conveyor portion 111 then transports the substrate 17 having a polymerized coating 37 on it to a cooler-humidifier combination 113. During this time, the product It cools in ambient air. The chiller-humidifier 113 rapidly reduces the temperature of the product to approximately 51 ° C (124 ° F), and rehumidifies the product before stacking. The conveyor portion 115 then transports the substrate to the stacking station 117 where the substrates 17 are lifted by a forklift for transfer to a stack of similar substrates. The substrates 17, which include the layers 23-37 thereon, are now in the form of substantially flat or non-molded door plates, which visually simulate molded plates on one side and thus are aesthetically pleasing. These plates are then secured to the door structures (5, 7, 9) on opposite sides thereof in order to form the hollow core doors 1 according to this invention (with the coated surface of the face plates). outward away from the frame). For example, two substantially identical door plates as described above can be secured to opposite sides of a door structure for the purpose of manufacturing a hollow core, flat plate door that aesthetically simulates a three-dimensional molded or carved door that includes the panels 11 and the planar portions 13. Figures 5 (a), 6 (b) and 5 (c) illustrate three different unflatted, flat plate doors that can be made according to this invention. Each door, while having plates 3, substantially flat and not molded, has simulated on it a door molded or carved three-dimensional, as well as a wood grain pattern. Each of these doors is designed in such a way that each of the printing rollers 69 and 71 can partially repeat once when in contact with the substrate 17. With respect to Figure 5 (b) for example, the substrate 17 is fed past the rollers 69 and 71 in contact relation in the feed direction 121. The first complete rotation of the roller 69 on the substrate applies all the lines 81 on one side of the dotted line 123 which includes the lines 81 of central panel 105, while the second rotation of roller 69 on the substrate (e.g., partial repeat rotation) applies all lines 81 on the other side of line 123 including lines 81 defining panels 102 and 104. In a similar manner, the first complete rotation of the roller 71 on the substrate, applies all the shadows 89 only on one side of the line 123 while the second rotation or repetition rotation Partially of roller 71 on the substrate applies shadows 89 on the other side of line 123. In this way, certain panel and shade patterns applied to the substrate to simulate the molded door are images in the mirror approximately of line 123 for making it possible for the pressure rollers to more efficiently apply the layers 33 and 35. In the preferred embodiments, the rollers 69 and 71 are repeated at least about 1.5 times on each substrate, so that a substantial portion of the image on each of said rolls is transferred to each substrate at least twice. With reference to Figure 5 (b) for example, the lines 81 of the layer 33 delineate a plurality of different simulated panels 11 on the face of the plate. In this embodiment, panel 101 is substantially linearly aligned with, but spaced from, panel 102, while panel 103 is substantially linearly aligned with, but spaced from panel 104. Meanwhile, central panel 105 is not linearly aligned with any of panels 101-104. In view of this orientation, the roller 69 during its first revolution on the plate can deposit the lines 81 forming the panels 101, 103 and 105, and on its second rotation on the plate can deposit the lines 81 forming the panels 102 and 104. Each panel 101-105 includes a line 106 defining the exterior (e.g., part of layer 33) defining the outer boundary / periphery of the simulated panel and an internal line 107 (also part of layer 33) defining the periphery of the substantially planar internal portion of each panel. Between the lines 106 and 107 in each panel, the angled area 15 receiving the shadow layer 35 is simulated. In this way, the peripheral peripheral lines 107, which extend vertically from the panel 101, are linearly aligned with the internal peripheral lines 107. , which extend vertically, of the panel 102, and the internal peripheral lines 107, extending horizontally, of the panel 101 are parallel to the horizontal peripheral lines 107 extending horizontally, of the panel 102. The same is true for the panel 103 in comparison to the panel 104. Similarly, the vertically extending outer peripheral lines 106 of the panel 101 are aligned in a linear fashion with the vertically extending outer peripheral lines 106 of the panel 102, and the internal lines that are laid out. vertically extending panels 101 and 102 are also linearly aligned with each other. The same is again true for panels 103 and 104. In addition, vertically extending shadow portions 109 (of portions 89) in panels 101 and 102 are both (i) located between layer 33, lines 106 and 107. , and (ii) are substantially linearly aligned with one another. This is also the case for the panels 103 and 104. The shadow portions 89 extending horizontally in the panels 101 and 102 are substantially parallel to one another, as are the horizontally extending shadow portions in the panels. panels 103 and 104. The door of Figure 5 (b) further includes flat, simulated portions 13 which are outside the simulated panels 11. The lower planar portion 122 is defined between planar portions 124 and 125, which extend vertically, with the lower flat portion that is located between the lower edge of the door and the simulated panels 103 and 104, to separate these two panels from the lower edge of the door. The upper planar portion 127 is also located between the planar portions 124 and 125, but at the top of the door, to separate the panels 101 and 103 from the upper edge of the door. The flat portions 122 and 127 are substantially parallel to one another, as are the flat portions 124 and 125. The central planar portions 131 and 133 are parallel to each other and sandwich the central panel 105 therebetween. carved, molded, or otherwise formed on the printing rollers 69 and 71 can be obtained as follows. A high quality photograph of a molded door can be taken which includes panels 11 and flat portions 13 to be simulated. This photograph can then be processed so that the lines defining the panels 11 and the flat portions 13 are patterned and formed on the peripheral surface of the roller 69, while the shadow lines are patterned and formed on the peripheral surface of the roller 71 (for example, the raised portions of the pattern on the roller surface receive the ink from the corresponding transfer roller and deposit this ink on the substrate 17, so that the notches or channels in the peripheries of the roller represent the inverse of what is to be printed on the substrate 17). Then, when the rollers 69 and 71 apply their corresponding inks to the door plate substrate, the original photograph of the door to be simulated is reproduced on the observation surface of the door plate substrate 17. Once given the above description, many other features, modifications and improvements will become apparent to the person skilled in the art. Other such features, modifications and improvements are therefore considered as part of this invention, the scope of which will be determined by the following claims.

It is noted that in relation to this, date the best method known by the applicant to carry out the said invention, is that which is clear from the present description of the invention.

Claims (17)

CLAIMS Having described the invention as above, the content of the following claims is claimed as property:

1. A hollow core door, characterized in that it comprises: a door frame or structure including first and second vertical struts that are oriented substantially parallel to each other, a top rail member, and a lower rail member; first and second outer door plates, each of the door plates is substantially flat; the first door plate is fixed to a first side of the door frame and the second door plate is fixed to a second side of the door frame; at least one of the first and second door plates includes the following layers formed thereon: a) a base coat layer of a first color, placed substantially over a complete surface of at least one door plate; b) a wood grain pattern layer that forms a wood grain pattern that is placed substantially on the entire surface of at least one door plate; c) a layer of panel ink placed only on a first portion of the surface of the at least one door plate, for simulation of the recessed panels in at least one door plate; d) a layer of shadow ink placed only on a second portion of the surface of the at least one door plate, wherein the second portion is mainly located on the substrate at sites that do not include the first portion, so that the layer Shade ink is formed where the ink layer of the panel is not present; and e) a protective, substantially transparent, polymerized coating layer.

2. The door according to claim 1, characterized in that each of the first and second door plates has substantially the same layers a) to e) applied to them.

3. The door according to claim 1, characterized in that the panel layer and the shadow layer are discontinuous on the surface of at least one door plate, and wherein each of the panel layer and the shadow layer independently cover less than about 10% of the surface area of the surface of at least one door plate.

4. The door according to claim 3, characterized in that the shadow layer covers at least about twice as much surface area on the surface of at least one door plate as the panel layer.

5. The door according to claim 3, characterized in that the panel layer defines first, second, third and fourth simulated, discrete panel portions on the surface of at least one door plate, and wherein each of the panel portions includes an outer periphery defining the discrete portion of the panel layer and an inner periphery defining the discrete portion of J to panel layer, and wherein a portion of the shadow layer is placed on the surface of at least one plate of door in each of the first, second, third, and fourth panel portions between the outer periphery defining the discrete portion and the inner periphery defining the discrete portion.

6. The door according to claim 5, characterized in that the wood grain pattern layer is discontinuous across the surface of the at least one door plate.

7. The door according to claim 5, characterized in that the panel layer and the shadow layer are each at least partially placed on top of and in contact with, a portion of the wood grain pattern layer.

8. The door according to claim 7, characterized in that the panel layer further defines, first, second, third, fourth, fifth, and sixth substantially planar portions, simulated, the first substantially flat portion is a lower flat portion, the second portion substantially planar is an upper planar portion, the third and fourth substantially planar portions extend vertically and are spaced from one another and parallel to each other, and the fifth and sixth substantially planar portions are located proximate a central area of at least a door plate; wherein the lower planar portion is positioned directly between and adjacent a lower edge of the door and the second and fourth panel portions, and the upper planar portion is positioned between and adjacent an upper edge of the door and the first and third panel portions; and wherein the third substantially planar portion is positioned between and adjacent a first side edge of the door, and the first and second panel portions, and the fourth substantially planar portion is positioned between and adjacent a second side edge of the door. door and the third and fourth panel portions.

9. The door according to claim 8, further characterized in that it comprises a second base coat layer placed between the first base coat layer and the wood grain pattern layer, and wherein the first and second base coat layers are same color.

10. The door according to claim 9, characterized in that the wood grain pattern layer, the panel layer, and the shadow layer are each of a different color, and wherein the color of the base coatings is different from that of the coatings. color of any of the wood grain pattern layer, the panel layer, and the shadow layer.

11. A method for manufacturing a hollow-core flat-plate door that aesthetically simulates a three-dimensional molded or carved door, the method is characterized in that it comprises the steps of: providing a first substantially flat door plate substrate; the application of at least one base coat layer on the first door plate substrate, substantially through a complete surface of the first door plate substrate; at least one base coat layer that is substantially dried; the provision of a first roller having a defined wood grain pattern on a peripheral surface thereof; the application in liquid form of a wood grain pattern layer on the first door plate substrate on at least one base coat layer, by rotating contact of the first door plate substrate with the first roller; the wood grain pattern layer is substantially dried; the provision of a second roller having a pattern that simulates a panel, defined on a peripheral surface thereof; the application of a panel simulation layer including the panel simulation pattern on the first door plate substrate on at least one base coat layer and on the wood grain pattern layer, by means of the rotating contact of the first substrate of door plate with the second roller; the provision of a third roller having a defined shadow pattern on a peripheral surface thereof; the application of a shadow simulation layer including the shadow pattern on the first door plate substrate on at least one base coat layer and the wood grain pattern layer by the rotating contact of the first plate substrate door with the third roller; the application of a protective coating layer, substantially transparent on the first door plate substrate, on the shadow simulation layer, on the wood grain pattern layer, on the panel simulation layer, and on at least a base coat layer; the polymerization of the protective coating layer; the provision of a door frame including first and second vertical posts that are aligned substantially parallel to each other, the door frame or structure further includes an upper rail and a lower rail; the provision of a second door plate substrate; and securing the first door plate substrate to a first side of the door frame and securing the second door plate substrate to a second side of the door frame to form a hollow core door that aesthetically simulates a molded door or carved three-dimensional.

12. The method according to claim 11, further characterized in that it comprises the steps of bringing the first substrate of the door plate into rotatable contact with the second roller through at least 1.5 full revolutions of the second roller, so that a substantial part of the panel pattern applied to the first door plate substrate by the second roller, is repeated on the first door plate substrate and the image in the mirror is copied approximately in a line defining the end of the first full rotation.

13. The method according to claim 12, further characterized by comprising the steps of bringing the first door plate substrate into rotatable contact with the third roller, through at least 1.5 complete revolutions of the third roller, so that a substantial part of the shadow pattern applied to the first door plate substrate by the third roller, is repeated around said line.

14. The method according to claim 11, characterized in that it further comprises the steps of: applying two base coat layers of a first color and passing the first door plate substrate through a first high speed oven after the first Two layers of basecoat have been applied, but before the wood grain pattern layer has been applied.

15. The method according to claim 11, characterized in that each of the first, second and third rollers is a printing roller and is in contact with a corresponding ink transfer roller, and wherein each of the transfer rollers of corresponding ink is at least partially immersed in a reservoir housing ink.

16. The method according to claim 11, characterized in that the indicated steps are carried out in the indicated order.

17. A method for manufacturing a hollow core, flat plate door that aesthetically simulates a three-dimensional molded or carved door, the method is characterized in that it comprises the steps of: providing a first flat or substantially flat door plate substrate; the application of at least one base coat layer on the first door plate substrate substantially through a full surface of the first door plate substrate; the application in liquid form of a wood grain pattern layer on the first door plate substrate, on at least one base coat layer, by rotating the first door plate substrate with the first roller; drying substantially the wood grain pattern layer; the application of a panel simulation layer that includes a panel simulation pattern on the first wood plate substrate, on at least one base coat layer and on the wood grain pattern layer, when put into rotary contact the first door plate substrate with a second roller; the application of a shadow-shading layer, including a shadow pattern on the first wood plate substrate, on at least one base coat layer and on the wood grain pattern layer, by putting the first one in rotary contact wooden door substrate with a third roller; the application of a substantially transparent protective coating layer on the first door plate substrate on the shadow simulation layer, on the wood grain pattern layer, on the panel simulation layer, and on at least one layer of base coating; the provision of a door frame including first and second vertical posts that are aligned substantially parallel to each other, the door frame further includes an upper rail and a lower rail; the provision of a second door plate substrate; and securing the first door plate substrate to a first side of the door frame, and securing the second door plate substrate to a second side of the door frame, to form a hollow core door that simulates aesthetically a three-dimensional door, molded or carved.