DK177139B1 - Insulated composite door with a layer of high pressure laminate - Google Patents

Insulated composite door with a layer of high pressure laminate Download PDF

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Publication number
DK177139B1
DK177139B1 DKPA201070429A DKPA201070429A DK177139B1 DK 177139 B1 DK177139 B1 DK 177139B1 DK PA201070429 A DKPA201070429 A DK PA201070429A DK PA201070429 A DKPA201070429 A DK PA201070429A DK 177139 B1 DK177139 B1 DK 177139B1
Authority
DK
Denmark
Prior art keywords
layer
door
insulated composite
veneer
composite door
Prior art date
Application number
DKPA201070429A
Other languages
Danish (da)
Inventor
Carsten Mols
Original Assignee
Vkr Holding As
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Vkr Holding As filed Critical Vkr Holding As
Priority to DKPA201070429A priority Critical patent/DK177139B1/en
Priority to DK201070429 priority
Application granted granted Critical
Publication of DK177139B1 publication Critical patent/DK177139B1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70Door leaves
    • E06B3/82Flush doors, i.e. with completely flat surface
    • E06B3/822Flush doors, i.e. with completely flat surface with an internal foursided frame
    • E06B3/825Flush doors, i.e. with completely flat surface with an internal foursided frame with a wooden frame
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70Door leaves
    • E06B2003/7049Specific panel characteristics
    • E06B2003/7051Specific panel characteristics of layered construction involving different materials

Abstract

An insulated composite door (1) comprising a wooden frame (2) covered by a facing sheet Iayer (3,4) an ane major surface of the door, said facing sheet Iayer comprising a Iayer of veneer (5) and a Iayer of High Pressure Lam mate (6), said Iayer of High Pressure Laminate being arranged further from the centre of the door than the Iayer of veneer, and where the thickness of the Iayer of High Pressure Lam mate is greater than 3mm.

Description

DK 177139 B1

Insulated composite door with a layer of High Pressure Laminate 5 The current invention relates to an insulated composite door comprising a wooden frame covered by a facing sheet layer on one major surface of the door, said facing sheet layer comprising both a layer of veneer and a layer of High Pressure Laminate, said layer of High Pressure Laminate being arranged further from the centre of the door than the layer of veneer.

10

Description of related art

Traditional insulated composite doors are formed from a wooden rectangular frame with a facing sheet layer of plywood glued to both sides of the frame.

15 This results in a light, cheap and strong door.

More advanced insulated composite doors comprise facing sheet layers comprising a number of different layers having different properties. For example, it is common to provide a facing sheet layer comprising a veneer 20 layer arranged closest to the frame, then a thin aluminium sheet layer which acts as a vapour barrier and then one or more external veneer layers to give a combination of strength and a nice appearance.

More recently plastic materials have also started to be used on doors. For 25 example thin layers of resin impregnated overlays have been added to the outside surface of insulated composite doors. Resin impregnated overlays are usually comprised of one of more layers of paper or thin fabric which are saturated with resin and pressed together under high pressure. For examples of such doors, see WO 2003/066321, EP 2192258, EP 2065183 and EP 30 1327048.

2 DK 177139 B1

Summary of the invention

The prior art doors however all have various disadvantages as will be known 5 to the person skilled in the art. It is therefore a first aspect of the current invention to provide a new type of insulated composite door having advantages over the prior art types of insulated composite doors.

This first aspect is provided by an insulated composite door as mentioned in 10 the opening paragraph where the thickness of the layer of High Pressure Laminate (HPL) is greater than 3mm. In this way, the layer of HPL acts as a proper vapour barrier without the need for an aluminium layer. Furthermore, the thickness of the HPL allows grooves to be machined into the exposed surface of the door without breaking through the HPL layer.

15

Previously, it has not been thought possible to build an insulated composite door with a wooden frame and a thick layer of HPL due to the fact that HPL is a material which has very low coefficients of expansion due to heat and/or moisture whereas wood has much higher coefficients of expansion due to 20 heat and/or moisture. By gluing a thick layer of HPL to a wooden frame, there would be serious delamination problems when the door was exposed to heat and/or moisture. However, by adding a thin layer of veneer between the wooden frame and the thick HPL layer, these problems are avoided. In the prior art insulated composite doors which comprise a layer of HPL, a thick 25 veneer layer is fastened to the wooden frame and a thin layer of HPL is fastened to the veneer layer.

Additional aspects of the invention are provided by the dependent claims.

30 It should be emphasized that the term "comprises/comprising/comprised of' when used in this specification is taken to specify the presence of stated 3 DK 177139 B1 features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. For example, in the claims it is stated that the door comprises a facing sheet layer arranged on one major surface of the door. However, it 5 should be clear to the reader, that this should be understood as “arranged on at least one major surface of the door”. The case where both major surfaces of the door are covered by a facing sheet layer is also included in the scope of protection. The facing sheet layers on the two major surfaces of the door could be identical or different. For example, on one side of the door could be 10 arranged a facing sheet layer according to the invention whereas on the other side only a simple veneer layer could be provided. Many possibilities will be available as should be understood by the person skilled in the art.

Brief description of the drawings 15

In the following, the invention will be described in greater detail with reference to embodiments shown by the enclosed figures. It should be emphasized that the embodiments shown are used for example purposes only and should not be used to limit the scope of the invention.

20

Figure 1 shows a perspective view of an insulated composite door according to the current invention.

Figure 2 shows a cross section view according to the line ll-ll defined in 25 figure 1.

Figure 3 shows a detailed cross section according to the circle III defined in figure 2.

30 Figure 4 shows a cross section view according to the line IV-IV defined in figure 1.

4 DK 177139 B1

Figure 5 shows a perspective exploded view of the insulated composite door shown in figure 1.

5 Detailed description of the embodiments

The door 1 shown in figures 1-5 comprises a wooden frame 2 which is made up of four frame elements 2a,2b,2c,2d. Two horizontal frame members 2a,2c are joined together to two vertical members 2b,2d to make up the rectangular 10 frame. In a typical frame, the frame elements would be joined together with fastening means (not shown) at the corners. A non-limiting list of example fastening means includes dowels, screws, nails and glue. The wooden frame when assembled has two major surfaces and four edge surfaces.

15 A facing sheet layer 3, 4 is then fastened to each of the two major surfaces of the rectangular frame with an adhesive. The facing sheet layers 3, 4 are identical in the current embodiment. The facing sheet layers 3, 4 both comprise a thin layer of veneer 5 adjacent to the wooden frame and a thicker layer of HPL 6 arranged on the layer of veneer. The veneer layer 5 in the 20 current embodiment is formed from a material having a high porosity which can absorb a large amount of adhesive and in this way establish a good connection to the HPL layer 6 and to the wooden frame 2. In the current embodiment, the layer of veneer is 1,5mm thick and the layer of HPL is 4 mm thick. It has been found that layers of HPL having a thickness of greater than 25 or equal to 4mm can in certain cases be advantageous, since this allows a deeper groove to be machined into the door without breaking through the HPL layer.

In the current embodiment, the door is designed as an exterior door. In this 30 case, the layer of HPL would be chosen as a type of HPL which is suitable for external use.

5 DK 177139 B1

In the hollow of the door between the frame and the facing sheet layers is arranged an insulating core of insulation material 7.

5 As can be seen from the figures, in the current embodiment, the facing sheet layers 3,4 cover essentially the entire surface area of the major surfaces of the door. The wooden frame defines the exterior dimensions of the surface area of the door and the facing sheet layers provide a covering for the door.

10 One method of manufacturing the insulated composite door according to the invention would proceed according to the following description. A layer of HPL and a layer of veneer are provided and the layer of veneer is glued to one side of the layer of HPL to form a first compound layer. The compound layer is pressed in a press at a high pressure. A second compound layer 15 identical to the first compound layer is then provided. The frame members 2a,2b,2c,2d are then assembled around the insulating core 7 and nailed at the corners. A compound layer of veneer and HPL is then glued to each side of the wooden door frame with the layer of veneer being in contact with the doorframe.

20

However, many different combination possibilities with regards to the method of manufacture will be possible and should be understandable to the person skilled in the art. For example, it is not necessary that two identical compound layers be fastened to the two sides of the door. One side could be 25 according to the current invention, the other side could be something different. Another example could be that the different layers are all glued together in a single operation and then the entire door is pressed in a press in one step. It should also be mentioned that the steps of the method above are varied, for example, the frame could be assembled before the compound 30 layers are provided.

6 DK 177139 B1

While the figures do not show it, it is possible to machine grooves into the exterior HPL layer which can be used to give the door a more interesting visual appearance. For example, spaced apart vertically arranged grooves which run the length of the door give the door a nice visual appearance.

5 These grooves are typically at least 2mm deep.

It should be noted that the figures have only shown one embodiment, however the person skilled in the art will be able to develop other insulated composite doors which are covered by the teaching of this invention. For 10 example, the embodiment shown has been a rectangular door, however, one could also imagine doors with a non-rectangular shape, for example a door with an arc shaped top portion.

It is to be noted that the figures and the above description have shown the 15 example embodiments in a simple and schematic manner. Detailed mechanical features have not been shown since the person skilled in the art should be familiar with these details and they would just unnecessarily complicate this description. For example, the frame members are shown as simple rectangular elements. Flowever in a real insulated composite door, the 20 frame members are often formed with engaging elements or fasteners whereby the frame members are structurally joined together before the facing sheet layers are applied.

25

Claims (8)

  1. An insulated composite door (1) comprising a wooden frame (2) with two main faces, one of the two main faces being covered by a 5 cover plate (3,4), said cover plate comprising a layer of veneer (5) and a layer of high pressure laminate (6), which layer of high pressure laminate is located further away from the center of the door than the veneer layer, characterized in that the thickness of the layer of high pressure laminate is greater than 3mm.
  2. An insulated composite door (1) according to claim 1, characterized in that the veneer layer (5) is glued to the wooden frame (2) of the door.
  3. An insulated composite door (1) according to any one of claims 1-2, characterized in that the layer of high-pressure laminate (6) is glued to the veneer layer 15 (5).
  4. An insulated composite door (1) according to any one of claims 1-3, characterized in that the thickness of the veneer layer (5) is between 1 and 2 mm.
  5. An insulated composite door (1) according to any one of claims 1-4, characterized in that the layer of high-pressure laminate (6) is at least twice the thickness of the veneer layer (5).
  6. An insulated composite door (1) according to any one of claims 1-5, 25, characterized in that a decorative groove is milled into the visible surface of the layer of high-pressure laminate (6).
  7. An insulated composite door (1) according to claim 6, characterized in that the groove has a depth of at least 2 mm. 30 2 DK 177139 B1
  8. A building comprising an insulated composite door (1) according to any one of claims 1-7, which door is arranged as an outside door and wherein the layer of HPL (6) is arranged on the outside of the door. 5 DK 177139 B1 II 1/3 T i 1 ^ ^ 'I 5 ^ X IV 2b V • V \ X • V \ XX, X IV' "'xt \ l ΝΝΧχ \. Fig. 1 3 DK 177139 B1 2 / 3 2d ^ Ml (f 2a \ 2b Fig. 2 ^ 4 2a 3 6 / ii \ \ * / '5 I ° 6 Fig. 3 2c 3 (7 / 2a „y ,,, Ju ^ i, Fig. 4 DK 177139 B1 3/3% HS 7-, hr \ ΓΝ I S. pSjv 6 - 7 5 _ £ ^ 2b 2c Fig. 5
DKPA201070429A 2010-10-01 2010-10-01 Insulated composite door with a layer of high pressure laminate DK177139B1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
DKPA201070429A DK177139B1 (en) 2010-10-01 2010-10-01 Insulated composite door with a layer of high pressure laminate
DK201070429 2010-10-01

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DKPA201070429A DK177139B1 (en) 2010-10-01 2010-10-01 Insulated composite door with a layer of high pressure laminate
EP11183675.5A EP2436867A3 (en) 2010-10-01 2011-10-03 Insulated composite door with a layer of high pressure laminate

Publications (1)

Publication Number Publication Date
DK177139B1 true DK177139B1 (en) 2012-01-30

Family

ID=44903081

Family Applications (1)

Application Number Title Priority Date Filing Date
DKPA201070429A DK177139B1 (en) 2010-10-01 2010-10-01 Insulated composite door with a layer of high pressure laminate

Country Status (2)

Country Link
EP (1) EP2436867A3 (en)
DK (1) DK177139B1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102014101876A1 (en) 2014-02-14 2015-08-20 G. Keller Fenster & Türen GmbH Door leaf

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4146662A (en) * 1978-01-30 1979-03-27 Simpson Timber Company Warp and weather resistant solid core wood door and method of making
GB2368364B (en) 2000-10-12 2004-06-02 Mdf Inc Fire door and method of assembly
US6667108B2 (en) 2002-02-07 2003-12-23 Erick Ellstrom Wearprotected wood veneer
DE20212046U1 (en) * 2002-08-05 2002-10-17 Schirling Gmbh Door leaf and door leaf for building interior doors and building interior door with such a door leaf
AT9351U3 (en) * 2007-05-03 2011-02-15 Reinex Tueren Gmbh Full plastic door
DE102007058034B4 (en) 2007-11-30 2009-11-26 Flooring Technologies Ltd. Panel comprising a support plate with a real wood veneer
SE533150C2 (en) 2008-11-26 2010-07-06 Ekstrand & Son Ab Door
DE202009006636U1 (en) * 2009-05-07 2010-09-23 Westag & Getalit Ag Wet or damp room door with plastic insert
DE202010004560U1 (en) * 2010-04-01 2010-07-29 Herholz Vertrieb Gmbh & Co. Kg Door leaf

Also Published As

Publication number Publication date
EP2436867A2 (en) 2012-04-04
EP2436867A3 (en) 2014-09-10

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