DE102012108929A1 - Door-door leaf and manufacturing method thereof - Google Patents

Abstract

The invention relates to a front door leaf (14) having a door leaf frame (40) and the door leaf broad sides (26, 30) forming panels (28, 32) and with an insulation (38) between the panels (28, 32), wherein the door leaf frame (40) of a metal half-shell (42) and a plastic half-shell (44) is formed.

Description

The invention relates to a door leaf for a front door, provided with such a door leaf door, and a manufacturing method for such a door leaf.

The invention is in the field of front doors. Front doors are doors that can be used as the exterior finish of a building.

The invention relates in particular to front doors, which are to be used as the main entrance of residential buildings, in particular single-family homes, multi-family houses, terraced houses, semi-detached houses.

Such front doors must fulfill primarily the two functions burglary protection and thermal insulation.

As materials for entrance doors, there are mainly front doors made of wood, plastic or metal on the market. Although wood and plastic have in comparison to metal materials a lower thermal conductivity, so basically easier heat protection seems achievable, on the other hand, wood and plastic are generally less resistant to metals designed so that based on metal materials doors are usually more robust, too warp less during frequent and prolonged operation and provide a good basis for increased burglary protection. Front doors based on metal materials have a high quality impression and can be produced very precisely with small gaps and can also be operated for a long time. Because of this, the front doors can be made closer tight, and high burglary protection can be achieved.

The invention therefore addresses exclusively metal doors based on metal materials.

The closest prior art is the EP 1 568 842 A2 which explains currently used design principles for such metal front doors.

House doors have a door leaf, also referred to as a door leaf, and a door frame, also referred to as a frame. The door frame may be a e.g. have glazed side part. The door leaf usually has a door leaf frame and a door panel.

In the prior art manufacture of commercially available front doors, it is standard that front door manufacturers have constructed the door leaf frame based on metal profiles and provided locking technology - door hinges, locks, etc. - with door panels typically supplied by door panel manufacturers. The door panel manufacturers had different front door designs in the program that have been developed by designers. The door panels have generally been constructed as sandwich panels, wherein a motif plate to be arranged on the outside carries the motif, wherein there is further an inner panel to be arranged inside and an insulation between the two panels. Depending on the selected motif, such door panels made of sandwich panels are also provided with glazing cut-outs with glazing.

For simpler door models such door panels are fitted in the door leaf frame, the outside of the door leaf frame therefore forms part of the outside door leaf broadside. Although such a door can be relatively easily manufactured, but due to the visible gap between door leaf frame and door panel provides an improvement design. If you want to make the front door in a desired color, both the door leaf frame and the motif plate must be painted in the desired color in this simple design.

Therefore, wing-covering designs are often desired on the market. The above mentioned EP 1 568 842 A2 shows different manufacturing methods for known wing-covering embodiments. In the in the 2 to 4 For this purpose, the insulation and the inner plate of the door panel designed as a sandwich panel is cut out for this purpose, while the motif plate is left substantially as large as the outer door leaf broadside, so that only the motif plate rests on the outside of the door leaf frame.

Such a configuration has, as in the simple construction with inserted into the door leaf frame door panel the disadvantage that the door leaf frame requires special measures against thermal insulation. For this purpose - as well as the door frame (the fixed door frame) is known and customary - an inner and an outer metal profile connected to connecting webs of poor thermal conductivity material, so as to avoid thermal bridges between the interior and exterior environment.

The EP 1 568 842 A2 Therefore proposes a wing-covering design, where the executed as a sandwich panel door panel rests with all its components on the outside of the door leaf frame. This makes it easier to edit the door panel because it is cut to size. In addition, the door leaf frame can be made simpler, since the insulation of the door panel can take over the thermal insulation function of the connecting webs, so that the door leaf frame only needs to be made from a simple metal profile without connecting webs.

Although this construction has been proven in practice and in the production, it is an object of the invention, a door door leaf over this closest prior art according to the EP 1 568 842 A2 still to improve in terms of thermal insulation properties and in terms of easier large-scale industrial manufacturability.

This object is achieved by a front door leaf according to claim 1. Furthermore, the invention relates to a front door provided with such a front door leaf and a method for producing such a door door leaf.

Advantageous embodiments of the invention are the subject of the dependent claims. The invention provides a front door leaf with a door leaf frame and the door leaf broad sides forming panels and with insulation between the panels, wherein the door leaf frame is formed of a metal half-shell and a plastic half-shell.

It is preferred that the door leaf frame is composed of frame spars, wherein the frame spars each consist of two frame spar half-shells, of which a first frame spar half shell is designed as a metal profile and a second frame spar half shell as a plastic profile.

It is preferably provided that the frame spar half-shells are connected to each other over their entire longitudinal extension by a plurality of tongue and groove connections, in which a tongue formation on one half shell positively engages a groove formation on the other frame spar half shell.

According to a preferred embodiment, it is provided that the two half-shells are formed from hollow profiles.

It is preferred that the hollow profiles are tube profiles.

It is particularly preferred that the hollow profiles of the plastic half-shell are formed substantially U-shaped profile with two U-legs and a U-leg connecting the U-legs, wherein between the U-legs and / or between each U-leg and the U -Steg stiffening webs are formed.

Preferably, it is provided that a first of the panels on the metal half-shell overlaps these to a large extent overlapping and the second panel rests on the plastic half-shell covering them to a large extent.

In an advantageous embodiment, it is provided that the second panel is glued directly to the plastic half-shell.

It is preferred that the panels rest over the full area on the broadside end face of the associated half-shells, wherein an end edge of the panel is substantially flush with an outer edge bounding the end face.

It is preferably provided that the insulation is formed by foaming the door leaf cavity formed between the door leaf frame and the panels applied on these.

According to a preferred embodiment, it is provided that each of the two half shells has at least one engaging in the door leaf cavity hook formation, which is encompassed by embracing around the insulation.

It is particularly preferred that the metal half-shell is thicker in the thickness direction of the door leaf than the plastic half-shell.

Preferably, at least one of the panels, in particular the outer broad side forming panel, is formed of metal. In particular, the panels are formed from sheet metal.

Preferably, the panel to be arranged outside is designed as a wing-covering aluminum sheet.

In the following some advantages of the invention or its advantageous embodiments are explained in more detail.

Due to the structure of the door leaf frame of two half-shells, wherein a half shell made of metal and the other half shell is formed of plastic materials, on the one hand can form a high-quality rigid door leaf frame, which provides a basis for good burglary protection, in particular due to the metal half shell provides a high quality impression and on the other due to the plastic half shell without connecting webs made of non-metal materials. It only need two sub-elements per frame spar manufactured and joined together. Due to the composite results in a high rigidity and high thermal insulation.

Preferably, the door leaf frame extends substantially the entire thickness of the door leaf so that the entire thickness of the door leaf is used to provide a stiff door leaf frame can be. Opposite in the EP 1 568 842 A2 This results in a higher rigidity, which achieves improvements in the sealing effects - improved defined gaps all around the door leaf - in terms of burglary protection - improved rigidity and higher resistance class.

Although it is basically conceivable that a metal half-shell frame and a plastic half-shell frame are manufactured separately and then the two frames are assembled, it is preferred to first produce frame spars, which consist of two frame half-shells. The door leaf frame itself is then preferably made such that four frame spars of the appropriate length are cut off and then joined together. The connection at the corners preferably takes place via corner connectors engaging on the metal half-shells. Due to the attachment of the corner connector to the metal elements of the door leaf frame, a firm and rigid connection can be achieved. Optionally, the second frame spar half shells with corner brackets can also be reinforced. Preferably, plastic corner brackets are used for this purpose.

The joining of the two frame half shells is preferably carried out - as is already known in principle for compounds of metal profiles with plastic connecting webs - via tongue and groove joints. Preferably, at least two mutually spaced groove-spring connections are provided between the half-shells, which extend along the length of the frame members. The tongue and groove connections are preferably provided near the end boundary walls of the half-shells.

A particularly high stiffening results when both half-shells are each formed from hollow profiles, in particular tubular profiles.

To form the tubular profiles of the plastic half-shells, a half-shell main body is preferably provided, which is substantially U-shaped and can be formed with a thicker wall thickness, wherein between U-legs with each other or between U-legs and a U-legs connecting web can run stiffening webs, which may have a thinner wall thickness. At least one of the stiffening webs may additionally have a stiffening tube profile.

As a result, several chambers can be formed within the plastic hollow profile, which is particularly useful for stiffening and heat insulation. Particularly preferably, these chambers can be foamed with an intumescent insulation material.

According to a particularly preferred embodiment, not only is the outer panel forming the outside of the front door panel outside on the door leaf frame. Rather, a provided on the inside panel is designed as a cover panel so that it covers at least a majority of the door leaf frame on the inside of the front door leaf. The front door leaf has on the one hand on the inside a visually appealing design; a step on the inside due to the door leaf frame is eliminated. On the other hand, especially if the panel is made of sheet metal, e.g. Light metal sheet is formed - due to the support of the inner panel to achieve additional reinforcement. Due to the outside and inside support of the two panels, a large cavity is created in the interior of the door leaf, which can be used for insulation purposes.

Preferably, remaining cavities of the door leaf frame are filled with foam.

Preferably, remaining cavities between the door leaf frame and other inserts within the door leaf frame are filled with foam. Particularly preferably, the half-shells are filled with foam.

This results in a particularly high thermal insulation and greater stiffening due to the foaming.

Preferably, the metal half-shell carries functional elements of the door, in particular door hinges or a multi-point lock. It is further preferred that the metal half-shell is made thicker than the plastic half-shell. As a result, a larger area of the door leaf thickness is used for the stiffer metal material and it can create more space for the functional elements and their attachment. Further preferably, the plastic half-shell is associated with an outer side of the door leaf, wherein a panel forming the outer side of the door leaf rests on the plastic half-shell. Between the outside and the metal half-shell with the functional elements is thus the plastic half-shell. This improves the insulation effect, the functionality and the burglary protection. Preferably, the panels lie on the entire surface on the broad side surfaces of the half-shells. By taking advantage of the entire surface of the half-shells as a support surface for the panels results in an attractive design, a good mounting option and high rigidity.

Preferably, the attachment between panels and door leaf frame in a material-locking manner, preferably by gluing.

Preferably, the broad-side bearing surfaces of the half-shells, on which rest the panels, provided with at least one extending in the longitudinal direction of the frame members, groove-shaped depression. More generally, the bearing surfaces are not completely flat, but formed with depressions. By forming such depressions, the bondability and the maintenance of the panels on the half-shells can be improved.

If at least one of the two half-shells, preferably both half-shells, is provided at the door leaf cavity facing areas with an engaging in the door leaf cavity hook training, then can be achieved when foaming the hook training a particularly strong bond between foaming and door leaf frame.

Embodiments of the invention will be explained in more detail with reference to the accompanying drawings. Show:

1 an interior view of an inner broad side of a front door according to an embodiment of the invention;

2 an exterior view on an outside of the front door of 1 ;

3 a section through the front door according to the line III-III of 1 ;

4 a section through the front door according to the line IV-IV of 1 ; and

5 an enlarged detail of the lock area from the representation of 3 ,

In 1 is an interior view on a front door 10 with a door frame 12 and a door leaf 14 shown. The door leaf 14 is by means of door hinges 16 on the door frame 12 pivoted to the inside. On the in 1 inside is a door handle 18 and a rosette 20 provided for the inner end of a lock cylinder of a door lock.

2 shows the exterior view on the front door 10 from 1 , As can be seen, the door frame covers 12 on the outside the outer edges of the door leaf 14 , On the outside is still a front door handle 22 and only a rosette 24 but no door handle 18 intended.

In the 1 illustrated inner broadside 26 inside the door frame 12 when the front door is closed 10 remains visible, is completely through an inner panel 28 educated. In the 2 illustrated outer broadside 30 of the door leaf 14 as far as they are within the doorframe 12 is visible, completely through an outer panel 32 educated. The outer panel 32 is as a motif plate 34 trained and has depending on the choice of motif different jewelry elements 36 and designs on. Here is a great variety of different motives with different conceivable.

In the 3 to 5 are different cuts through the front door 10 shown, in 3 a horizontal section along the line III-III of 1 , in 4 a vertical section along the line IV-IV of 1 and in 5 an enlarged detail of the lock area from the representation of 3 is shown.

Like from the 3 to 5 can be seen, the door leaf 14 a door leaf frame 40 and the door leaf broadsides 26 . 30 forming panels 28 . 32 and an insulation 38 between the panels 28 . 32 on. The door leaf frame 40 is made of a metal half shell 42 and a plastic half shell 44 educated.

The door leaf frame 40 is from an upper horizontal frame spar 46 , a lower horizontal frame spar 48 , a lock-side vertical frame spar 50 and a band-side vertical frame spar 52 built up.

Each of the frame spars 46 . 48 . 50 . 52 consists of two frame half-shells, with a first frame spar half shell 54 from a metal profile 56 and a second frame spar half shell 58 from a plastic profile 60 is formed.

The metal profile 56 is, for example, a hollow profile in the form of a tubular profile 62 made of metal, in particular light metal, such as aluminum alloys or the like.

The plastic profile 60 is made of a suitable plastic, such as polyamide, aramid or fiber-reinforced plastic materials (CFK, GRP) or the like. Preferably, the plastic profile 60 a hollow profile in the form of a tubular profile 64 ,

The plastic profile 60 the plastic half shell 44 is preferably substantially U-shaped with two U-legs 66 . 68 and one the U-thighs 66 . 68 connecting subway 70 educated.

Between the U-thighs 66 . 68 is a transverse stiffening bridge 72 intended. Between each of the U-thighs 66 . 68 and the U-web is in the corner areas each a diagonal diagonal stiffening web 74 intended.

The transverse reinforcement bar 72 has a rectangular profile 76 with stiffening ribs 78 on.

The frame spar half shells 54 . 58 point to that of the door leaf frame 40 enclosed interior facing inside 80 in the door leaf cavity 82 that between the panels 28 . 32 and the door leaf frame 40 is formed, projecting hook formations 84 on.

How best 5 can be seen, has the plastic profile 60 at the door leaf cavity 82 facing inside 80 in the region of the transition between the inner U-leg 68 and the subway 70 an inward projection 86 on. For this purpose, for example, the part of the inner U-leg 68 trained inner wall 88 the frame spar on the plastic profile 60 a wall portion extending in the thickness direction 90 and an obliquely in the interior and outwardly extending wall area 92 on. The underground bridge 70 is correspondingly inclined in the area of the projection 86 over the wall area extending in the thickness direction 90 led out inward and goes in the area of the projection 86 in one piece in the sloping wall area 92 above.

By training the projection 86 becomes the outward facing surface 94 the plastic profile 60 to the middle of the broadsides 26 . 30 enlarged. This outward-facing surface 94 serves as a support surface 96 for the outer panel 32 , The bearing surface 96 is with several wells 98 Mistake. For example, the wells 98 groove-like or bead-like along the longitudinal extent of the plastic profile 60 intended. For example, three or more parallel gutter grooves are spaced apart side by side.

At the projection 86 picks up the hook training 84 in one piece. The hook training 84 points one from the top of the projection 86 that the edge between inner wall 88 and bearing surface 96 forms obliquely inwardly extending oblique area 100 on, at which a in the thickness direction inwardly projecting area 102 followed. At the free end of the in the thickness direction inwardly projecting area 102 is a projecting Endflanschbereich back to the U-shaped main body of the plastic hollow profile 104 intended.

Between the two frame half shells 54 are at least two positively engaging behind interlocking tongue and groove joints 106 intended. For example, the tongue and groove connections 106 formed with dovetail-like rear handles.

For example, the plastic profile has 60 at ends in the thickness direction of the door panel 14 extending wall areas thickening 108 formed in C-shaped groove margins 110 on the metal profile 56 interlock positively secured against withdrawal.

In the examples shown, the thickenings 108 at the free end edges of the two U-legs 66 . 68 intended.

To make a flush transition between the frame spar half shells 54 . 58 To achieve on both end faces, these are the end portions of the U-legs 66 . 68 formed in the profile interior in a recessed cranked, as shown in the drawings.

The following is based on the representation in the 3 to 5 the structure of the metal half shell 42 or the first frame half shell 54 forming metal profile 56 explained in more detail. The metal profile 56 is a tube profile 62 which is substantially rectangular with two parallel to the broad sides extending profile walls 112 . 114 and two substantially in the thickness direction extending profile walls 116 . 118 is trained. The very on the inside of the door leaf 14 arranged, extending in the thickness direction outer profile wall 116 is wider than the inside of the door leaf frame 40 at the transition to the plastic profile 60 extending, parallel to the broad side direction extending inner profile wall 114 , This outer profile wall 112 stands on the lock side, vertical frame spar 50 , at the upper horizontal frame spar 46 and on the band-side vertical frame spar 52 over a front side 120 of the door leaf frame 40 and forms a stop fold 122 of the door leaf 14 , Inwardly, this is parallel to the broad side direction extending outer profile wall 112 over the inner wall 88 of the door leaf frame 40 before, so that at the edge area between the inner wall 88 and a support surface 124 forming, outwardly facing surface 126 a lead 128 comparable to the lead 86 the plastic profile 60 is trained. At this projection 128 closes in one piece the hook training 84 analogous to the plastic profile 60 formed with a sloping area 100 , in the thickness direction inwardly projecting area 102 and end flange area 104 at. The extending in the thickness direction inner profile wall 118 forms together with the inner U-thigh 68 the inner wall 88 of the door leaf frame 40 , This inner extending in the thickness direction profile wall 118 similar to the inner U-leg 68 a wall portion extending in the thickness direction 130 and a sloping wall area 132 for forming the approximately triangular projection 128 on.

The parallel to the broadside direction extending inner profile wall 114 is formed in the embodiment shown here is substantially flat and plate-shaped, wherein at the two edge regions near the front side 120 of the door leaf frame 40 on the one hand and near the inner wall 88 of the door leaf frame 40 on the other hand, the C-shaped Nutberandungen 110 by two mutually directed hook-shaped projections 134 are formed.

The extending in the thickness direction outer profile wall 116 has a C-shaped, substantially rectangular recess - eg formed as a C-shaped profile recess 136 - For forming a receiving groove for a seal or the like.

As 4 shows is in the embodiment shown here, the lower horizontal frame spar 48 the same profile as the other frame beams 46 . 50 . 52 educated. Accordingly, also the lower horizontal frame spar 48 with the stop fold 122 Mistake. In this lower horizontal frame spar 48 is in the recess of the C-shaped profile recess 136 in the thickness direction outer profile wall 116 is formed, a seal 138 for sealing the lower door gap 140 intended.

The entire outward-facing surface 126 the parallel to the broadside direction extending outer profile wall 112 is as a support surface 124 for the inner panel 28 educated. The inner panel 28 lies flügeldeckend over its entire surface on this outward-facing surface 126 the parallel to the broadside direction extending outer profile wall 112 on. In the illustrated embodiment, only a few depressions 142 provided in the support surface, which depressions 142 to improve a cohesive connection between the panel 28 and metal profile 56 serve. The wells 142 are formed, for example, as extending along the metal profile channels or grooves.

The metal half shell 42 has in the thickness direction of the door leaf 14 a larger extension than the plastic half shell 44 , For example, the first frame spar half shell extends 54 over 55% to 80% of the thickness of the door leaf frame 40 and the remainder of respectively 65% to 20% is from the second frame spar half shell 58 ingested.

The following is the structure of the door leaf 14 in the thickness direction in the area of the door leaf frame 40 an embodiment described in more detail. Starting from the in 2 shown outside in the thickness direction towards the in 1 The interior of the door leaf begins to build 14 with an outer panel 150 , which is formed for example of aluminum or other light metal (in particular aluminum alloy), then follows an outer profile 152 from a plastic material, for example the plastic profile 60 , eg formed as a polyamide profile (thermally insulated). Then follows a metal profile 56 , For example, formed of a light metal, in particular aluminum profile. Finally, an inner sheet follows 154 , eg formed of light metal, eg aluminum alloy.

outer panel 150 and inner sheet 154 are examples of the design of the panels 28 . 32 , The panels 28 . 32 lie directly on the door leaf frame 40 on, so that is between the panels 28 . 32 and the door leaf frame 40 if necessary, an adhesive is located.

Such a construction of the door leaf 14 is of quality standard comparable to the door leaf construction as used in the EP 1 568 842 A2 is placed under protection, however, not only the outside, but also an attractive interior design is achieved by a wing-covering design and in addition, the production in industrial mass production is less expensive than that in the EP 1 568 842 A2 shown solution with external sandwich plate.

An advantage of this new design is that the outer profile no longer has to contain a metal-non-metal composite profile onto which an aluminum sheet must additionally be applied. Rather, the design is simplified and the thermal insulation significantly improved.

The following is based on the representation in the 3 to 5 an exemplary construction of the entire front door 10 explained in detail.

As in the 3 . 4 and 5 shown, the door frame points 12 Door frame spars 160 on, each consisting of a three-part frame composite profile 162 are constructed. The three-part frame composite profile 162 has a metal outer shell 164 For example, made of aluminum, other light metal or alloys, a metal inner shell 166 , For example, made of aluminum, other light metal or alloys, and as a third sub-element plastic insulating bars 168 - For example, polyamide insulating bars - for thermal separation.

The metal inner shell 166 is with one in the direction of the door leaf 14 projecting Anschlagfalz 170 provided, against which the edge region of the outer panel 32 in the closed state of the front door 10 strikes. On the stop side, the frame-side Anschlagfalz 170 a C-profile shaped receiving groove in which an outer stop seal 172 attacks.

For example, the door frame 12 a lock-side vertical door frame spar 160a , an upper horizontal door frame spar 160b and a door hinge side vertical door frame spar 160c on. All three door frame spars 160a . 160b . 160c are from identical frame composite profiles 162 with the stop fold 170 educated. Accordingly, the outer stopper seal 172 provided on three sides circumferentially. The outer stop seal 172 is formed of EPDM, for example.

The door leaf side stop fold 122 is in the embodiment shown here on all four door leaf frame spars 46 . 48 . 50 . 52 intended. Analogous to the frame-side stop fold 170 also has the door leaf-side Anschlagfalz 122 a C-shaped sealing groove in which an inner

stop seal 174 is housed. The inner stop seal 174 is for example provided on all four sides. The inner stop seal 174 is formed of EPDM, for example.

The frame spars 46 . 48 . 50 . 52 of the door leaf frame 40 have a circumferential, two-piece wing composite profile 176 with an outer shell 178 as the first partial element and an inner shell 180 as a second subelement.

For example, the outer shell 178 through the plastic half shell 44 and the inner shell 188 through the metal half shell 42 educated. The plastic half shell 44 is preferably a polyamide shell. The inner shell is preferably an aluminum inner shell. Preferably, the inner shell 180 formed with a "Euro-groove" (standardized groove) for receiving locks with multiple locking. Such a castle 182 is particular in 5 indicated, with the lock 182 one through the door handle 18 operated catch 184 and a multiple lock (not shown).

In a particularly preferred embodiment, the door leaf 14 for forming the outer panel 32 the outer panel 150 , For example in the form of an outer light metal cover plate. The outer panel 150 in particular has a thickness of greater than about 0.8 mm, preferably between 1.0 mm and 3.0 mm and in particular about 1.5 mm. The outer panel 150 is preferably powder-coated, with edge regions and outer edges are provided with a Randbepulverung. The outer panel 150 forms the motif plate 34 and thus can be provided with a large number of different motifs.

In a particularly preferred embodiment, the door leaf 14 to form the inner panel 28 the inner sheet 154 on, for example, as an inner light metal cover plate, preferably made of aluminum materials, such as alloys or the like. The inner panel preferably has a thickness or sheet thickness of greater than about 0.8 mm, in particular between 1.0 mm and 3.0 mm, and preferably a thickness of about 1.5 mm. In a particularly preferred embodiment, the inner panel 154 powder coated. For this purpose, edge regions and marginal edges are preferably also provided with edge powdering. The cover plates - outer panel 150 and inner sheet 154 - Are in a particularly preferred embodiment with the door leaf frame 40 bonded. For this purpose, preferably a circumferential, permanently elastic cover plate bonding 190 intended. The cover plate bonding 190 is formed for example by means of a 1-component MS polymer adhesive. In addition, to facilitate the manufacturing process a cover plate fixing - "Position Tack" - be provided by means of short strips. This cover plate fixing is carried out, for example, by means of a 2-component PUR adhesive.

The door leaf cavity 82 is in particular between the door leaf frame 40 and the panels 28 . 32 with a foam filling 192 Mistake. This foam filling 192 serves as insulation 38 , Preferably, the foam filling 192 filled in as PUR foam filling. The door leaf 14 is preferably foamed in the factory; This is in contrast to conventional door-to-door manufacturing where the insulation 38 is provided by attaching a sandwich plate. The castle 182 is preferably an automatic lock or engine lock. The backset can be for example 40 mm. Preferably, a rectangular stainless steel forend is provided for termination and for forming a visually appealing, lock-side end face. As an abutment for the castle 182 is on the doorframe 12 preferably an electric door opener 185 , For example, with stainless steel strike plate, provided.

The in the illustrated embodiment, the front door 10 illustrated door hinges 16 can eg screw-on hinges 200 as they are available on the market from door hinge suppliers. Alternatively, concealed hinges (not shown) may be used, as described more fully in US Pat DE 10 2009 004 210 B3 described and shown.

The following is based on the illustration in 4 the formation of the threshold of the front door 10 explained in more detail. In the threshold area in the ground is preferably a one-piece plastic threshold 202 , in particular of polyamide, provided. At the vertical door frame spars 160a . 160c is in the threshold range, as in 3 on the hinge side door frame spar 160c indicated by dashed lines, a plastic threshold recording 204 , For example of polyamide, eg with brush seal and with stop contour for the wing-side seal 138 , intended. The seal 138 on the door leaf 14 extends like this in 4 is shown along the entire lower door gap 140 and is still laterally by a certain distance, for example between 50 mm and 100 mm, preferably about 80 mm, along the vertical frame spars 50 . 52 led upwards to an extension 208 the base gasket 206 to build. The side-raised areas of the seal 138 hit against the plastic threshold mount 204 at. This plastic threshold holder 204 is along the vertical door frame spars 160a . 160c in the appropriate amount led upwards. The seal 138 is preferably designed as EPDM molded part. This seal 138 serves as a stop against the threshold 202 and the threshold recording 204 as protection against backwater. Thus, the seal points 138 a base gasket 206 along the lower door gap 140 as well as lateral extensions 208 the base gasket 206 on the lower wing corners, for example formed as molded parts, more particularly as EPDM molded parts, for protection against backwater. The threshold 202 can be with several screws 210 to a variably positionable system profile 212 screw on as a ground recess. For this purpose, the ground sill 202 a screw channel 214 on, in which the screw heads of the screws 210 be recorded. In this screw channel 214 is a threshold seal 216 intended for cover. The variably positionable system profile 212 has, for example, Keder shots for common sealing foil connections. The system profile is with mounting brackets, eg steel brackets (not shown), with the door frame 12 screwed.

Optionally, to strengthen the system profile 212 a reinforcing metal profile 218 For example, a steel square tube (eg 30 × 30 × 1.5 mm) may be provided.

In the following, the production of the front door shown in the figures 10 described in more detail.

First, the production of the door frame 12 explained in more detail.

The frame composite profiles 162 are connected in the door manufacturing plant on their own plants and powder-coated. As a thermal separation between the metal outer shell 164 and the metal inner shell 166 serve the plastic insulating bars. These are for example 34 mm long and 2 mm thick and consist for example of polyamide. All material specifications and dimensions given here are sample values that can be modified at will by appropriate other materials or dimensions.

The plastic insulating bars 168 be in appropriate shots of the metal outer shell 164 and the metal inner shell 166 rolled.

The finished frame composite profiles produced in this way 162 to make the door frame spars 160 are mitred. The connection between the door frame spars 160a . 160b . 160c takes place by means of corner angles (not shown), for example by means of light metal corner angles. In this case, corner angles engage both between the outer shells 164 as well as between the inner shells 166 one. Preferably, the corner angles are pressed and glued.

The following is the production of the front door leaf, ie the door leaf 14 , explained in more detail. The door leaf frame 40 consists of a circumferential two-part composite profile with a metal half shell 42 as inner shell 180 and a plastic half shell 44 as an outer shell 178 , Preferably, an aluminum inner shell 180 intended. The term "aluminum" is here as an example representative of all suitable metals, in particular light metals. Further preferably, a polyamide outer shell 178 intended. The term "polyamide" is used here throughout the documents as an example of all suitable plastics and materials based on plastic materials.

The connection of the two frame rail shells 54 . 58 takes place analogously to the frame connection. Also the wing composite profiles 176 are cut mitred, finished and connected on a 4-corner jointing machine. The connection takes place by means of corner angles, for example of metal, more particularly of aluminum-based materials, in the region of the metal half-shell 42 , The corner angles (not shown) are pressed mechanically - fixation - and additionally bonded with an adhesive, in particular 2-component PUR adhesive. After curing, the final stability results. Optionally, the plastic half shell 44 reinforced with additional corner angles, preferably plastic corner angles. The so fixed door leaf frame 40 can be further processed immediately and prepared for the foaming process.

In a next step, the merging and bonding of the door leaf frame takes place 40 with the previously cut, milled and powder-coated (including edge powder) cover plates - panels 28 . 32 ,

Preferably, the outer panel is located 32 initially below, the adhesives are machine-controlled, for example, CNC-controlled, applied. For this purpose, the adhesive beads with the wells 98 . 142 forming, circumferential grooves on both bearing surfaces 96 . 194 (eg three grooves on the outside and three grooves on the inside) synchronized.

For permanent elastic bonding, a 1-component MS polymer adhesive is further applied.

The foaming process becomes the panels 28 . 32 fixed on each side. For this purpose, on each side, at least two strips of 2-component polyurethane-based adhesive are placed in the middle of the outer edges of the vertical door leaf frame - frame spars 50 . 52 - applied. Preferably, the strips are a few decimeters long, for example about 200 mm long.

On this construction is also prepared with adhesive inner panel 154 to form the inner panel 28 hung up. The result is a mold, which is now filled with foam. The foaming process is explained in more detail below.

The thus prepared door leaf blanks are transported horizontally to a heated multi-daylight press. The molds are brought in the press to the specified size and held.

The PUR foam is introduced via a CNC-controlled mixing head through a previously in the lower area (depending on the motif) of the door leaf frame 40 prepared injection port (not shown). The injection port is closed automatically after retraction of an injection lance. This happens, for example, by means of two overlapping polystyrene sheets on the side facing the foam side of the sash.

The now expanding foam fills the entire interior of the door leaf 14 out. Venting is realized by way of motif-related bores. The holes are covered on the inside with air-permeable fleece pads, which do not allow the foam to pass.

After foam expansion, the door leaf remains in the press for a certain period of time to cure. The duration is for example about 30 minutes. The final curing takes place over the following days, for example within two days.

The next steps are fitting fittings. Preferably, a fastening of the front door handle 22 in the area of foam filling by means of adhesive dowels made of light metal die casting (die-cast aluminum). For this purpose, in the outer panel 150 Provided openings, which are closed for the foaming process with an adhesive film. After demolding, the holes are reopened and extended into the foam core. Adhesive is injected into the cylindrical holes and the adhesive plug is inserted. The adhesive bucket has a movable threaded insert for tolerance compensation when mounting the handle.

The attachment of the overlying hinged door hinges 200 takes place by means of screw anchors (not shown) in the inner shell. Other than this in 3 is shown, in a particularly preferred further embodiment, the attachment not only to the parallel to the broadside direction extending outer profile wall, but also by extending parallel to the broadside direction inner profile wall 114 therethrough.

LIST OF REFERENCE NUMBERS

10

 front door

12

 doorframe

14

 door leaf

16

 door hinges

18

 door handles

20

 rosette

22

 Door handle

24

 rosette

26

 inside broadside

28

 inner panel

30

 outer broadside

32

 outer panel

34

 motive plate

36

 decorative element

38

 insulation

40

 Door Frame

42

 Metal half-shell

44

 Plastic half shell

46

 Upper horizontal frame spar

48

 lower horizontal frame spar

50

 lock-side vertical frame spar

52

 hinge-side vertical frame spar

54

 first frame half shell

56

 metal profile

58

 second frame spar half shell

60

 Plastic profile

62

 Pipe profile (metal)

64

 Pipe profile (plastic)

66

 outer U-thigh

68

 inner U-thigh

70

 U-web

72

 Cross bracing web

74

 Diagonal bracing web

76

 rectangular profile

78

 stiffening rib

80

 inside

82

 Door leaf cavity

84

 hook formation

86

 head Start

88

 inner wall

90

 extending in the thickness direction wall area

92

 sloping wall area

94

 outward surface

96

 bearing surface

98

 wells

100

 sloping area of hook training

102

 in the thickness direction inwardly projecting area

104

 end flange portion

106

 Tongue and groove

108

 thickening

110

 C-shaped groove border

112

 parallel to the broadside direction extending outer profile wall

114

 extending parallel to the broadside direction inner profile wall

116

 extending in the thickness direction outer profile wall

118

 extending in the thickness direction inner profile wall

120

 Front side of the door leaf frame

122

 Anschlagfalz

124

 bearing surface

126

 outward surface

128

 head Start

130

 extending in the thickness direction wall area

132

 sloping wall area

134

 hook-shaped projections

136

 C-shaped profile recess

138

 Gasket for lower door gap

140

 lower door gap

142

 deepening

150

 outer panel

152

 outer profile

154

 inner panel

160

 Door frame spars

160a

 lock-side vertical door frame spar

160b

 Upper horizontal door frame spar

160c

 hinge-side door frame spar

162

 Frame composite profile

164

 Metal outer shell

166

 Metal inner shell

168

 Plastic thermal

170

 Anschlagfalz

172

 outer stop seal

174

 inner stop seal

176

 two-piece wing composite profile

178

 outer shell

180

 inner shell

182

 lock

184

 Catches

185

 Electric strike

190

 Deckblechverklebung

192

 Foam filling

200

 Screw-on hinges

202

 Plastic speed bump

204

 Plastic threshold recording

206

 socket seal

208

 lateral extension of the base gasket

210

 screw

212

 system profile

214

 screw

216

 threshold seal

218

 Reinforcing metal profile

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 1568842 A2 [0007, 0011, 0013, 0014, 0032, 0080, 0080]
• DE 102009004210 B3 [0093]

Claims (15)

Front door leaf ( 14 ) with a door leaf frame ( 40 ) and the door leaf broadsides ( 26 . 30 ) forming panels ( 28 . 32 ) and with insulation ( 38 ) between the panels ( 28 . 32 ), whereby the door leaf frame ( 40 ) from a metal half shell ( 42 ) and a plastic half-shell ( 44 ) is formed. Front door leaf ( 14 ) according to claim 1, characterized in that the door leaf frame ( 40 ) from frame beams ( 46 . 48 . 50 . 52 ), the frame beams ( 46 . 48 . 50 . 52 ) each consist of two frame spar half-shells ( 54 . 58 ), of which a first frame spar half shell ( 54 ) as metal profile ( 56 ) and a second frame spar half shell ( 58 ) as plastic profile ( 60 ) is trained. Front door leaf ( 14 ) according to claim 2, characterized in that the frame spar half shells ( 54 . 58 ) over its entire longitudinal extent by a plurality of tongue and groove joints ( 106 ), in which a spring training on the one half shell ( 54 ) form-fitting a groove formation on the other frame spar half-shell ( 58 ), are connected with each other. Front door leaf ( 14 ) according to one of the preceding claims, characterized in that the two half shells ( 54 . 58 ) are formed from hollow profiles. Front door leaf ( 14 ) according to claim 4, characterized in that the hollow profiles pipe profiles ( 62 . 64 ) are. Front door leaf ( 14 ) according to one of claims 4 or 5, characterized in that the hollow profiles of the plastic half shell ( 44 ) substantially U-shaped profile with two U-legs ( 66 . 68 ) and one the U-thighs ( 66 . 68 ) connecting U-web ( 70 ) are formed, wherein between the U-legs ( 66 . 68 ) and / or between each U-leg ( 66 . 68 ) and the underground bridge ( 70 ) Stiffening webs ( 72 . 74 ) are formed. Front door leaf ( 14 ) according to one of the preceding claims, characterized in that a first of the panels ( 28 ) on the metal half shell ( 42 ) overlaps them to a large extent and the second panel ( 32 ) on the plastic half-shell ( 44 ) this overlaps to a large extent. Front door leaf ( 14 ) according to claim 7, characterized in that the second panel ( 32 ) directly with the plastic half-shell ( 44 ) is glued. Front door leaf ( 14 ) according to claim 7 or claim 8, characterized in that the panels ( 28 . 32 ) over the entire surface on the broadside end face of the associated half shells ( 42 . 44 ), wherein an end edge of the panel ( 28 . 32 ) terminates substantially flush with an outer edge bounding the end surface. Front door leaf ( 14 ) according to one of the preceding claims, characterized in that the insulation ( 38 ) by foaming the between the door leaf frame ( 40 ) and the panels applied thereto ( 28 . 32 ) formed door leaf cavity ( 82 ) is formed. Front door leaf ( 14 ) according to claim 10, characterized in that each of the two half shells ( 42 . 44 ) at least one in the door leaf cavity ( 82 ) engaging hook training ( 84 ) through the insulation ( 38 ) is surrounded by foam. Front door leaf ( 14 ) according to one of the preceding claims, characterized in that the metal half-shell ( 42 ) in the thickness direction of the door leaf ( 14 ) thicker than the plastic half shell ( 44 ) is trained. Front door ( 10 ) with a front door door leaf ( 14 ) according to any one of the preceding claims. Method for producing a front door panel ( 14 ), in particular according to one of claims 1 to 12, with the steps: construction of a door leaf frame ( 40 ) of composite profiles consisting of a first half-shell ( 42 ) made of metal and a second half-shell ( 44 ) are made of plastic, and firm surface bonding of plate elements with the door leaf frame ( 40 ), so the broadsides ( 26 . 30 ) of the door leaf ( 14 ) to build. Method according to claim 14, characterized by the additional step of foaming one between the door leaf frame ( 40 ) and the panel elements formed door leaf cavity ( 82 ) so as to provide insulation ( 38 ) between the plate elements.

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