DE102015100358A1 - Method for producing a door element made of wood-based material and thus producible door element - Google Patents

Abstract

To provide a door element with a high surface quality and a particularly high-quality visual impression, the invention provides a method for producing a door element (10) based on wood-based materials for a building door, comprising molding a radiused edge (66) of the door element (10), characterized by the following steps: a) provision of a door element raw body with an outer layer of HPL applied to a base material (36), b) material removal of the base material (36) under the HPL layer (24) so that the HPL layer (24) protruding beyond the base material (36), wherein also material of the HPL layer (24) on the bottom material (36) facing bottom (52) of the HPL layer (24) is removed, c) introducing a flowable curable material (64) at the bottom (52) of the HPL layer (24); d) reshaping the HPL layer (24) by folding the HPL layer (24) around the backing material (36) r forming the radius on the outside of the HPL layer (24) and e) curing the curable material (64).

Description

The invention relates to a method for producing a door element based on wood-based materials for a building door, comprising molding a radiused edge of the door element. By the method are door elements of building doors, e.g. Door leaves or frames of room doors, apartment doors, hotel doors or doors of other buildings to produce. Moreover, the invention relates to a door element obtainable by the method, e.g. a door leaf or a door frame, based on wood-based materials, for a building door.

Such a method is from the DE 20 2010 004 560 U1 known. This document describes a door element in the form of a door leaf, in which at least one edge with a radius of 2.5 mm or less is rounded. For this purpose, a CPL coating is applied to a door leaf base body based on wood-based materials. Subsequently, in the postforming process, the backing material under the CPL coating is removed such that an edge is formed on the backing material with a radius of 2.5 mm or less. Then the CPL material is wrapped around the rounded edge. Placing the CPL material around the edge is difficult. Only small thicknesses can be reshaped accordingly, which is why CPL can only be applied with a small layer thickness. Thicker material can cause warping. Even with thin materials, the forming process is difficult. Therefore, it is proposed in the prior art that a CPL material is used, which is not yet completely condensed out.

The object of the invention is to provide a door element which is provided with at least one with a very small radius of 2.5 mm or rounded edge, which is optically high quality and long optically high quality even in harsh conditions of use.

This object is achieved by a method for producing a door element according to claim 1 and an available door element according to the independent claim.

Advantageous embodiments of the invention are the subject of the dependent claims.

• a) Vorsehen eines Türelementrohkörpers mit einer auf einem Untergrundmaterial aufgebrachten Außenschicht aus HPL,
• b) Materialabtrag des Untergrundmaterials unter der HPL-Schicht, so dass die HPL-Schicht über das Untergrundmaterial hervorsteht, wobei auch Material der HPL-Schicht auf der dem Untergrundmaterial zugewandten Unterseite der HPL-Schicht abgetragen wird,
• c) Einbringen eines fließfähigen aushärtbaren Materials an der Unterseite der HPL-Schicht,
• d) Umformen der HPL-Schicht durch Umlegen der HPL-Schicht um das Untergrundmaterial unter Ausformen des Radius‘ an der Außenseite der HPL-Schicht und
• e) Aushärten des aushärtbaren Materials.

According to a first aspect, the invention provides a method for producing a door element based on wood-based materials for a building door, comprising molding a radius-rounded edge of the door element, comprising the following steps:

• a) providing a door element raw body with an outer layer of HPL applied to a base material,
• b) material removal of the substrate material under the HPL layer, so that the HPL layer protrudes beyond the substrate material, wherein material of the HPL layer is also removed on the underside of the HPL layer facing the substrate material,
• c) introducing a flowable curable material to the underside of the HPL layer,
• d) reshaping the HPL layer by flipping the HPL layer around the backing material, forming the radius on the outside of the HPL layer and
• e) curing the curable material.

It is preferred that step a) comprises:
Providing a Türblattrohkörpers for producing a door leaf.

It is preferred that step a) comprises:
Providing a Zargenstabrohkörpers for producing at least one Zargenstabs a door frame.

It is preferred that step a) comprises:
Producing a door element main body from one or more components, which consist of materials selected from MDF, chipboard, solid wood, wood-based material and coating the door element base body with the HPL outer layer.

It is preferred that step a) comprises:
Producing a door element main body from a frame component, a filling component and at least one cover plate component and coating the outside of the cover plate component with the HPL outer layer.

It is preferred that step a) comprises:
Connecting a door element basic body component to a cover plate component made of thin chip, MDF, HDF, plywood, wood-based materials and / or board materials.

It is preferred that step a) comprises:
Provide the HPL layer in a layer thickness of 0.5 mm to 1.9 mm.

It is preferred that step b) comprises:
Milling a plant recess on a contact area against which the HPL layer is to be applied in step d), and forming a projection complementary to the recess on the inside of the HPL layer to be converted.

It is preferred that step b) comprises:
Milling a forming recess at the bottom of the HPL layer to be converted into the HPL layer into, in relation to the original HPL layer thickness thinner, to be converted to the radius forming area of HPL.

It is preferred that step b) comprises:
Forming an inclined step at the abutment area and a complementary inclined step at the inside of the HPL layer.

It is preferred that step b) comprises:
Milling a fold of a door rebate in a Türblattrohkörper.

It is preferred that step b) comprises:
Forming a concave internal structure for forming and introducing the hardening material.

It is preferred that step c) comprises:
Introduction of a hot melt adhesive.

It is preferred that step c) comprises:
Introducing a thermoplastic.

It is preferred that step c) comprises:
Introduction of a thermoset.

It is preferred that step c) comprises:
Introducing the hardening material into a material recess on a forming area to be reshaped to the radius.

It is preferred that step c) comprises:
Introducing the curing material such that it supports in the finished door element the deformed to the radius forming area.

It is preferred that step d) comprises:
Forming the HPL layer with molded shoes.

It is preferred that step d) comprises:
Forming with movement of form shoes.

It is preferred that step d) comprises:
Supply of heat for forming.

It is preferred that step d) comprises:
Forming an outer radius of less than or equal to 2.5 mm.

It is preferred that step d) comprises:
Forming in a continuous process by relative movement of a mold unit and the door element for gradual and / or gradual transformation of a straight forming area up to the radius-rounded forming area.

It is preferred that step d) comprises:
Pressing the reshaped HPL layer to an abutment area extending across the remainder of the HPL layer.

According to a further aspect, the invention provides a door element based on wood-based materials, obtainable by a method according to one of the preceding claims, comprising:
a door element base body whose surface is coated with an HPL layer and an edge formed on the HPL layer which is rounded with a radius of 2.5 mm or smaller, wherein the HPL layer at the edge by a hardened material, as in particular a hot melt adhesive or other thermoplastic or thermosetting plastic is supported.

The door element is preferably designed as a door leaf or as a door frame.

In another aspect, the invention provides a building door comprising such a door element.

An embodiment will be explained in more detail below with reference to the accompanying drawings. It shows:

1 a horizontal section through a door element of a building door on the example of a door leaf in the course of its manufacture, wherein a door element blank is shown after a material removal step;

2 and 3 Views comparable to 1 during different phases of a forming step; and

4 a view comparable to 1 for the finished door element.

Hereinafter, a manufacturing method for producing a door member 10 a building door, such as a door panel 12 or a door frame, explained in more detail with reference to FIGS. The method is based on the example of a production of a door leaf 12 explained. With comparable steps, however, a door frame or another door element can be produced.

For this purpose, first a door element blank 14 made on the basis of wood-based materials.

For producing the door element blank 14 can have different door panel components 16 cut from wood materials and to a door element main body 18 be joined together. The surfaces of the door element main body 18 are coated with a surface coating of HPL (High Pressure Laminate).

HPL is understood to mean thicker laminates of papers impregnated with synthetic resins. That is, HPL consists of more than four layers of paper. To produce HPL laminates, several papers impregnated with melamine resin and phenolic resin are pressed together under pressure and temperature with a topcoat. Such building materials are available on the market, for example, under the brand names Dekodur, Duropal, Resopal, FunderMax or Sprelacart. The HPL coatings are easy to care for and clean, fade-resistant and odorless and resistant to alcohol, organic solvents and water. HPL is particularly scratch-resistant and is also used on kitchen worktops.

In the embodiment shown in the figures is as a door element blank 14 a door leaf blank 20 processed, consisting of a door leaf body 22 with at least one side or, as shown here, two-sided surface coating of an HPL layer 24 is made.

The illustrated as an example door leaf main body 22 has as door element components 16 one or more frame bars 26 , a filling 28 and at least one or two cover plates 30 on. The cover plate 30 is on at least one broadside the frame bar 26 and the filling 28 provided covering.

In one embodiment, the frame bar 26 made of MDF, the filling 28 made of MDF and the cover plate 30 made of thin chip.

The frame bar 26 Can be made of MDF or alternatively chipboard, solid wood or other wood-based materials.

The filling 28 Can be made of MDF or alternatively chipboard, solid wood or other wood-based materials.

The cover plate 30 Can be made of thin chip or alternatively MDF, HDF, plywood, other wood-based materials or other board materials (including plastics or other materials).

On the viewing surface of the door element main body 18 , such as on the cover plates 30 of the door leaf main body 22 , is the HPL layer 24 applied with a thickness of 0.5 mm to about 1.9 mm.

The door element blank thus formed, in particular the door leaf blank, is produced, for example, as a block-shaped or cuboidal plate, which is subsequently machined at the edges by material removal, around the door element blank already processed correspondingly with the material removal step 14 from 1 to obtain.

In the example of the door leaf blank 20 For this purpose, in a milling step, a folding step 30 produced, with a rebate 34 stop.

In the area of the rebate projection 34 becomes the background material in one or more further milling steps 36 of the door element main body 18 further removed.

This is done on the narrow end face 38 of the rebate projection 34 on the underground material 36 an investment contour 40 for later application of the reshaped HPL layer 24 formed. The plant contour 40 points close to the seam 32 a further outwardly projecting projection 42 on, to which to the reshaped edge area 44 towards a plant recess 46 with a sloping plant stage 48 followed.

In the area of the cover plate 30 and the HPL layer 24 is first outwardly to the plant contour 40 complementary internal structure 50 at the bottom of the HPL layer 24 created. This is done at the area of the bottom 52 (which could also be called inside), which is on the ledge 42 the plant contour 40 to come to rest, the underground material 36 to the HPL layer 24 ablated.

Then follow to the middle of the door element blank 14 towards the plant recess 46 complementary projection 54 also with a sloping step 56 is provided. This lead 54 For example, by leaving the material of the cover plate 30 in one of the recesses 46 manufactured corresponding layer thickness.

Further, in the material removal step near the edge to be reshaped, edge area 44 - A Umformausnehmung 58 on the bottom 52 by removing the entire underground material 36 right down to the HPL layer 24 formed into it.

It only becomes a thinner area of the HPL layer 24 ditched. For example, here HPL material in a layer thickness of 0.1 to 0.5 mm, preferably about 0.3 mm, stand.

This thinner left area of the HPL layer 24 in the area of Umformausnehmung is later transformed to the radius and therefore now as Umformbereich 60 designated.

The so with the contour of the 1 molded door element blank 14 is then transformed in a forming step.

For this purpose, the door element blank 14 moved relative to a molding unit, not shown, which is provided with forming shoes, which gradually the forming area 60 to reshape into a radius. The form shoes are eg segments, which are each advanced piece by piece. It can also be supplied heat to make the deformation easier. The in the 2 and 3 shown forming step is carried out, for example in a continuous process. On a passage of slightly more than one meter in length, for example about 1.5 m, the step-by-step transformation takes place while the door element blank moves along the corresponding shaped shoes.

Before or during the forming step is in the Umformausnehmung 58 on the bottom 52 introduced into flowable, curable material, such as a hot melt adhesive 62 , Alternatively, other thermoplastics or thermosets can be used as curable materials.

The hardenable material 64 is in during the 2 and 3 Forming step shown still flowable and deformable in shape.

4 shows the door element 10 after that in the 2 and 3 illustrated forming step; during the forming and / or shortly thereafter, the curable material is subjected to a curing step. When using the hot melt adhesive 62 the curing takes place by appropriate cooling after the forming step.

The hardenable material 64 becomes correspondingly hard and serves as a base and support for the forming area converted to the radius 60 ,

With this process, despite the high rigidity and resilience of HPL coatings 24 also HPL surfaces even with very small radii of 2.5 mm and less at one edge 66 rounded off.

Thus, a method of manufacturing the door member 10 , which is made on the basis of wood materials and represents a door element of a building door, proposed in which a rounded radius with an edge 66 of the door element 10 in the postforming process can also be realized with a very small radius.

• a) Vorsehen des Türelementrohlings 14 mit einer auf einem Untergrundmaterial 36 aufgebrachten Außenschicht aus HPL – HPL-Schicht 24 –,
• b) Materialabtrag des Untergrundmaterials 36 unter der HPL-Schicht 24, so dass die HPL-Schicht 24 über das Untergrundmaterial 36 hervorsteht, wobei auch Material der HPL-Schicht 24 auf der dem Untergrundmaterial 36 zugewandten Unterseite 52 abgetragen wird,
• c) Einbringen eines fließfähigen aushärtbaren Materials 64 an der Unterseite 52 der HPL-Schicht 24,
• d) Umformen der HPL-Schicht 24 durch Umlegen der HPL-Schicht 24 um das Untergrundmaterial unter Ausformung des Radius an der Außenseite der HPL-Schicht 24 und
• e) Aushärten des aushärtbaren Materials 64.

The method has the following steps in particular:

• a) Provision of the door element blank 14 with one on a background material 36 Applied outer layer of HPL - HPL layer 24 -
• b) Material removal of the substrate material 36 under the HPL layer 24 so that the HPL layer 24 over the underground material 36 protrudes, including material of the HPL layer 24 on the underground material 36 facing bottom 52 is removed,
• c) introducing a flowable curable material 64 on the bottom 52 the HPL layer 24 .
• d) Forming the HPL layer 24 by flipping the HPL layer 24 around the substrate material forming the radius on the outside of the HPL layer 24 and
• e) curing the curable material 64 ,

This is a door element 10 such as a door leaf 12 or a door frame of a built of wood materials building door with a very robust and scratch-resistant surface, yet at least one edge 66 with a very small radius is described.

Thus, a method is created, with which you can make a radius of 2 mm and smaller on certain materials. With the new process, this radius can also be produced on HPL surfaces.

The rounding is not made on a round base; Rather, a cured, flowable introduced material serves as a support material below the rounded edge 66 ,

At the door element 10 The outer layers are made by HPL layers 24 educated.

The method comprises a material removal step in the form of a milling step, where it is up to the HPL layer 24 works in it. In one embodiment, the HPL layer has 24 a layer thickness of 0.8 mm. In other embodiments, thicker or thinner layer thicknesses are used. For example, HPL layers are processed with layer thicknesses of 0.5 mm to 1.9 mm.

The milling is done to form a forming area 60 into the HPL layer 24 into it. There remains a thinner strip of HPL material with a lower thickness compared to the original HPL layer thickness. For example, about 0.3 mm remain.

In a preferred embodiment remains on the remaining edge strip of the protruding HPL layer 24 also a piece of the underground plate - eg cover plate 30 - stand. The cover plate 30 is eg a thin chip layer or an HDF layer.

As in the 2 and 3 shown in further steps, a transformation with form shoes, so as to form an externally measured radius, for example, 2 mm. Before the forming takes place, in the corner in the area of Conditioning recess 46 and the forming recess 58 injected a hot melt adhesive. This hot melt adhesive 62 serves in the finished door element 10 as background for the radius.

The material which is at the bottom 52 the HPL layer 24 is left, corresponds to the investment contour 40 at the fold. In 4 is the engagement between the investment contour 40 and inner contour 50 shown.

In addition to the example of a door leaf shown in the figures 12 can be used as a door element 10 in a corresponding manner, for example, a door frame, such as a Umfassungszarge made of wood, (not shown).

Different HPL materials are possible. To create the HPL layers 24 For example, decorative paper can also be used. So a wide variety of surface decorations is possible. For example, decorative paper can be used to create a metallic appearance.

HPL has a greater material thickness compared to CPL. While CPL is largely made from melamine, HPL also contains phenolic soaked layers. CPL consists of a maximum of four layers of paper. HPL consists of multiple layers that are more than four layers.

In particular, HPL is much more resilient than CPL. HPL is e.g. also used for kitchen work surfaces, for which CPL is not suitable. However, HPL is also much more difficult to reform because of its greater thickness and resistance.

Nevertheless, the method presented here makes it possible to produce rounded edges with a very small radius even on HPL surfaces. This is possible in particular because the thickness of the HPL layer 24 in the forming area 60 is reduced accordingly and because only still flowable, curable material 64 serves as a substrate and thus forms a flexible during forming substrate that hardens only afterwards.

The still flowable material 64 flows in every crack and forms a good background for the radius.

The advantage of using HPL over CPL is that HPL's greater thickness and resistance means that even a less than perfectly flat surface will not lead to optical defects. Overall, the surface is smoother and more attractive than other thinner cover materials. This results in a high surface quality.

LIST OF REFERENCE NUMBERS

10

 door element

12

 door leaf

14

 Door element blank

16

 Door element component

18

 Door element base

20

 Door panel blank

22

 Door leaf base

24

 HPL layer

26

 frame bar

28

 filling

30

 cover plate

32

 folding stage

34

 Falzüberstand

36

 Base materials

38

 Narrow front side

40

 contact contour

42

 Projection of the plant contour

44

 edge region

46

 Conditioning recess

48

 oblique attachment level

50

 inner contour

52

 bottom

54

 Tab on the bottom

56

 oblique step

58

 Umformausnehmung

60

 forming region

62

 melt adhesive

64

 hardenable material

66

 edge

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

• DE 202010004560 U1 [0002]

Claims (8)

Method for producing a door element ( 10 ) based on wood-based materials for a building door, comprising molding a radius-rounded edge ( 66 ) of the door element ( 10 ), characterized by the following steps: a) providing a door element raw body with one on a base material ( 36 ) applied outer layer of HPL, b) material removal of the substrate material ( 36 ) under the HPL layer ( 24 ), so that the HPL layer ( 24 ) over the underground material ( 36 ) protruding, wherein also material of the HPL layer ( 24 ) on the base material ( 36 ) facing the underside ( 52 ) of the HPL layer ( 24 ), c) introducing a flowable curable material ( 64 ) on the bottom ( 52 ) of the HPL layer ( 24 ), d) reshaping the HPL layer ( 24 ) by flipping the HPL layer ( 24 ) around the underground material ( 36 ) forming the radius' on the outside of the HPL layer ( 24 ) and e) curing the curable material ( 64 ). A method according to claim 1, characterized in that the step a) comprises one or more of the following steps: providing a door leaf raw body for producing a door leaf ( 12 ) or • providing a Zargenstabrohkörpers for producing at least one Zargenstabs a door frame; Producing a door element main body ( 18 ) of one or more components consisting of materials selected from MDF, chipboard, solid wood, wood-based material and coating of the door element body ( 18 ) with the HPL outer layer; Producing a door element main body ( 18 ) of a frame member, a filling member and at least one cover plate member and coating the outside of the cover plate member with the HPL outer layer; Bonding a door element main body component to a cover plate component made of thin chip, MDF, HDF, plywood, wood-based materials and / or board materials; and / or providing the HPL layer ( 24 ) in a layer thickness of 0.5 mm to 1.9 mm. Method according to one of the preceding claims, characterized in that step b) comprises one or more of the following steps: milling out a plant recess ( 46 ) at an investment area against which the HPL layer ( 24 ) in step d), and forming one to the recess ( 46 ) complementary projection ( 54 ) at the bottom of the HPL layer to be converted ( 24 ); Milling out a forming recess 58 ) on the inside of the HPL layer to be converted ( 24 ) into the HPL layer ( 24 ) in order to produce a thinning area which is thinner than the original HPL layer thickness and which is to be reshaped to the radius ( 60 ) from HPL; and / or • forming an inclined step ( 48 ) at the abutment area and a complementary oblique step ( 56 ) on the bottom ( 52 ) of the HPL layer ( 24 ); and / or • milling out a folding step ( 32 ) of a door rebate in a Türblattrohkörper; Forming a concave inner structure for forming and introducing the hardening material ( 64 ). Method according to one of the preceding claims, characterized in that step c) comprises one or more of the following steps: introduction of a hotmelt adhesive ( 62 ); • introducing a thermoplastic; • introducing a thermoset; and / or introducing the hardening material ( 64 ) in a material recess on a to be reshaped to the radius forming area ( 60 ); and / or introducing the hardening material ( 64 ) such that in the finished door element ( 10 ) the reshaped to the radius forming area ( 60 ) supported. Method according to one of the preceding claims, characterized in that step d) comprises one or more of the following steps: • reshaping the HPL layer ( 24 ) with form shoes • Forming with movement of form shoes; • supply of heat for forming; • forming an outer radius of less than or equal to 2.5 mm; • continuous forming by relative movement of a mold unit and the door element ( 10 ) for the gradual and / or gradual transformation of a straight forming area ( 60 ) up to the radius-rounded forming area ( 60 ); and / or pressing on the reshaped HPL layer ( 24 ) to one across the rest of the HPL layer ( 24 ) extending investment area. Door element ( 10 ) based on wood-based materials, obtainable by a method according to one of the preceding claims, comprising: a door element main body ( 18 ) whose surface is coated with an HPL layer ( 24 ) and one at the HPL layer ( 24 ) formed edge ( 66 ) with a radius of 2.5 mm or smaller rounded off, with the HPL layer ( 24 ) on the edge ( 66 ) by a hardened material ( 64 ) is supported. Door element ( 10 ) according to claim 6, designed as a door leaf ( 12 ) or as a door frame. Building door comprising a door element ( 10 ) produced by the method according to one of claims 1 to 5 and / or a door element ( 10 ) according to one of claims 6 or 7.

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