EP2581540B1 - Method for manufacturing a building door leaf and door leaf manufactured according to the method - Google Patents

Description

The invention relates to a method for producing a building door leaf. More particularly, the invention relates to a method of manufacturing a front door panel for a front door to be used as the exterior of a building. Furthermore, the invention relates to a producible with such a method door door leaf, in particular a front door leaf for a door to be used as the outer end of a building door.

Front doors are used as the main entrance for buildings, in particular residential buildings. So they have to fulfill several functions. As a main entrance door, the design aspect is very important. In particular, the design should match the appearance of the building. Often an individual design is desired. Therefore, almost all door manufacturers offer a large variety of different designs for their front doors.

Often, it is hereby desirable for the door leaves of house doors to have glazings which are at least translucent. Accordingly, many door manufacturers also offer motifs with differently designed glazing in the door leaf.

In addition to the design aspect, the front door should provide high insulation and good climate protection, as it serves as the outer closure.

The burglar resistance, which is described by resistance classes according to DIN V ENV1627, is of increasing importance for house doors. As a rule, at least resistance class WK2 for house doors is desired.

In practice, door leaves of front doors in the form of door leaves are usually made such that a door leaf frame and a door panel attached thereto are provided. Examples of corresponding front door leaves as well as for manufacturing processes can be found in the DE 296 17 479 U1 , of the EP 1 568 842 B1 as well as the EP 1 780 368 A2 ,

The DE 296 17 479 U1 discloses a front door with a front door leaf in which aluminum profiles a door leaf frame is made and motif plates are attached to the door leaf frame. Between the motif plates filling elements for thermal insulation and / or sound insulation can be provided.

In the EP 1 568 842 B1 a door leaf door is described for a front door, which has a door leaf frame made of light metal profiles. On the door leaf frame a sandwich panel is held as a door panel, which is formed of a motif plate and a cover plate and insulation material in between.

The EP 1 780 368 A2 discloses a front door with a front door leaf with door leaf frame, in which a door panel is inserted, which has a motif plate.

All the door door leaves described above are usually made so that a most peripheral door leaf frame is provided on which the fittings are arranged. The door leaf frame is formed of a light metal such as an aluminum alloy. In or on this door leaf frame then a door leaf filling is used. As a door leaf filling come to sandwich panels in question. These sandwich panels have cover plates with insulation material in between. For example, a cover plate is a motif plate, which forms an outside broadside of the door leaf and provides an appealing design motif. Another cover plate is, for example, a cover plate, e.g. can form the inner broad side of the front door door leaf.

In order to meet the great demand for different designs for entrance doors, a market for door leaf fillings has become established. Accordingly, there are many companies on the doorstep market, which have specialized exclusively in the production of door leaf fillings. Locksmiths or larger front door manufacturers can thus provide their own door leaf frame with appropriate locking technology and then attach to this door leaf frame purchased door panels.

A newer interesting way of manufacturing front door panels is in the DE 10 2009 032 039 A1 , of the DE 10 2009 032 041 A1 as well as the DE 10 2009 032 040 A1 disclosed. In the manufacture of the door door panels described here, the procedure is such that a door leaf frame is constructed in particular of frame profiles, which at least partially comprises profile elements made of fiber-reinforced plastic material, whereby a cavity is created by attaching cover plates on the door leaf frame, which is then foamed.

Thus, in the prior art door leaf door panels, door panel bodies formed from cover panels forming the broad sides of the front door panel and insulating material or insulating material therebetween can be manufactured in two ways. By far the most common type of manufacturing used in practice, the door panels are made from sandwich panels and then fastened from sandwich panels to a door leaf frame; in the newer manufacturing the cover plates are first attached to the door leaf frame and then the resulting cavity foamed.

However, no matter how the door leaf bodies are made, glazing and motif glazing have been applied to the door leaf bodies to first provide the door leaf body assembly, then to cut out window openings by removing both the cover plates and the insulating material corresponding to the window opening, and then a glazing is inserted into the window opening produced in this way.

This manufacturing method of glazing has become established because the design variety requires a very wide variety of different glazing shapes and window cutout shapes that must be individually incorporated.

In the manufacturing method, where the finished door panels are obtained from a door panel manufacturer, first the sandwich panels, which form the basic structure of the door panels, are made with cover panels and intermediate insulating material, then the desired panel is inserted into this sandwich panel. If several glazings within the door panel desired, more windows are introduced accordingly. Glazing elements are then inserted into these window openings and fastened accordingly, as has been established in decades of door technology.

In general, door leaves which are to be provided with individual glazing cut-outs are first produced in such a way that the door leaf body is produced over the entire surface, then a window cut-out is made and only then a glazing is introduced at the window cut-out. Exceptions to this form only fully glazed wings, in which a glazing is introduced alone in a door leaf frame. There is no cutting, but the door leaf frame is made accordingly as a glazing frame.

However, hardly any different motifs with different shapes of windows and in particular different window contours (round windows, oval windows, square windows with round corners, sloping windows, curved windows, crescent-shaped windows, etc.) can be produced. For producing such window cutouts, a full-surface door leaf body is produced accordingly, which is then cut out accordingly.

A deviation from this established manufacturing method shows the DE 197 18 015 A1 , Here, a manufacturing method for a front door with door leaf frame and inserted therein door panel is disclosed, wherein the door panel is to be provided with a glazing. Here, a window cutout is already introduced in the manufacture of the door panel, wherein the cover plates are formed from sheets, wherein a window frame is already introduced by a stamping or deep drawing tool in the metal plate and then the window panel is opened by punching or milling. Subsequently, congruent metal plates are stacked together and provided with spacers. A fitting is inserted into the window opening so that this window opening remains free during foaming. Then the foaming takes place between the two metal plates. Then the molding is removed and the insulating glass insert is inserted into the window opening thus formed and existing joints are closed by silicone or the like. In an alternative method of manufacture, the sandwich panel is overall produced with embossed window frame and then the window cutout cut by milling, in which case the insulating glass is used.

Accordingly, in the state of the art, a glass insert is only finally inserted into the finished manufactured and foamed door pane body provided with a window opening and then grouted.

US Pat. No. 4,720,951 discloses a frame assembly for doors and windows. A frame receives a central plate that defines an edge around its outer periphery. The frame includes a first and second lid defining a cavity therebetween opposite each other. The inner edge of the frame has internal support ribs which, together with the inner edge of the frame, grip the edge of the center plate, while the outer edges of the lids are separated by a variable-size insert. The cavity between the lids is filled with a foamable insulating material which surrounds the edge of the central plate and forms a weatherproof seal. The US Pat. No. 4,720,951 discloses a building door leaf having the features of the preamble of claim 7, and a method of manufacturing such a door leaf having the features of the preamble of claim 1.

The object of the invention is to provide a method for producing a glazed door of a building door, in such a way that the door leaf produced therewith is both easier to produce and better suited as an outer door.

In addition, a corresponding door leaf with glazing is to be created, which is particularly suitable for a front door.

This object is achieved by a method according to claim 1 and a door leaf according to the independent claim.

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

1. a) Herstellen eines Türblattkörpers mit Hilfe der Deckplatten
2. b) Vorsehen eines Fensterausschnitts an den Deckplatten und
3. c) Anordnen der Isolierglasscheibenanordnung im Bereich der Fensterausnehmung der Deckplatten, so dass die Isolierglasscheibenanordnung und die Deckplatten einen Hohlraum in dem Türblattkörper begrenzen, und
4. d) Ausschäumen des in Schritt c) gebildeten Hohlraums, um so die Isolationsschicht zu bilden sowie
5. e) Vorsehen eines Klebemittels zwischen einem Randbereich einer der Deckplatten und der Isolierglasscheibenanordnung als Abdichtung und Einfügen eines Dichtbandes zwischen dem

Klebemittel und der Fensterausnehmung für einen Toleranzausgleich zwischen dem Randbereich und der Isolierglasscheibenanordnung. Dabei sind die Deckplatten aus Metallblech gebildet.The invention provides a method for producing a building door leaf, in particular a front door panel for a door to be used as the outer closure of a building, the building door leaf having a first cover plate forming a first broad side, a second cover plate forming a second broad side and an insulating layer between the cover plates and at least one insulating glass pane arrangement, with the steps:

1. a) producing a door leaf body using the cover plates
2. b) providing a window cutout on the cover plates and
3. c) arranging the insulating glass pane assembly in the region of the window recess of the cover plates, so that the insulating glass pane assembly and the cover plates define a cavity in the door leaf body, and
4. d) foaming the cavity formed in step c) so as to form the insulating layer and
5. e) providing an adhesive between an edge region of one of the cover plates and the insulating glass pane assembly as a seal and inserting a sealing tape between the

Adhesive and the window recess for a tolerance compensation between the edge region and the insulating glass pane assembly. The cover plates are made of sheet metal.

The use of the letters a), b), c) etc. is only intended to simplify the clear reference to the individual steps and does not contain any information about a specific order of the individual steps.

However, it is clear from the wording of step d) that here the cavity formed in step c) is to be foamed, i. the step d) is performed after step c).

Otherwise, the order is arbitrary; the window cutout can be made before attaching the respective cover plate to form the door leaf body or even after attaching the cover plate.

Preferably, the method is carried out such that steps a), b) and c) intermesh. It could, for example, first be provided with a window cutout one or both of the cover plates, then the insulating glass pane arrangement are arranged in the region of the window opening of de cover plates and then produced by adding the other cover plate of the door leaf body and thus simultaneously the cavity in the door leaf body are produced.

This latter preferred embodiment has the advantage that the window cutouts in the cover plates can be smaller than the insulating glass pane arrangement, so that the edge regions of the cover plates rest on the outside of the insulating glass pane arrangement and fix them.

This has the further advantage that the window cutouts in the cover plates do not necessarily have to correspond to the contour of the insulating glass pane arrangement and vice versa. It could, for example, a larger insulating glass pane arrangement are arranged in the interior of the door leaf body and then covered with a cover plate having a plurality of window cutouts, but which all rest completely above the insulating glass pane arrangement. Thus, a standardized insulating glass pane assembly could be mass produced, and yet quite differently designed window cutouts could be provided that simply over the Insulating glass pane arrangement are placed. Thus, a great variety of different design options is created with simple manufacturing.

On the other hand, it is of course also possible that a plurality of window openings are provided in the cover plates and each individual Isolierglasscheibenanordnungen be provided with adapted to the window openings contours per pane, in which case the foaming preferably takes place each around the individual Isolierglasscheibenanordnungen around.

It is preferred that steps a) to c) be performed such that the cavity completely surrounds the insulating glass pane arrangement and is bounded directly by the insulating glass pane arrangement.

It is preferred that step d) be performed such that the foam forming the insulating layer directly contacts glass materials of the insulating glass pane assembly.

It is preferable that the insulating glass sheet assembly is a multi-pane insulating glass formed as a multi-layered disk structure.

• Befestigen der Deckplatten an einem Türblattrahmen,
• wobei in Schritt c) der Hohlraum zwischen Türblattrahmen, Deckplatten und Isolierglasscheibenanordnung gebildet wird.

It is preferred that step a) comprises:

• Attaching the cover plates to a door leaf frame,
• wherein in step c) the cavity between the door leaf frame, cover plates and insulating glass pane assembly is formed.

Preferably, the door leaf frame is made of frame spars made of fiber-reinforced composite material, in particular of glass fiber reinforced or carbon fiber reinforced plastic material (GRP or CFRP).

Preferably, the frame spars are made by pultrusion technique, with the fibers having the plastic matrix injected through a spray mask to form predetermined profile shapes. It is thus an individual profile design easily possible.

Preferably, the frame spars are produced as hollow chamber profiles with one or more hollow chambers in the interior of the frame profile.

More preferably, at least one of the hollow chambers is filled with foam in step d).

• einen Türblattkörper, dessen Breitseiten durch Deckplatten gebildet wird,
• eine Isoliermaterialschicht, die zwischen den Deckplatten eingebettet ist und
• einer Isolierglasscheibenanordnung, die im Bereich wenigstens einer Fensterausnehmung in wenigstens einer der Deckplatten angeordnet ist,
• wobei die Isoliermaterialschicht aus einem Schaummaterial durch Ausschäumen eines Hohlraums zwischen den Deckplatten gebildet ist,
• wobei die Isolierglasscheibenanordnung mit in das Schaummaterial eingeschäumt ist, wobei die Deckplatten aus Metallblech gebildet sind und wobei ein Klebemittel zwischen einem Randbereich einer der Deckplatten und der Isolierglasscheibenanordnung als Abdichtung vorgesehen ist, wobei ein Dichtband zwischen dem Klebemittel und der Fensterausnehmung für einen Toleranzausgleich zwischen dem Randbereich und der Isolierglasscheibenanordnung eingefügt ist.

According to a further aspect, the invention provides a building door leaf, in particular front door leaf, for a front door to be used as the outer closure of a building, the building door leaf comprising:

• a door leaf body whose broad sides are formed by cover plates,
• an insulating material layer embedded between the cover plates and
• an insulating glass pane arrangement which is arranged in the region of at least one window recess in at least one of the cover plates,
• wherein the insulating material layer is formed of a foam material by foaming a cavity between the cover plates,
• wherein the insulating glass pane assembly is foamed into the foam material, wherein the cover plates are formed of sheet metal and wherein an adhesive is provided between an edge region of the cover plates and the insulating glass pane assembly as a seal, wherein a sealing tape between the adhesive and the window recess for a tolerance compensation between the edge region and the insulating glass pane assembly is inserted.

It is preferred that the foam material surrounding the insulating glass pane assembly framing around the window recess.

It is preferred that the foam material surrounds an edge of the insulating glass pane arrangement in the thickness direction of the door leaf body.

It is preferred that the foam material directly contact a glass material of the insulating glass pane assembly and / or an edge skirt of the unitary insulating glass pane assembly.

It is preferable that the insulating glass pane assembly is a device constructed as a unit.

• ein Mehrscheiben-Isolierglas,
• ein Sonnenschutzglas,
• ein Klimaschutzglas,
• ein Einbruchschutzglas,
• ein Schallschutzglas,
• ein Vakuumisolierglas und/oder
• ein Verbundscheibenglas.

It is preferred that the insulating glass pane assembly is selected from a group of components comprising:

• a multi-pane insulating glass,
• a solar control glass,
• a climate protection glass,
• a burglary protection glass,
• a soundproof glass,
• a vacuum insulating glass and / or
• a laminated glass.

It is preferred that the door leaf body comprises a door leaf frame, the frame spars forming the end faces of the Haustürblatt, the cover plates are mounted on the door leaf frame resting thereon.

It is preferred that the frame spars are at least partially formed of fiber-reinforced composite material, in particular of glass fiber or carbon fiber reinforced plastic.

In the prior art, therefore, the procedure has hitherto always been to first create a sandwich structure which is then milled out according to the desired window cut-out shape, with at least 1 cm of air remaining around the glazing unit. The glazing unit was then retrofitted and subsequently fixed with fasteners.

Often, cavities were created around the glazing unit, or cold spots caused by the fastening elements.

According to the invention, the procedure is such that the glazing element is first inserted, even before the cavity is filled between the cover plates, and then foaming takes place with inserted glazing element, so that the glazing element is foamed with.

This has several advantages.

A significant advantage is that the foam of the insulating material extends all the way to the glazing unit.

It can be used, for example, insulating glass pane arrangements that provide appropriate thermal insulation. For example, a multi-pane insulating glass (MIG), a thermal insulation glazing or an insulating glazing is used here. The multiple insulating glass pane arrangement has e.g. at least two glass sheets and is a composite component. Between the discs is a cavity, e.g. is hermetically sealed and the thermal insulation is used.

One can here for example use an insulating glazing, which is an independent system that does not require a surrounding frame to function. This is achieved, e.g. by means of a marginal composite, which holds the individual glass sheets at a distance and at the same time hermetically seals the space between the panes. In the space between the panes is e.g. Air or a specific heat-insulating gas, e.g. the noble gas argon. But there are also glazing units in which the interior is evacuated, which provides even better thermal insulation. For example, is provided between the discs a spacer which hermetically sealed the discs by means of sealant and adhesive with each other at a distance from each other.

These insulating glass pane assemblies on the market can be manufactured in different shapes and designs and with different patterns and used as glazing elements in the door leaf bodies.

In the method according to the invention, an insulating glass pane arrangement is now inserted into the door leaf hollow body, so that the insulating glass pane arrangement together with the cover plates forms a door leaf cavity, which is then foamed up. As a result, the insulating glass pane arrangement is foamed with.

The insulating glass pane assembly is thus fixed by the foam material and fits perfectly into the door leaf body. There is no longer any remaining cavity around the insulating glass pane assembly, as was the case earlier. Subsequent sealing measures or fastening measures are eliminated.

In addition, this has the advantage that both cover plates can have a window opening which is smaller than the outer contour of the insulating glazing. The edge area of the window openings in the cover plates can thus rest on both sides on the insulating glazing. It is not anymore necessary to subsequently add additional frame elements to border the glazing edge. Of course, it is still possible to provide additional edge borders for design reasons; but this is not necessary for technical reasons.

It can also be provided that the foaming surrounds all edges of the glazing unit in all directions. Thus, the glazing unit is optimally embedded, the edge is protected by the foam material. Cold bridges are avoided.

In addition, the burglary protection is increased because there are no more points of attack in the area of the edge of the glazing.

Fig. 1

eine perspektivische Ansicht einer Haustür mit Zarge und einer ersten Ausführungsform eines Haustür-Türblatts in Außenansicht und Innenansicht;

Fig. 2

eine Außenansicht auf eine zweite Ausführungsform einer Haustür mit Zarge und einer zweiten Ausführungsform eines Haustür-Türblatts;

Fig. 3

eine dritte Außenansicht einer Ausführungsform einer Haustür mit Zarge und darin angelenktem Haustür-Türblatt gemäß einer dritten Ausführungsform des Türblatts;

Fig. 4

eine Außenansicht einer vierten Ausführungsform der Haustür mit einer vierten Ausführungsform des Haustür-Türblatts;

Fig. 5

eine Querschnittsansicht einer Randeinfassung einer Verglasung in einem der Haustürblätter gemäß den Fig. 1 bis 4 anhand eines beispielhaften Schnittes entlang einer der Linien Va bis Vd von Fig. 3 oder Vf in Fig. 2 oder Ve) in Fig. 3 in einer grundsätzlichen Ausführungsform des Haustür-Türblatts;

Fig. 6

eine Darstellung vergleichbar der Fig. 5 in einer weiteren grundsätzlichen Ausführungsform des Haustür-Türblatts;

Fig. 7

einen Schnitt entlang der Linie VII-VII durch die Haustüren der Fig. 1 bis 4 im Bereich eines Schlosses zur beispielhaften Darlegung des Aufbaus eines Türblattrahmens;

Fig. 8

eine schematische, perspektivische Ansicht eines Türblattrahmens mit einer Deckplatte zur Illustration eines Herstellschritts bei dem Verfahren zum Herstellen der Türblätter gemäß den Fig. 1 bis 4;

Fig. 9

eine perspektivische Explosionsdarstellung einer Vorform des Türblattkörpers im Rahmen der Herstellung mit Türblattrahmen, Deckplatten und darin eingesetztem Verglasungselement;

Fig. 10

eine schematische Draufsicht auf einen Türblattkörper während eines Ausschäumvorganges zur Darstellung eines weiteren Schritts des Herstellverfahrens;

Fig. 11

eine Innenansicht auf eine innere Breitseite einer Haustür gemäß einer Ausführungsform der Erfindung;

Fig. 12

eine Außenansicht auf eine Außenbreitseite der Haustür von Fig. 11;

Fig. 13

einen Schnitt durch die Haustür gemäß der Linie III-III von Fig. 11;

Fig. 14

einen Schnitt durch die Haustür gemäß der Linie IV-IV von Fig. 11; und

Fig. 15

ein vergrößertes Detail des Schlossbereichs aus der Darstellung von Fig. 13.

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

Fig. 1

a perspective view of a front door with frame and a first embodiment of a front door-door leaf in exterior view and interior view;

Fig. 2

an external view of a second embodiment of a front door with frame and a second embodiment of a front door door leaf;

Fig. 3

a third external view of an embodiment of a front door with frame and hinged front door door leaf according to a third embodiment of the door panel;

Fig. 4

an external view of a fourth embodiment of the front door with a fourth embodiment of the front door door leaf;

Fig. 5

a cross-sectional view of a border of a glazing in one of the front door leaves according to the Fig. 1 to 4 with reference to an exemplary section along one of the lines Va to Vd of Fig. 3 or Vf in Fig. 2 or Ve) in Fig. 3 in a basic embodiment of the front door panel;

Fig. 6

a representation comparable to Fig. 5 in another basic embodiment of the front door panel;

Fig. 7

a section along the line VII-VII through the front doors of Fig. 1 to 4 in the area of a lock for exemplifying the structure of a door leaf frame;

Fig. 8

a schematic perspective view of a door leaf frame with a cover plate for illustrating a manufacturing step in the method for producing the door panels according to the Fig. 1 to 4 ;

Fig. 9

an exploded perspective view of a preform of the door leaf body in the context of production with door leaf frame, cover plates and glazing element inserted therein;

Fig. 10

a schematic plan view of a door leaf body during a foaming process to illustrate a further step of the manufacturing process;

Fig. 11

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

Fig. 12

an exterior view on an outside of the front door of Fig. 11 ;

Fig. 13

a section through the front door according to the line III-III of Fig. 11 ;

Fig. 14

a section through the front door according to the line IV-IV of Fig. 11 ; and

Fig. 15

an enlarged detail of the lock area from the representation of Fig. 13 ,

The Fig. 1 to 4 show four different embodiments of house doors 10 as an example of building doors. The front doors 10 each have a trained for stationary mounting in a building door frame - hereinafter referred to as frame 12 - and one on the frame 12 via hinges or hinges 14 rotatably held door 16. Each door 16 is in the different embodiments of the front door 10 according to the Fig. 1 to 4 by differently designed door-door leaves - hereinafter simply called door leaves 18 - formed, which form examples of building door leaves.

The door leaves 18 each have a door leaf body 20 which is provided with at least one window recess 22 in or on which a glazing element 24 is located.

The Fig. 1 to 4 show different motifs for the door leaves 18 with different design variants, in particular, the window recesses 22 are designed differently in number or shape.

As in Fig. 1 illustrated, the door leaf body 20 cover plates 26, which form the broad sides of the door panel 18. A first cover plate 26 is formed by a motif plate 28 to be mounted on the outside, which forms the outside broad side 30 of the door leaf 18. A second cover plate 26 is formed by a cover plate 32, which forms an inside broad side 34. In addition, a plurality of motif elements 36 such as frame surrounds 38, panels 40 or covers 42 may be applied to one or both panels 26, 28, 32.

The plates 26, 28, 32 are formed of metal, in particular aluminum sheet, and are provided with an optically high-quality surface finish, such as e.g. Paint, provided. Although white is shown here as an example, different colors - even color combinations - can be applied.

It is thus out of the Fig. 1 to 4 Clear that a wide variety of different designs for the door panel 18 is possible.

The following is based on the FIGS. 5 and 6 explained in more detail how the glazing elements 24 are introduced into the door leaf body 20.

The FIGS. 5 and 6 show sections through two embodiments of the door leaf 18, which differ substantially by the thickness of the door leaf 18, wherein the in Fig. 5 shown thicker variant provides greater thermal insulation than that in Fig. 6 shown slightly thinner variant.

The FIGS. 5 and 6 show by way of example a section as it is present at each edge of the glazing element 24. Accordingly, the section of the FIGS. 5 and 6 each of the sections Va, Vb, Vc and Vd of Fig. 3 , the section Ve of Fig. 4 , the section Vf and the section Vg of Fig. 2 represent.

Like from the FIGS. 5 and 6 As can be seen, the door leaf body 20, the two cover plates 26 and an insulating material or 44 between them. The insulating material 44 is formed by a foaming 46, for example made of polyurethane.

As a result, a sandwich structure is formed on the door leaf body 20 between the cover plates 26, 28, 32.

The glazing element 24 is formed by an insulating glass sheath assembly 48 having a plurality of glass sheets 50. For example, between two outer glass panes 52, 54 at least a first intermediate glass pane 56 or a first intermediate glass pane 56 and a second intermediate glass pane 58 is inserted.

Between the glass sheets 50 spacers 60 are provided, which connect the glass sheets 50 with distance from each other and hermetically sealed interior 61 therebetween.

Such insulating glass pane assemblies 48 are available as a multi-pane insulating glass. Such multi-pane insulating glass is also referred to as insulating or glazing. This is a composite of at least two glass panes component. Between the discs is a cavity, e.g. is hermetically sealed and the thermal insulation is used.

Additional functions may be present so that the insulating glass pane assembly 48 also serves as a solar control glass, privacy glass, anti-burglar glass, or soundproof glass.

The spacers 60 are part of a marginal composite 59, which holds the individual glass sheets at a distance and at the same time hermetically seals the space between the panes. In the space between the panes - the interior 61 - is, for example, air, or a better heat-insulating gas, such. Argon. Depending on the desired thermal insulation value of the gap can also be evacuated, so that a vacuum insulating glass is formed.

The spacers 60 are inserted between the individual glass panes 50, so that the glass panes 50 protrude slightly at the edge.

As the FIGS. 5 and 6 show, the foaming 46 now extends directly to the entire insulating glass pane assembly 48 and thus also to the glass materials of the glass pane 50 zoom.

The two outer glass panes 52, 54 are e.g. Laminated safety glass. At least one of the glass sheets 50 may be a motif glass, e.g. Ornamental glass, rolled glass, sandblasted glass.

For example, the outside glass pane 52 mounted on the outside - outer broadside 30 - is a laminated safety glass (VSG) in the thickness between 6 mm and 10 mm and preferably 8 mm; the outer glass pane 54 mounted on the inside - inside broadside 34 - is e.g. a laminated safety glass (VSG) with a thickness of 8 to 12 mm and in particular 10 mm. If burglary resistance with resistance class WK2 is to be achieved, glazing of class P4A (or higher) is required. Preferably, both outer disks 52, 54 or only the outer outer pane 52 or only the inner glass pane 54 are designed as glazing with the class of at least P4A.

How further from the FIGS. 5 and 6 the edge regions 62 of the cover plates 26, which delimit the window recess 22, for example window cutouts, in the cover plates 26, extend over the edges of the insulating glass pane arrangement 48; in other words, the insulating glass pane assembly 48 has a greater extent than the window recesses 22 in the cover plates 26, so that it is bordered on both sides by the edge regions 62.

Between the motif plate 28 and the insulating glass pane arrangement 48, a double-sided adhesive tape 17 is provided on the edge region 62 in order to connect the insulating glass pane arrangement 48 to the motif plate 28. For example, an adhesive tape of the dimension 1x25 mm is provided here, which is provided on the entire edge region 62 around the window cutout 22.

Between the edge region 62 of the end plate 32 and the insulating glass pane assembly 48, an adhesive is provided as a seal. Here, for example, a 2K adhesive 66 is provided, which rotates around the entire window recess 22 around at the edge region 62 and thus acts as a circumferential structural bonding and sealing.

In general, the edge region of the window recess 22 on each cover plate 26 is sealed to the insulating glass pane assembly with a sealing device. Possibly vents may be provided here in the course of production, which are sealed again after foaming.

In addition, a sealing tape 68 for tolerance compensation between the edge region 62 and the insulating glass pane 48 is inserted between the adhesive 66 and the window opening 22. The sealing tape 68 is, for example, a sealing tape of the dimension 3x19 mm and serves to compensate for tolerances and is formed, for example, from PE or silicone.

The spacers 60 are each made so wide that the respective outwardly facing sides of the insulating glass pane arrangement (outer surfaces of the outer glass panes 52, 54) reach close to the cover plates 26 and thus the insulating glass pane arrangement 48 with the corresponding sealing measures 64, 66, 68 the complete thickness the interior of the door leaf body 20 fills.

For example, the spacers 60 are designed as widened to 20 mm disc rim assembly. These spacers 60 or spacers are designed as a standard "warm edge", so that a Glaseinstand of about 30 mm is formed.

Thus, the door leaf body 20 is limited inside the window recess 22 through the insulating glass pane assembly 48.

Fig. 7 shows the outside boundary of the door leaf body 20 using the example of the lock side. In Fig. 7 is shown a section in the area of the castle, wherein the cut in each of the front doors 10 from the Fig. 1 to 4 can look essentially the same.

As can be seen, the door leaf body 20 at the edge region on a door leaf frame 70, which is formed by frame spars 72 to which door fittings, such as a lock 78 with multiple locking, or attack the door hinges 14.

The frame members 72 are designed as hollow profiles. For example, These hollow profiles are formed from fiber composite material. Preferably, the frame spars 72 are formed of fiber composite material in carbon look.

Each frame spar 72 has a profile wedge 80 towards the interior of the door leaf body 20 - e.g. formed as PUR hard foam wedge in the form of a profile blank, on.

The frame members 72 are therefore preferably formed of a wing profile 82, which forms the front side of the outside of the door panel 18 and offers a special look. For example, the airfoil 82 is formed of fiber reinforced composite material, such as carbon fiber reinforced or glass fiber reinforced plastic. Preferably, by the appearance of the airfoil 82 at each of the end faces of the airfoil carbon optics and a corresponding carbon structuring is provided.

Between this airfoil 82 and the cover plates 26, a layer of adhesive (eg, with the thickness of less than 1 mm, in particular 0.65 mm) is provided to the cover plates 26 formed with the example of aluminum with a thickness of about 1.5 mm with the airfoil 82 to connect.

The foaming 46 and the insulating material 44 thus formed are formed in particular by a rigid polyurethane foam, which is produced by foaming a cavity 88 within the door leaf body 20 after composition of the individual parts of the door leaf body 20. In this case, preferably also at least one inner chamber 90 of the airfoil 82 is filled with foam.

The corresponding manufacturing method will be described below with reference to Fig. 8 to 10 explained in more detail. For more details on the design of the frame members 72, the cover plates 26 and the function of the profile wedge 80 is also on the non-prepublished German patent application 10 2011 084 377.9 referenced, the contents of which are hereby incorporated by reference.

The manufacturing method for producing the door leaf 18 is such that the cover plates 26 are provided with respective window cutouts 22 (for forming the window recess and subsequently one of the cover plates 26 is connected to the door leaf frame 70, as shown in FIG Fig. 8 is shown. The connection takes place, for example, via the adhesive layer 86 Fig. 8 are still ventilation openings 92 shown in the door leaf frame 70. For example, here the motif plate 28 is first to be connected to the door leaf frame 70.

Subsequently, the insulating glass pane assembly 48 is used as a suitably manufactured and provided component and to connect at the edge with the already existing cover plate 26. For example, the edge region 62 of the motif plate 28 is provided with the two-sided adhesive tape 64 and then the insulating glass pane assembly 48 is pressed. In this construction of door leaf frame 70, the motif plate 28 and insulating glass pane assembly 48, the end plate 82 is placed, as in Fig. 9 is shown, and connected by means of the adhesive 86 with the door leaf frame 70 and by means of the 2K adhesive 66 with the insulating glass pane assembly 48. This results in the door leaf body 20 of the cavity 88. The cavity 88 is substantially up to the vent openings 92 - formed closed.

The cavity 88 surrounds the insulating glass pane assembly 48 all around, i. surrounding the window recess 22. This cavity 88 is thus limited to the broad sides 30, 34 by the cover plates 26, at the end faces 84 through the door leaf frame 70 and in the region of the window recess 22 through the insulating glass pane assembly 48.

Just before applying the second cover plate 26, as shown in FIG Fig. 9 is indicated, a foam mass 94 is entered into this resulting cavity 88, which foams after the application of the second cover plate 26.

In an alternative approach, the foam mass 94 is initiated into the cavity 88 through an opening (eg, one of the vents 92).

When foaming, the door leaf body 20 is externally held by corresponding counter-pressure plates (not shown), as is known for example in the manufacture of sandwich panels or in the production of foamed Torblattpaneelen. The ventilation openings 92 are introduced in such a way that during the foaming process of the foam mass 94, the air advantageously escapes and the foam mass is correspondingly distributed in the cavity 88, as shown in FIG Fig. 10 is shown in more detail.

As a result, the complete foaming of the insulating glass pane assembly 48, as shown in FIG Fig. 4 and 5 is shown. The foam mass 94 thus forms an insulating layer 96 of insulating material between the cover plates 26, which engages and fixes the insulating glass pane assembly 48.

A further embodiment of a front door 10, whose door leaf 214 can be produced according to the method described above, will be described below with reference to FIG Fig. 11 to 15 described.

In Fig. 11 an interior view of a front door 10 with a door frame 212 and a door leaf 214 is shown. The door leaf 214 is pivotally mounted by means of door hinges 216 on the door frame 212 inwardly. On the in Fig. 11 shown inside a door handle 218 and a rosette 220 are provided for the inner end of a lock cylinder of a door lock.

Fig. 12 shows the exterior view of the front door 10 of Fig. 11 , As can be seen, the door frame 212 on the outside covers the outer edges of the door leaf 214. On the outside, a front door handle 222 and only a rosette 224, but no door handle 218 is further provided.

In the Fig. 11 shown inner broadside 226, which remains visible within the door frame 212 in the closed state of the front door 10, is completely formed by an inner panel 228 (this is an example of the cover plate 26). In the Fig. 2 As shown within the door frame 212, the outer broad side 230 of the door panel 214 shown is completely formed by an outer panel 232 (this is an example of the motif panel 28). The outer panel 232 is designed as a motif plate 234 and has different decorative elements or glazings depending on the motif selection. The motif plate 234 in the FIGS. 11 and 12 Front door 10 shown has a glazing 236. For example, the glazing 236 is arranged centrally in the door leaf 214 as an elongated, raised rectangle. Here is a large variety of different designs with different glazing conceivable.

In the FIGS. 13 to 15 are different cuts through in the FIGS. 11 and 12 shown front door 10, wherein in Fig. 13 a horizontal section along the line III-III of Fig. 11 , in Fig. 14 a vertical section along the line IV-IV of Fig. 11 and in Fig. 15 an enlarged detail of the lock area from the representation of Fig. 13 is shown.

Like from the FIGS. 13 to 15 As can be seen, the door leaf 214 has a door leaf frame 240 and the door leaf broad sides 226, 230 forming panels 228, 232 and an insulation 238 between the panels 228, 232 on. The door leaf frame 240 is formed of a metal half shell 242 and a plastic half shell 244.

The door leaf frame 240 is composed of an upper horizontal frame rail 246, a lower horizontal frame rail 248, a lock-side vertical frame rail 250, and a belt-side vertical frame rail 252.

Each of the frame members 246, 248, 250, 252 consists of two frame half-shells, wherein a first frame member half-shell 254 is formed of a metal profile 256 and a second frame member half-shell 258 of a plastic profile 260.

The metal profile 256 is, for example, a hollow profile in the form of a tubular profile 262 made of metal, in particular light metal, such as aluminum. Aluminum alloys or the like.

The plastic profile 260 is made of suitable plastic, e.g. Polyamide, aramid or fiber-reinforced plastic materials (CFK, GRP) or the like. Preferably, the plastic profile 260 is a hollow profile in the form of a tubular profile 264th

The plastic profile 260 of the plastic half-shell 244 is preferably formed substantially U-shaped profile with two U-legs 266, 268 and a U-web 270 connecting the U-legs 266, 268.

Between the U-legs 266, 268, a transverse stiffening web 272 is provided. Between each of the U-legs 266, 268 and the U-web in each case a diagonal stiffening web 274 is provided in the corner regions.

The transverse stiffening web 272 has a rectangular profile 276 with stiffening ribs 278.

The frame spar half-shells 254, 258 have on the interior 280 facing the door leaf frame 240 inner side 280 in the door leaf cavity 282, which is formed between the panels 228, 232 and the door leaf frame 240, protruding hook formations 284.

How best Fig. 15 As can be seen, the plastic profile 260 on the door leaf cavity 282 facing inside 280 in the region of the transition between the inner U-leg 268 and the U-web 270 has an inwardly projecting projection 286. For this purpose, for example, partially formed on the inner U-leg 268 inner wall 288 of the Frame Holms on the plastic profile 260 a extending in the thickness direction wall portion 290 and an obliquely in the interior and outwardly extending wall portion 292. The U-web 270 is guided correspondingly in the region of the projection 286 beyond the extending in the thickness direction wall portion 290 inwardly and merges in the region of the projection 286 in one piece in the inclined wall portion 292.

Due to the formation of the projection 286, the outwardly directed surface 294 of the plastic profile 260 is enlarged toward the middle of the broad sides 226, 230. This outwardly directed surface 294 serves as a support surface 296 for the outer panel 232. The support surface 296 is provided with a plurality of recesses 298. For example, the recesses 298 are provided in a groove-like or bead-like manner along the longitudinal extent of the plastic profile 260. For example, three or more parallel gutter grooves are spaced apart side by side.

At the projection 286, the hook formation 284 integrally engages. The hook formation 284 has an obliquely inwardly extending portion 100 from the tip of the protrusion 286 which forms the edge between the inner wall 288 and the bearing surface 296, and is adjoined by a thickness-inwardly projecting portion 102. At the free end of the in the thickness direction inwardly projecting portion 102 a projecting back to the U-shaped main body of the plastic hollow profile Endflanschbereich 104 is provided.

Between the two frame half-shells 254 at least two positively interlocking interlocking tongue and groove connections 106 are provided. For example, the tongue and groove connections 106 are formed with dovetail-like rear handles.

For example, the plastic profile 260 at ends of extending in the thickness direction of the door panel 214 wall portions thickening 108, which engage in C-shaped groove landings 110 on the metal profile 256 positively against withdrawal pulled engage.

In the illustrated examples, the thickenings 108 are provided at the free end edges of the two U-legs 266, 268.

In order to achieve a flush transition between the frame spar half-shells 254, 258 on both end face areas, the end portions of the U-legs 266, 268 are formed in the interior of the profile in a recessed cranked, as shown in the drawings.

The structure of the metal half shell 242 or the first frame half shell 254 forming the metal profile 256 is explained in more detail below. The metal profile 256 is a tubular profile 262, which is substantially rectangular with two parallel to the broad sides extending profile walls 112, 114 and two extending substantially in the thickness direction Profile walls 116, 118 is formed. The arranged on the inside of the door panel 214, extending in the thickness direction outer profile wall 116 is wider than the inside of the door leaf frame 240 at the transition to the plastic profile 260 extending parallel to the wide side direction extending inner profile wall 114. This outer profile wall 112 is on the lock side, vertical frame spar 250, the upper horizontal frame spar 246 and the band-side vertical frame spar 252 on an end face 120 of the door leaf frame 240 and forms a Anschlagfalz 122 of the door leaf 214. Inwardly this is parallel to the broad side direction extending outer profile wall 112 via the inner wall 288 of the door leaf frame 214, so that at the edge region between the inner wall 288 and a support surface 124 forming, outwardly facing surface 126, a projection 128 is formed comparable to the projection 286 of the plastic profile 260. The hook formation 284 integrally connects to this projection 128 in the same way as in the case of the plastic profile 260 formed with an oblique region 100, in the thickness direction inwardly projecting region 102 and end flange region 104. The extending in the thickness direction inner profile wall 118 forms, together with the inner U-leg 88, the inner wall 88 of the door leaf frame 240. This extending in the thickness direction inner profile wall 118 has similar to the inner U-leg 268 extending in the thickness direction wall portion 130 and a oblique wall portion 132 for forming the approximately triangular projection 128 on.

The parallel to the broad side direction extending inner profile wall 114 is formed in the embodiment shown here is substantially flat and plate-shaped, at the two edge regions near the end face 120 of the door leaf frame 240 on the one hand and near the inner wall 288 of the door leaf frame 240 on the other hand, the C-shaped groove boundaries 110th are formed by two mutually directed hook-shaped projections 134.

The thicknesswise extending outer profile wall 116 has a C-shaped substantially rectangular depression - e.g. formed as a C-shaped profile recess 136 - to form a receiving groove for a seal or the like.

As Fig. 14 shows is in the in the Fig. 11 to 15 illustrated embodiment, the lower horizontal frame rail 248 profile of the same as the other frame members 246, 250, 252 formed. Accordingly, the lower horizontal frame rail 248 is provided with the Anschlagfalz 122. In this lower horizontal frame rail 248, a seal 138 for sealing the lower door gap 140 is provided in the recess of the C-shaped profile recess 136 formed in the thicknesswise extending outer profile wall 116.

The entire outward facing surface 126 of the outer profile wall 112 extending parallel to the broadside direction is formed as a bearing surface 124 for the inner panel 228 (the inner cover plate). The inner panel 228 is wing-covering full on this outwardly facing surface 126 of extending parallel to the widthwise direction outer profile wall 112. In the illustrated embodiment, only a few recesses 142 are provided in the support surface, which depressions 142 serve to improve a cohesive connection between the panel 228 and metal profile 256. The depressions 142 are formed, for example, as grooves or grooves extending along the metal profile.

The metal half-shell 242 has a greater extension in the thickness direction of the door leaf 214 than the plastic half-shell 244. For example, the first frame spar half-shell 254 extends over 55% to 80% of the thickness of the door leaf frame 240, and the remainder of 65% to 20, respectively % is occupied by the second frame half shell 258.

Hereinafter, the structure of the door panel 214 in the thickness direction in the region of the door leaf frame of a more concrete embodiment with reference to the representations in the Fig. 11 to 15 described in more detail. Starting from the in Fig. 12 shown outside in the thickness direction towards the in Fig. 11 shown inside the construction of the door leaf 214 begins 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 of a plastic material, such as the plastic profile 260, for example formed as a polyamide profile (thermally insulated) , Then follows a metal profile 256, for example, formed of a light metal, in particular aluminum profile. Finally, an inner plate 154 follows, for example formed from light metal, eg aluminum alloy.

Outer sheet 150 and inner sheet 154 are examples of the design of the cover plates 26, 28 or panels 228, 232. The panels 228, 232 lie directly on the door leaf frame 240, so that between the panels 228, 232 and the door leaf frame 240 at best Adhesive is located.

Such a construction of the door panel 214 is comparable to the quality of the door leaf construction, as shown 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 FIGS. 13 to 15 an exemplary structure of the entire front door 10 explained in detail.

As in the Figures 13 . 14 and 15 shown, the door frame 212 on door frame spars 160, each of which is composed of a three-part frame composite profile 162. 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 subelement plastic insulating bars 168 - eg polyamide insulating bars - for thermal separation.

The metal inner shell 166 is provided with a stop fold 170 projecting in the direction of the door leaf 214, against which the edge region of the outer panel 232 abuts the front door 10 in the closed state. On the stop side, the frame-side Anschlagfalz 170 on a C-shaped profile receiving groove in which an outer stop seal 172 attacks. For example, the door frame 212 has a lock-side vertical door frame rail 160a, an upper horizontal door frame rail 160b and a door hinge-side vertical door frame rail 160c. All three door frame spars 160a, 160b, 160c are formed of identical frame composite profiles 162 with the stop fold 170. Accordingly, the outer stop seal 172 is provided on three sides circumferentially. The outer stop seal 172 is formed of EPDM, for example.

The door leaf-side Anschlagfalz 122 is provided in the embodiment shown here on all four door leaf frame beams 246, 248, 250, 252. Analogous to the frame-side Anschlagfalz 170 and the door leaf-side Anschlagfalz 122 has a C-shaped sealing groove in which an inner stop seal 174 is housed. The inner stop seal 174 is e.g. provided on four sides circumferentially. The inner stop seal 174 is formed of EPDM, for example.

The frame members 246, 248, 250, 252 of the door leaf frame 240 have a circumferential, two-part wing composite profile 176 with an outer shell 178 as a first sub-element and an inner shell 180 as a second sub-element.

For example, the outer shell 178 is formed by the plastic half shell 244 and the inner shell 180 by the metal half shell 242. The plastic half-shell 44 is preferably a polyamide shell. The inner shell 180 is preferably an aluminum inner shell. Preferably, the inner shell 180 is formed with a "Euro-groove" (standard groove) for receiving locks with multiple locking. Such a lock 182 is particularly in Fig. 15 indicated, wherein the lock 182 has an operable by the door handle 218 snap 184 and a multiple lock (not shown).

In a particularly preferred embodiment, the door panel 214 for forming the outer panel 232 or the outer cover plate, the outer panel 150, for example in the form of an outer light metal cover plate. The outer panel 150 has in particular 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, wherein edge areas and outer edges are provided with a Randbepulverung. The outer panel 150 forms the motif plate 234, 28 and can thus be provided with a large number of different motifs. Depending on the subject, motif-dependent cutouts 186 may be provided for motif glasses 188.

In a particularly preferred embodiment, the door panel 214 for forming the inner panel 228 or the inner cover panel 26 comprises the inner panel 154, e.g. as an inner light metal cover sheet, preferably of aluminum materials, e.g. Alloys or the like is formed. 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 is powder-coated. For this purpose, edge regions and marginal edges are preferably also provided with edge powdering. The inner panel 154 forming the inner broad side 226 can also be provided with different motifs, wherein cutouts 186 are preferably oriented on the motifs of the outer panel 150 in order to accommodate the corresponding motif glasses 188. The cover plates - outer panel 150 and inner panel 154 - are glued in a particularly preferred embodiment with the door leaf frame 240. For this purpose, a circumferential, permanently elastic cover plate bonding 190 is preferably provided. The cover plate bond 190 is e.g. formed 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 282 is particularly provided between the door leaf frame 240 and the panels 228, 232 with a foam filling 192. This foam filling 192 serves as insulation 238. Preferably, the foam filling 192 is filled in as a PUR foam filling. The door leaf 214 is preferably foamed in the factory; this is in contrast to conventional door-to-door fabrication where the insulation 238 is provided by attaching a sandwich panel. The lock 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 lock 182, an electric door opener 185, for example with a stainless steel strike plate, is preferably provided on the door frame 212.

As the motif glass 188 is preferably an insulating glass 194 (eg triple insulating glass) with a thickness of the door panel 214 substantially corresponding thickness used. In particular, the thickness of the insulating glass 194 is equal to the thickness of the door leaf frame 240. The edge on the inner broad side 226 (warm edge) is preferably foamed on all sides.

The edge region of the cutouts 186 in both panels 228, 232 preferably rests on the outside edges of the glazing 236. Between the outer panel 232 and the insulating glass 194, a cover tape 196 is provided. The cover tape consists e.g. double-sided acrylic pressure-sensitive adhesive tape (e.g., 2 x 20 mm), preferably with foam backing. Alternatively, an adhesive may also be employed here, e.g. 2-component MS polymer adhesive.

On the inside, a sealing device 198 is provided between the inner panel 228 and the insulating glass 194. The sealing device 198 has a permanently elastic adhesive (for example 2-component MS polymer adhesive) and an adhesive sealing tape (for example single-sided sealing tape, for example 3 × 10 mm) for internal sealing to the adhesive and for tolerance compensation during the foaming process. The sealing strip is used in particular for tolerance compensation during on-size pressing.

The hinges 216 shown in the illustrated embodiment of the front door 10 may be, for example screw-on hinges 200, as they are available in the market of 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 Fig. 14 the formation of the threshold area of the front door 10 explained in more detail. In the threshold area, a one-piece plastic floor sill 302, in particular made of polyamide, is preferably provided in the floor. On the vertical door frame beams 160a, 160c is in the threshold area as shown in FIG Fig. 13 on the hinge-side door frame spar 160c is indicated by dashed lines, a plastic threshold receptacle 304, for example made of polyamide, eg with brush seal and with stop contour for the wing-side seal 138, is provided. The seal 138 on the door leaf 214 extends as shown in FIG Fig. 14 is shown, along the entire lower door gap 140 and laterally by a certain distance, for example between 50 mm and 100 mm, preferably about 80 mm, along the vertical frame rails 50, 52 led up to an extension 308 of the base seal 306th to build. The side-raised portions of the seal 138 abut against the plastic threshold receptacle 304. This plastic threshold receptacle 304 is guided along the vertical door frame spars 160a, 160c at a corresponding height upwards. The seal 138 is preferably designed as an EPDM molded part. This seal 138 is in abutment against the bottom sill 302 and the threshold receptacle 304 as protection against backwater. Thus, the seal 138 has a base seal 306 along the lower door gap 140 and lateral extensions 308 of the base seal 306 at the lower wing corners, eg formed as moldings, more particularly as EPDM moldings, for protection against backwater. The bottom threshold 302 can be screwed with a plurality of screws 310 to a variably positionable system profile 312 as Bodeneinstand. For this purpose, the bottom threshold 302 has a screw 314 in which the screw heads of the screws 310 are received. In This screw 314 is a threshold seal 316 is provided to cover. The variably positionable system profile 312 has, for example, piping supports for common sealing film connections. The system profile 312 is screwed to the door frame 212 with fastening angles, eg steel angles (not shown).

Optionally, a reinforcing metal profile 318, such as a steel square tube (e.g., 30 x 30 x 1.5 mm), may be provided to reinforce the system profile 312.

The following is the preparation of the in the FIGS. 11 to 15 shown door 10 described in more detail.

First, the production of the door frame 212 will be 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 e.g. 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 webs 168 are rolled into corresponding receptacles of the metal outer shell 164 and the metal inner shell 166.

The finished frame composite profiles 162 thus produced for forming the door frame spars 160 are mitred. The connection between the door frame spars 160a, 160b, 160c is made by means of corner angles (not shown), e.g. using light metal corner angles. In this case, corner angles engage both between the outer shells 164 and between the inner shells 166. Preferably, the corner angles are pressed and glued.

In the following, the manufacture of the front door leaf, i. the door leaf 214, explained in more detail. The door leaf frame 240 consists of a circumferential two-part composite profile with a metal half-shell 242 as the inner shell 180 and a plastic half-shell 244 as the outer shell 178. Preferably, an aluminum inner shell 180 is provided. The term "aluminum" is here as an example representative of all suitable metals, in particular light metals. Further preferably, a polyamide outer shell 178 is provided. 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 Rahmenholmschalen 254, 258 is analogous to the frame connection. Also, the wing composite profiles 176 are cut mitred, finished and on one 4-fold corner joint machine connected. 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 242. The corner angles (not shown) are pressed mechanically - fixation - and additionally with an adhesive, in particular 2-component polyurethane Adhesive, glued. After curing, the final stability results. Optionally, the plastic half-shell 244 can be reinforced with additional corner angles, preferably plastic corner angles. The thus fixed door leaf frame 240 can be further processed immediately and prepared for the foaming process.

In a next step, the merging and bonding of the door leaf frame 240 takes place with the previously cut, milled and powder-coated (including edge powder) cover plates-panels 228, 232 or cover plates-as well as the motif glasses 188.

Preferably, the outer panel 232 is initially below, the adhesives are machine-controlled, for example, CNC-controlled, applied. For this purpose, the adhesive beads are synchronized with the peripheral grooves forming the recesses 298, 142 on both bearing surfaces 296, 194 (e.g., three grooves on the outside and three grooves on the inside).

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

For the foaming process, the panels 228, 232 are fixed on each side. For this purpose, at least two strips of 2-component polyurethane-based adhesive are applied centrally on each side to the outer edges of the vertical door leaf frames - frame members 250, 252. Preferably, the strips are a few decimeters long, e.g. about 200 mm long.

Then, the cover sheet 196 is applied to the outer panel 232 and the glass sheets of the motif glass 188 are inserted. Both are done manually.

In this construction, also prepared with adhesive inner plate 154 is placed to form the inner panel 228. 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 by means of an injection opening (not shown) previously prepared in the lower region (depending on the motif) of the door leaf frame 240. The injection port becomes independent again after retraction of an injection lance locked. 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 282 of the door panel 214 and completely surrounds the motif glass insert. 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 the foam expansion, the door leaf 214 lingers for a certain period of time in the press for curing. 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, attachment of the front door handle 222 in the foam filling area by means of adhesive dowels made of light metal die-cast (aluminum die-cast). For this purpose, 150 openings are provided in the outer panel, 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 resting screw-on door hinges 300 by means of screw anchors (not shown) in the inner shell. Other than this in Fig. 13 is shown, in a particularly preferred further embodiment, the attachment not only at the extending parallel to the broadside direction outer profile wall, but also by extending parallel to the broadside direction inner profile wall 114 therethrough.

The motif glasses 188 are preferably designed as a triple glazing 236 in door leaf thickness with "warm edge" as a bordering system.

LIST OF REFERENCE NUMBERS

10

front door

12

frame

14

door hinges

16

door

18

door leaf

20

Door blade body

22

window opening

24

glazing element

26

Cover plate (example for first cover plate)

28

Motif plate (example for second cover plate)

30

Broadside outside

32

End plate

34

Broadside inside

36

motif element

38

frame mount

40

cover

42

cover

44

insulating material

46

foaming

48

Insulating glass pane arrangement

50

pane

52

Outer glass pane outside

54

Outside glass pane inside

56

first intermediate glass pane

58

second intermediate glass pane

59

edge seal

60

spacer

61

inner space

62

border area

64

two-sided adhesive tape

66

2K adhesive

68

sealing tape

70

Door Frame

72

frame spars

78

lock

80

profile wedge

82

airfoil

84

front

86

adhesive

88

cavity

90

inner chamber

92

vents

94

foam mass

96

insulation layer

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 broad side 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

Seal for lower door gap

140

lower door gap

142

deepening

150

Outer panel (example for second cover panel)

152

outer profile

154

Inner plate (example for first cover plate)

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

186

countersink

188

motif glass

190

Deckblechverklebung

192

Foam filling

194

insulating glass

196

glazing tape

198

sealing device

212

doorframe

214

door leaf

216

door hinges

218

door handles

220

rosette

222

Door handle

224

rosette

226

inside broadside

228

inner panel (example for first cover plate)

230

outer broadside

232

outer panel (example for second cover plate)

234

Motif plate (example for second cover plate)

236

glazing

238

insulation

240

Door Frame

242

Metal half shell

244

Plastic half-shell

246

Upper horizontal frame spar

248

lower horizontal frame spar

250

lock-side vertical frame spar

252

hinge-side vertical frame spar

254

first frame half shell

256

metal profile

258

second frame spar shell

260

Plastic profile

262

Pipe profile (metal)

264

Pipe profile (plastic)

266

outer U-thigh

268

inner U-thigh

270

U-web

272

Cross bracing web

274

Diagonal bracing web

276

rectangular profile

278

stiffening rib

280

inside

282

Door leaf cavity

284

hook formation

286

head Start

288

inner wall

290

extending in the thickness direction wall area

292

sloping wall area

294

outward surface

296

bearing surface

298

wells

300

Screw-on hinges

302

Plastic speed bump

304

Plastic threshold recording

306

socket seal

308

lateral extension of the base gasket

310

screw

312

system profile

314

screw

316

threshold seal

318

Reinforcing metal profile

Claims (14)

1. Method for manufacturing a building door leaf, in particular a house door door leaf (18, 214) for a house door (10) to be used as an external closure of a building, wherein the building door leaf comprises a first cover panel (26; 150) forming a first broadside, a second cover panel (26, 28, 154) forming a second broadside, and an insulating layer (96, 238, 192) between said cover panels (26, 28, 154, 150), and at least one insulating glass pane assembly (48, 194), the method comprising the steps of:

   a) manufacturing a door leaf body (20) with the aid of the cover panels (26, 28, 154, 150)

   b) providing a window recess (22) at the cover plates (26, 28, 154, 150) and

   c) arranging the insulating glass pane assembly (48, 194) in the region of the window recess (22) of the cover panels (26, 28, 154, 150) so that the insulating glass pane assembly (48, 194) and the cover panels (26, 28, 154, 150) define a cavity (88, 282) in the door leaf body (20), and

   d) foaming the cavity (88, 282) formed in step c) to thus form said insulating layer (96, 238, 192),

   characterized in that
   the cover panels (26, 28, 154, 150) are made of sheet metal (154, 150) and that the method further comprises the step:

   e) providing an adhesive (66) between a rim portion (62) of one of the cover panels (26, 28) and the insulating glass pane assembly (48) as a sealing, and inserting a sealing strip (68) between the adhesive (66) and the window recess (22) to compensate tolerances between the rim portion (62) and the insulating glass pane assembly (48).
2. Method according to claim 1,
   characterized in that steps a) through c) are performed in such a manner that the cavity (88, 282) completely surrounds and frames the insulating glass pane assembly (48, 194) and is directly defined by said insulating glass pane assembly (48, 194).
3. Method according to one of the preceding claims,
   characterized in that step d) is performed in such a manner that the foam forming the insulating layer (96, 238, 192) directly contacts glass materials of the insulating glass pane assembly (48, 194).
4. Method according to one of the preceding claims,
   characterized in that a multi-pane insulating glass (194), which is formed as a structural element made of a multi-layer pane structure, is used as an insulating glass pane assembly (48, 194).
5. Method according to one of the preceding claims,
   characterized in that
   step a) comprises:

   fixing the cover panels (26, 28, 150, 154) to a door leaf frame (70, 240),

   wherein, in step c), the cavity (88, 282) is formed between the door leaf frame (70, 240), the cover panels (26, 28, 150, 154) and the insulating glass pane assembly (48, 194).
6. Method according to claim 5,
   characterized by:
   fabricating the door leaf frame (70, 240) from frame bars (72, 160) made of a fiber-reinforced composite material and/or made of a glass fiber or carbon fiber-reinforced plastic.
7. Door leaf of a building door, in particular a house door door leaf (18, 214) of a house door (10) to be used as an external closure of a building, wherein the door leaf of the building door comprises:

   a door leaf body (20) the broadsides (30, 34; 226, 230) of which are formed by cover panels (26, 28, 228, 232),

   an insulating material layer (44, 238, 192) embedded between said cover panels (26, 28, 228, 232) and

   an insulating glass pane assembly (48, 194) disposed in the region of at least one window recess (22) in at least one of the cover panels (26, 28, 228, 232),

   wherein said insulating material layer (44, 238, 192) is formed from a foam material by foaming a cavity (88, 282) between the cover panels (26, 28, 228, 232),

   wherein said insulating glass pane assembly (48, 194) is also foamed into the foam material,

   characterized in that the cover panels (26, 28) are formed from sheet metal (150, 154) and that an adhesive (66) is provided as a sealing between a rim portion (62) of one of the cover panels (26, 28) and the insulating glass pane assembly (48), wherein a sealing strip (68) is inserted between the adhesive (66) and the window recess (22) to compensate tolerances between said rim portion (62) and said insulating glass pane assembly (48).
8. Door leaf of a building door according to claim 7,
   characterized in that the foam material surrounds and frames the insulating glass pane assembly (48, 194) around the window recess (22).
9. Door leaf of a building door according to one of the claims 7 or 8,
   characterized in that the foam material surrounds a rim of the insulating glass pane assembly (48, 194) seen in the thickness direction of the door leaf body (20).
10. Door leaf of a building door according to one of the preceding claims,
    characterized in that the foam material directly contacts a glass material of the insulating glass pane assembly (48, 194) and/or a laminated rim (59) of the insulating glass pane assembly (48, 194) formed as one unit.
11. Door leaf of a building door according to one of the preceding claims,
    characterized in that the insulating glass pane assembly (48, 194) is a structural element constructed as one unit.
12. Door leaf of a building door according to claim 11,
    characterized in that the insulating glass pane assembly (48, 194) is selected from a group of structural elements comprising:

    multi-pane insulating glass (194),

    sun protection glass,

    climate protection glass,

    burglar-resistant glass,

    noise protection glass,

    vacuum insulating glass and/or

    laminated pane glass.
13. Door leaf of a building door according to one of the preceding claims,
    characterized in that the door leaf body (20) has a door leaf frame (70, 240) the frame bars (72, 160) of which form the front faces (84, 120) of the house door leaf (18), wherein the cover panels (26, 28, 150, 154) are fixed to and supported on the door leaf frame (70, 240).
14. Door leaf of a building door according to claim 13,
    characterized in that the frame bars (72, 160) are formed from a fiber-reinforced composite material, in particular from a glass fiber and/or carbon fiber-reinforced plastic.

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