EP1664473B1 - Process for producing a hollow door element for a door leaf composed of a hollow element and a cover element - Google Patents

Description

The invention relates to a method for producing a door latch of a door leaf formed from box and ceiling according to the preamble of claim 1 appended hereto.

Door leaves formed from metal are often, as is also known from some DIN regulations, made of a box sheet, which is filled with a suitable for the respective purposes of the door filling and is closed with a cover plate.

The box sheet or often also simply called box, then forms a first broad side of the door leaf and - depending on the presence or size of a Türfalzes completely or partially the four narrow sides or end faces of the later door leaf.

Accordingly, the box actually has a box shape consisting of the bottom forming the door leaf broad side and the side walls forming the door leaf narrow sides.

The GB 2 109 277 A discloses a method of manufacturing a door leaf box of a door panel formed of box and lid. To form an upper end side, a first edge strip and a second edge strip of a metal sheet is bent over to form a lateral narrow side of the door leaf. Subsequently, opposite side edges of the edge strips are welded in a corner region by means of an inert gas welding process.

Further, the US 3,440,722 a method for producing a door leaf box of a door leaf formed from box and cover, in which a metal sheet is bent such that a first edge strip an upper end side of the door leaf and a second edge strip form a narrow side of the door leaf. Subsequently, a welding of the two edge strips along a contact edge. The welding of the side edges takes place with the help of in Fig. 1 pictured device that carries on the one hand the door leaf and the other a welding gun or leads.

Finally, the reveals DE 24 02 110 A a method for resistance welding a metal plate to a metal part to which welding projections are produced by an embossing process and / or attaching separate welding bodies to the metal part. The projecting embossments are produced by squeezing. Alternatively to the embossing process for producing the welding protrusions from a round or square material (see Fig. 1a, b ), hat-shaped formations can be made by a deep embossing operation of a metal strip.

The Fig. 1 and 2 illustrate a previously common manufacturing method for the manufacture of the above-mentioned box panel. In Fig. 1 is a corner of the box plate in partially cutaway view and in Fig. 2 is the corner of a metal sheet, from which this corner is formed represented.

The box panel is usually formed from a single metal sheet by bending edge strips and welding the edge strips in the corner region of the door leaf box together. Fig. 1 shows the finished corner joint and Fig. 2 shows the metal sheet just before bending.

The in Fig. 1 illustrated corner portion 8 of a (door leaf) box 10 is formed by a bottom plate 12, which forms a door leaf broad side 14, and by two lateral edgings or edge strips 16 and 18, which respectively form narrow sides 20 and 22 of the box.

A first edge strip 16 forms a short narrow side, d. H. an upper or lower end face 20. The second edge strip 18 forms a narrow side on the long side of a door leaf, d. H. Here, one of the two lateral narrow sides 22. The two edge strips 16 and 18 thus according to their Alkantung perpendicular to each other. The second edge strip 18 has in the example shown at its outermost edge region 24, a further fold 26 to which the cover sheet, not shown here, in a known manner can be fastened.

The two edge strips are connected to form a fixed corner joint via a welded joint 28. The known weld 28 is formed by one of the two edge strips, here of the first edge strip 16, parallel to the other, a second edge strip 18, extending bent welding tabs 30, which is welded to the second edge strip 18 with two 2 welding bosses 32 ,

The two edge strips 16, 18 are connected to the welding flaps 30 by notching a correspondingly shaped corner region 33 during the punching of a sheet metal Rohform box plate 34-, as shown in FIG Fig. 2 shown is formed.

In the hitherto customary production of a door leaf box 10, the procedure is thus that the edge strips forming the end faces or narrow sides 20, 22 form 16, 18 after making the edge strips 16 and 18 as in FIG Fig. 2 shown to be folded inwards by 90 °. The end face 20 is connected to the lateral narrow side 22 via the welding flap connection 28. The welding tabs 30, in turn, must be folded over by 90 ° before the actual bending of the first edge strip 16, ie be raised. In this case, the welding flap 30 is usually over-arched by special machines (bent over more than 90 °) so that it does not hit the second edge strip 18 of the box plate 34 in the subsequent inward edges of the first edge strip 16.

In other methods not shown here, such a corner joint of two highly curved edge strips 16 can also be carried out by a separate welding corner angle, which of course must be fed separately beforehand.

The previously described methods are internal prior art, the prior publication is unclear. The described methods used so far are relatively complex and require special machinery.

The object of the invention is to improve a method for producing a door leaf box that the door leaf box can be made comparatively easy and inexpensive while ensuring sufficient rigidity, especially in the corner regions.

This object is achieved by a manufacturing method having the steps of appended claim 1.

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

According to the invention, the previously customary welding flaps 30 are dispensed with. Instead, the abutting edge portions of the two edge strips are welded directly to each other in abutment.

This eliminates the additional bending measures that were previously necessary due to the welding flaps 30. The corner regions of the box plate can be much easier, namely notched substantially at right angles to provide the edge strips to be bent over the box panel. The resulting substantially rectangular shape of the edge strips is significantly easier to handle industrially.

Now, the door leaf box produced according to the invention are also for fire doors or other doors that are exposed to special mechanical stress, can be used. For this reason, it has been provided to provide a secure welded joint, the two weld humps and the welding tabs. The weld bumps 32 had to be introduced into the welding flaps 30 in an additional step.

According to the invention, a secure welded joint, which also withstands the requirements of fire doors and / or other heavy duty exposed doors for a long time, created by one of the two edge strips at that side edge, with the side edge of the second edge strip in the corner Shock comes into contact, is provided with welding humps. The weld bumps are preferably formed so that they over the side edge, d. H. protrude in the direction of the other bent edge strip. The Schweißbuckel are equal to the shaping of the edge strips on the side edge provided with and shaped. For example, the weld bumps may be formed simply by forming a portion of the side edge in a wave form. This can be done in a particularly advantageous manner by the fact that the waveform or the otherwise shaped projections on the side edge are unlatched at the same time when notching the corner region of the still unbent box panel.

The invention eliminates the additional steps discussed above with respect to the prior art. The corner joint is only after the Bending the one opposite narrow side in the connecting region to the other opposite narrow sides, preferably butt welded in T-joint.

About a projection welding connection a very strong connection is achieved. The weld bumps are punched directly over the usual corner notches in the appropriate size. The size of the weld hump depends on the material thickness and is generally based on valid DIN standards for relevant connections.

In the context of welding tests already carried out, it could be demonstrated that the strength values for the welding method according to the invention are comparable to those of the welding methods explained above with reference to the prior art.

The production is greatly facilitated in the method according to the invention in that variably adjustable bending tools can be constructed much easier in flexible bending machines. Due to the simple shape to be bent also a positioning of the bending tools is possible, so that special dimensions can be made very easily. The bending tools can be easily positioned in the corner of the door leaf box.

An "air bending", which was necessary in the usual procedure and was the cause of some quality defects, is eliminated.

Fig. 1

eine perspektivische, teilweise weggeschnittene Darstellung einer Eckverbindung eines Türblatt-Kastens nach dem Stand der Technik:

Fig. 2

eine Draufsicht auf einen Eckbereich eines Kastenbleches nach dem Stand der Technik, aus der die in Fig. 1 gezeigte Ecke gebildet wird;

Fig. 3

eine Ansicht vergleichbar derjenigen von Fig. 1 auf einen Eckbereich einer Ausführungsform eines erfindungsgemäß hergestellten Türblatt-Kastens;

Fig. 4

eine Fig. 2 entsprechende Draufsicht auf einen Eckbereich eines Kastenbleches, aus dem die in Fig. 3 dargestellte Ecke gebildet wird;

Fig. 5

eine Draufsicht auf den in Fig. 3 dargestellten Eckbereich von oben; und

Fig. 6

eine Detailansicht des Details X von Fig. 5.

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

Fig. 1

a perspective, partially cut away view of a corner joint of a door leaf box according to the prior art:

Fig. 2

a plan view of a corner region of a box panel according to the prior art, from the in Fig. 1 formed corner is formed;

Fig. 3

a view comparable to that of Fig. 1 to a corner portion of an embodiment of a door leaf box made according to the invention;

Fig. 4

a Fig. 2 corresponding plan view of a corner region of a box plate from which the in Fig. 3 formed corner is formed;

Fig. 5

a top view of the in Fig. 3 illustrated corner area from above; and

Fig. 6

a detailed view of the detail X of Fig. 5 ,

An embodiment of the method according to the invention and the door leaf box 40 produced therewith will be described below with reference to the illustration of Fig. 3 - 6 explained in more detail. In this case, the same reference numerals for corresponding parts as in the previous description of the prior art with reference to Fig. 1 and 2 used. The description of these corresponding parts will not be repeated here; Reference is made to the above description.

The in Fig. 3 illustrated corner region 8 of the box 40 is characterized in comparison to the in Fig. 1 represented corner region 8 of the box 10 according to the prior art, characterized in that the corner joint is not formed via a welding flaps 30 with welding boss 32, but by a projection weld a side edge 42 of the substantially rectangular shape without the welding flaps first edge strip 16.

As in Fig. 4 shown, the corner notch 33 in the box plate is substantially rectangular. The turned to the second edge strip 18 added Side edge 44 of the short narrow side 20 or front side forming first edge strip 16 is not formed with a welding cloth, but with a wavy-shaped portion 46. The wave form results in four weld bumps 48 projecting beyond the remaining edge region 50 by a specific amount of 0.5-2 mm, in this example 1 mm.

In the Fig. 4 The shape shown is achieved simply by appropriate design of the notching tool or punching tool (not shown) in a step in the punching of the box plate 34. In the production of the box 10 is then proceeded so that first the first edge strip 16 is bent with the provided with weld hump 48 side edge and then the second edge dispute 18 is bent and welded.

Fig. 5 then shows the obtained welded joint from above and Fig. 6 shows the burnout of the weld bumps 48. About half (0.5mm) of the board (1mm) of the weld bumps 48 were "burned off" in this example and used to form the weld joint. The protruding portions of the weld bumps 48 are thus firmly welded to the second edge strip.

In the illustrated embodiment, not the two side edges of the edge strips are welded directly to each other, but the second edge strip 18 is still a piece on the welded connection with the first edge strip 16 out. As a result, on the front side 20 of the later door leaf a recess for seals, Brandaufschäumer, u. s. w. achieved. In addition, the strength of the welded joint is increased compared to a connection of two side edges.

Although only one of the four corner regions 8 has been described above by way of example, it should be clear that all the corner regions of the box 40 in a corresponding manner as in Fig. 3 can be welded welded. The reference numeral 52 records the T-joint or impact area at which the first edge strip 16 is welded via the weld boss 48 to the second edge strip is. The reference numeral 33 shows the substantially rectangular Eckausklinkung of Fig. 4 compared to the approximately L-shaped notch 33 after Fig. 3 ,

Claims (8)

1. Process for producing a door leaf case (10) for a door leaf composed of a hollow element (10) and a cover, the process comprising:

   a) providing a sheet metal (34) and forming a first edge strip (16) and a second edge strip (18) of said sheet metal (34),

   b) bending said first edge strip (16) for at least partly forming an upper and lower front face (20) of the door leaf,

   c) bending said second edge strip (18) for at least partly forming a lateral narrow side (22) of the door leaf,

   d) welding together said two edge strips (16, 18) in a corner region (8) of said case (10),

   wherein the sequence of steps b) and c) is arbitrary and wherein said two edge strips (16, 18) are directly welded to each other at a joint area (52) where the edge strips (16, 18) join each other diagonally, without the use of straps, characterized in that at least one of the edge strips (16, 18) is formed by stamping, wherein there are formed projection welds (48) simultaneously with the stamping of said edge strip (16, 18) at a to-be-welded lateral edge (44) of one of the edge strips (16, 18), which lateral edge (44) abuts against an other region (18) of the sheet metal (34) after performing steps b) and c).
2. Process according to claim 1, characterized in that the projection welds (48) protrude over a remaining edge region (50) of said lateral edge (44).
3. Process according to claim 1 or 2, characterized in that the projection welds (48) are formed by the lateral edge (44) being shaped in wavelike manner (46) entirely or partly, when viewed from above.
4. Process according to one of the preceding claims, characterized in that the size of the projection welds (48) is selected dependent on the material thickness and/or the thickness of the sheet metal (34).
5. Process according to one of the preceding claims, characterized in that in step a) said metal sheet (34) is provided in a manner preformed with the respective edge strips (16, 18) destined for later bending.
6. Process according to one of the preceding claims, characterized in that a corner of the preformed sheet metal (34) at which the later welding process according to step d) is performed, is cut out (33) substantially rectangular, for forming edge regions of the two edge strips which lie on top of each other so as to butt in the corner of the door leaf case.
7. Process according to one of the preceding claims, characterized in that prior to bending, the edge strips (16, 18) at the sheet metal (34) merely present a substantially rectangular shape.
8. Process according to one of the preceding claims, characterized in that in step d), a corner joint is butt-welded in a T-joint manner only in the joining area of the first edge strip (16) to the second edge strip (18).

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