EP2581543A2 - Method for manufacturing a building door leaf, door leaf frame and door leaf - Google Patents

Abstract

The method involves forming a door cavity (50) defined by narrow front end (35) forming the side boundaries (44) and the door leaf broad sides (34,40) forming the plate elements (42). A projecting formation (58) is extended into the door cavity along the side boundary. The side surface (59) of the projecting formation is extended diagonally into the door cavity. The door cavity is filled with foam. Independent claims are included for the following: (1) a door leaf frame; and (2) a door leaf.

Description

The invention relates to a method for producing a building door leaf, in particular front door leaf, wherein a door leaf cavity is formed and this door leaf cavity is filled with foam. Furthermore, the invention also relates to a door leaf frame profile and a door leaf produced by the method.

Building doors, especially front doors, have a variety of features that they need to meet. These include technical functions such as the provision of good thermal insulation or burglar resistance as well as contributions to the visual impact of the building on which they are installed.

Special standards have been issued for the technical functions, which specify the requirements for, for example, the thermal insulation properties or the burglar-resistant properties of the front doors.

Of particular importance to the customer, however, is the design aspect, as a front door is the calling card of a building. The front door is almost always the most beautiful door on a building, in contrast to doors that are merely functional, such as fire doors on the boiler room or similar.

In order to provide a wide variety of design on front doors, front doors are often made such that a frame is provided and secured thereto or in a door panel that determines the design, such as in EP 1 568 842 B1 or EP 1 780 368 A2 described.

An effective thermal insulation according to the specified standards is the case of the sandwich plate resting on the frame by the sandwich panel itself provided. However, house doors produced in this way have the disadvantage that they are very thick and thus appear bulky. This can negatively influence the purchase decision of the customer.

Front doors in which the sandwich panel is inserted into the frame are on the one hand comparatively expensive to manufacture and must additionally have thermal insulation bridges in the frame. As a result, they are expensive to manufacture.

A method of production that results in a light-acting and well-insulated door would be the foaming of a door leaf box with heat-insulating foam material. The disadvantage here, however, that result from the pressure when foaming unsightly dents and bulges in the door leaf. This is not desirable for front doors, and the customer is also less willing to overlook such blemishes than, for example, invisible cellar doors. Therefore, if such a method is used, the door leaf before foaming would have to be elaborately weighted and compressed during curing of the foaming material in order to obtain a planar door leaf. This would be very expensive.

During curing also shrinks the insulation, creating a circumferential spacing to the door leaf forming elements. This also makes it difficult to obtain door leaves with absolutely flat broadsides. Especially with front doors, e.g. with gleaming surfaces, however, one would easily notice every little bump and feel like a lack of the door.

The object of the invention is to propose a method for producing a building door door leaf, which is less complicated to carry out and results in a better, in particular visually high-quality, door leaf.

This object is achieved by a method according to claim 1.

A door leaf frame profile for use in such a method as well as a door leaf obtainable by such a method are the subject of the subsidiary claims.

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

1. a) Ausbilden eines Türblatthohlraumes, der durch Schmalstirnseiten bildende Seitenberandungen und Türblattbreitseiten bildende Plattenelemente begrenzt wird, wobei in dem Türblatthohlraum an wenigstens einer der Seitenberandungen wenigstens eine sich entlang der Seitenberandung erstreckende, in den Hohlraum hineinragende, Vorsprungsausbildung ausgebildet wird, die den Plattenelementen zugewandte Seitenflächen hat, von denen sich wenigstens eine zu dem zugeordneten Plattenelement derart schräg erstreckt, dass sich der Türblatthohlraum von innen nach außen gesehen zu der Seitenberandung hin verjüngt; und
2. b) Ausschäumen des Türblatthohlraums.

A method of manufacturing a building door panel, in particular a front door panel, comprises the following steps:

1. a) forming a Türblatthohlraumes, which is bounded by narrow end side forming side edges and door leaf broad sides forming plate elements, wherein in the Türblatthohlraum at least one of the side boundaries at least one extending along the side boundary, protruding into the cavity, projection formation is formed which has the plate elements facing side surfaces of which at least one extends obliquely to the associated plate element such that the door leaf cavity tapers from the inside to the outside towards the side boundary; and
2. b) foaming the door leaf cavity.

In the method, a door leaf cavity is formed in the usual way, which is then foamed. For this purpose, side boundaries and plate elements are joined together. The cavity, which is usually substantially rectangular in the case of door leaves on the market, now projects into a projection formation. As a result, the door leaf cavity becomes narrower towards the side boundaries.

• Durch die Verjüngung des Türblatthohlraums zu den Seitenberandungen hin steht dem Dämmmaterial beim Ausschäumen weniger Raum zur Verfügung, so dass in diesem sich verjüngenden Bereich auch weniger Druck gegen die die Türblattbreitseiten bildenden Plattenelemente aufgebaut wird. Dadurch kann auch schon ohne oder mit nur geringer Beschwerung der Plattenelemente eine bessere Planität des Türblattes erreicht werden. Je nach Ausbildung ist es dabei sogar möglich, vollständig auf die Beschwerung zu verzichten, und dennoch ein planes Türblatt zu erhalten. Das Verfahren wird dadurch wesentlich vereinfacht.
• Beim Aushärten des Dämmmaterials resultiert nun durch die in den Hohlraum hineinragende Vorsprungsausbildung ein Schrumpf, der nicht mehr abrupt lokal umlaufend ist, sondern homogen und zum Mittelpunkt des Türblatthohlraums gleitend verläuft. Dadurch wird der Schrumpf verhaltener und es resultiert insgesamt ein verbessertes Türblatt.

This training has the following positive effects:

• As a result of the tapering of the door leaf cavity towards the side boundaries, the insulating material has less space available during foaming, so that less pressure is built up against the plate elements forming the door leaf broad sides in this tapering region. As a result, even without or with only slight weighting of the plate elements, a better planarity of the door leaf can be achieved. Depending on Training it is even possible to completely dispense with the weighting, and still get a flat door leaf. The process is thereby considerably simplified.
• During curing of the insulating material now resulting from the protruding into the cavity projection formation shrinkage, which is no longer abruptly locally encircling, but is homogeneous and slidably to the center of the door leaf cavity. As a result, the shrinkage is restrained and it results in an overall improved door leaf.

Preferably, the projection formation is formed with a wedge-shaped cross-section. The wedge shape (e.g., with a pointed or blunt end) is sufficient to achieve the above-mentioned. Advantages of the preferred form, since it advantageously allows a symmetrical taper of the door leaf cavity to the side edges and the shrinkage by their special shape advantageously further than other geometric shapes into the interior of the door leaf cavity.

Particularly advantageously, in step a), each of the side boundaries is provided with the projection formation on the entire inner peripheral side delimiting the door leaf cavity. If this protrusion formation is then advantageously wedge-shaped, the door leaf cavity tapers on four sides preferably symmetrically to the side boundaries and the positive effects can preferably act on both narrow sides of the door leaf.

• a1) Ausbilden der Türblattbreitseiten mittels der Plattenelemente;
• a2) Bilden der Seitenberandungen durch Bereitstellen eines Türblattrahmens mit wenigstens einem auf der inneren Umfangsseite mit der Vorsprungsausbildung versehenen Rahmenprofil; und
• a3) Zusammenfügen des Türblattrahmens mit den Plattenelementen.

It is preferred that step a) comprises the following steps:

• a1) forming the door leaf broad sides by means of the plate elements;
• a2) forming the side boundaries by providing a door leaf frame having at least one frame profile provided with the projection formation on the inner peripheral side; and
• a3) joining the door leaf frame with the plate elements.

Particularly preferably, in step a2), the frame profile is composed of a door leaf frame profile bar and a spline profile. Thus, on Door leaf frame profile bar preferred additional work to be performed, such as the insertion of cabling for example, a power supply of electronic components on the door leaf, and then the wedge profile are placed as a preferred closure.

Preferably, the frame profile is provided at the parallel to the door leaf broadside broadsides with a disc holder. Thus, the attachment of the plate elements to form the door leaf is preferably particularly simplified.

More preferably, the frame profile is provided at the corner regions between the broad side and the inner peripheral side with an inclined surface. The inclined surface can then advantageously form the projection formation.

Vent openings are preferably provided on the inclined surface and a cavity is preferably formed in the frame profile, so that it is particularly preferably possible to vent it during foaming through the vent openings and the hollow space. It then advantageously no additional vents, for example, in the insulating material, are provided.

Particularly preferably, the wedge profile is secured flush with inclined surfaces on both sides of the door leaf frame profile bar. In a particularly preferred embodiment, the inclined surfaces of the spline are aligned flush with the inclined surfaces of the frame profile, so that advantageously a seamless transition between the individual parts of the frame profile can be created.

In an advantageous embodiment, the wedge profile and the door leaf frame profile bar are fastened by means of a self-centering projection-recess formation form-fitting together. Thus, the joining of the two elements is advantageous particularly easy, because by the self-centering can preferably be dispensed with readjustment of the assembled elements.

Particularly preferably, the frame profiles are made of fiber-reinforced plastic. Plastic has the advantage over the commonly used aluminum profiles that it is poorly heat-conducting. Thus, the formation of the frame profiles made of plastic contributes overall to a poor heat transfer between the plate elements and thus advantageously to a good thermal insulation. Fiber-reinforced plastic is a material that consists of reinforcing fibers and a plastic matrix. The fibers may for example be glass fibers or carbon fibers, but there are also other types of fibers known. The reinforcing fibers are characterized in that they have high specific strengths and stiffnesses, which can be adjusted together with the surrounding plastic matrix with respect to their mechanical and thermal properties to the desired parameters. Fiber-reinforced plastic materials have a very high strength and can be adapted to the particular needs particularly well.

Advantageously, the plate elements are formed of metal.

Particularly preferably, the wedge profile is formed on the basis of polyurethane. Since more often the door leaf cavity is foamed with an insulating material with polyurethane foam, so a particularly advantageous interaction between the spline and the insulating material can be achieved, which contributes to improved door leaf stability.

In an advantageous application, a door leaf frame profile is used in the described method, which has a door leaf frame section bar and a spline.

A door leaf, in particular a front door leaf, is preferably obtainable by the method described above.

Fig. 1

einen Horizontalschnitt durch eine Tür mit einem Gebäudetür-Türblatt und einer Türzarge.

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

Fig. 1

a horizontal section through a door with a building door door leaf and a door frame.

Fig. 1 shows a horizontal section through a building door 10 in the form of an outer door, in particular a front door, with a building door leaf 12, in particular a front door leaf, and a door frame 14th

The door frame 14 has a first and a second door frame profile 16, 18, which are connected to each other via webs 20 of heat-insulating material.

The first door frame profile 16 is designed as a stop region 22 for a folding region 24 of the building door leaf 12. Furthermore, the first door frame profile 16 has an abutment 26 for a catch 28 arranged in the building door leaf 12.

The second door frame profile 18 has a holding device 30 for a seal 32, against which, when the door is closed, a first door leaf broad side 34 of the building door leaf 12 strikes.

The web 20 directed toward the building door leaf 12 has a further abutment region 22 for a narrow end side 35 of the building door leaf 12.

Due to the special design of the door frame 14, the building door leaf 12 strikes the door frame 14 at three locations. Because seals 32 are arranged on these stop regions 22, a particularly good thermal separation is provided between a warm inner side 36 and a colder outer side 38 of the building door 10. In addition, relatively thick door leaves with high thermal insulation can be very narrow, with tight door gaps, insert in the frame, without causing it to tilt when opening and closing.

The building of the building door-door leaf 12 is in Fig. 1 shown only in the region of a narrow end face 35. The opposite narrow end face 35 with the door frame 14 is formed substantially mirror-symmetrically thereto.

The building door leaf 12 has the first door leaf broad side 34 and a second door leaf broad side 40, both of which are provided by metal plate members 42.

Next, the building door leaf 12 has a narrow end face 35 forming side boundary 44, which is formed by a door leaf frame 46 which is formed from a frame section 48 made of fiber reinforced plastic 49.

The door leaf broad sides 34, 40 and the side boundary 44 together form a door leaf cavity 50. The door leaf cavity 50 is foamed with an insulating material 52 based on polyurethane.

The frame profile 48 is composed of a door leaf frame profile bar 54 and a spline 56 which together form a projection formation 58 which projects into the door leaf cavity 50 by extending side surfaces 59 of the projection formation 58 obliquely into the door leaf cavity 50.

By projecting the projection formation 58, taper regions 60 are formed in the door leaf cavity 50, in which the door leaf cavity 50 tapers from the inside to the outside. During foaming with the insulating material 52, less damping material 52 passes into these tapering regions 60 than into the non-tapered region of the door leaf cavity 50, so that a smaller pressure is built up by the insulating material 52 onto the plate elements 42 in the tapering regions 60.

The spline 56 is disposed on the inner peripheral side 57 of the door leaf frame section bar 54.

The door leaf frame profile bar 54 has on its broad sides 61 plate receptacles 62 to which the plate members 42 are fixed, as well as corner areas 63 between the broad sides 61 and the inner peripheral side 57 inclined surfaces 64 on which flush the wedge profile 56 attaches with its inclined surfaces 66.

The spline 56 has a projection 68 which engages a recess 70 in the door leaf frame rail 54 and thus centers the spline 56. By this projection-recess formation 72, the spline 56 and the door leaf frame section bar 54 are positively secured together.

The spline 56 forms with the inclined surfaces 64 a cavity 74, are guided by the cable 76 for electronic devices (not shown) of the building door leaf 12. The inclined surfaces 64 have vent openings 78, through which gases emerging during hardening of the insulating material 52 can escape.

The door leaf frame profile bar 54 is formed of fiber reinforced plastic 49 and both the spline 56 and the insulating material 52 are formed on the basis of polyurethane 82. Thus, only door leaf elements of poorly heat-conducting materials are located between the metal plate elements 42, so that a good thermal insulation can be created by the poor heat transfer from the inside 36 to the outside 38 of the building door 10.

For this purpose, the door leaf frame profile bar 54 is additionally formed on its side facing the door frame 14 with holding devices 30 for receiving seals 32. Next, the door leaf frame profile bar 54 a Schnäpperaufnahme 84 for receiving the latch 28 and a handle receptacle 86 for attaching a door handle 88 and a rosette 90 on.

The special design of the frame profile 58, in particular by the polyurethane 82 based wedge profile 56, in conjunction with the trained in a line to the inclined surfaces 66 of the spline 56 inclined surfaces 64 of the Türblattrahmenprofilstabes 54 advantageously leads to the plate members 42 to a flat surface during foaming with the insulating material 52. In addition, the transition from the frame section 48 to the insulating material 52 is no longer abrupt, but sliding and homogeneous. As a result, the shrinkage in the polyurethane 82, which can not be prevented, no longer locally circulating in one place. By the in Fig. 1 shown geometry of the frame profile 48, the shrinkage is more restrained. A change of the building door leaf 12 during the foaming or curing of the insulating material 52 is now almost invisible to the human eye, because the shrinkage is guided by the special design of the frame profile 48 in the middle of the building door leaf 12.

Vent apertures 78 may be machine-positioned in the inclined surfaces 64. As a result, work on Dämmmaterialkern can be omitted. In addition, the inclined surfaces 64 and the resulting cavity 74 have the advantage that the cables 76 can be introduced for the power supply of any existing electronic components in the frame section 48 without additional parts or other measures are required.

LIST OF REFERENCE NUMBERS

10

building door

12

Building door door leaf

14

door frame

16

first door frame profile

18

second door frame profile

20

web

22

stop area

24

folding area

26

thrust bearing

28

Catches

30

holder

32

poetry

34

first door leaf broadside

35

Narrow front side

36

inside

38

outside

40

second door leaf broadside

42

panel members

44

Side boundary

46

Door Frame

48

frame profile

49

fiber reinforced plastic

50

Door leaf cavity

52

insulation

54

Door leaf frame profile rod

56

spline

57

inner peripheral side

58

lead training

59

side surface

60

tapering region

61

broadside

62

Record number

63

corner

64

Inclined surface (door leaf frame profile bar)

66

Inclined surface (wedge profile)

68

head Start

70

return

72

Lead-retreat training

74

cavity

76

electric wire

78

Venting breakthrough

82

polyurethane

84

Schnäpperaufnahme

86

handle seat

88

door handle

90

rosette

Claims (15)

Method for producing a building door panel (12), in particular a front door door leaf, with a) forming a door leaf cavity (50) delimited by narrow side end walls (35) forming side boundaries (44) and door leaf broad sides (34, 40) forming plate elements (42), wherein in the door leaf cavity (50) at least one of the side boundaries (44) at least one projection formation (58) extending along the side boundary (44) and projecting into the door leaf cavity (50) is provided which has side surfaces (59) facing the plate elements (42), at least one of which faces the associated plate element (42 ) extends obliquely so that the door leaf cavity (50), seen from the inside outwards, tapers towards the side boundary (44); and b) foaming the door leaf cavity (50). Method according to claim 1,
characterized in that the projection formation (58) is formed with a wedge-shaped cross section. Method according to one of the preceding claims,
characterized,
that (in their entirety to the door leaf bounding the cavity 50) inner peripheral side (57) is provided with the projection forming (58) in step a) each of the side boundaries (44). Method according to one of the preceding claims,
characterized,
that step a) the steps a1) forming the door leaf broad sides (34, 40) by means of the plate elements (42); a2) forming the side boundaries (44) by providing a door leaf frame (46) having at least one frame profile (48) provided on the inner peripheral side (57) with the projection formation (58); and a3) comprises joining the door leaf frame (46) with the plate elements (42). Method according to claim 4,
characterized in that in step a2) the frame profile (48) is composed of a door leaf frame profile bar (54) and a spline (56). Method according to claim 4 or 5,
characterized in that the frame profile (48) on the parallel to the door leaf broad side (34, 40) to be arranged broadsides (61) with a plate receptacle (62) and at the corner regions (63) between the broad side (61) and the inner peripheral side (57) is provided with an inclined surface (64). Method according to claim 6,
characterized in that on the inclined surface (64) ventilation openings (78) are provided and that is vented during foaming through the vent openings (78) and in the frame profile (48) formed cavity (74). Method according to one of claims 5 to 7,
characterized,
that the wedge profile (56) with inclined surfaces (66) is aligned flush on both sides attached to the door leaf frame profile rod (54). Method according to one of claims 5 to 8,
characterized,
in that the wedge profile (56) and the door leaf frame profile bar (54) are fastened to one another in a form-fitting manner by means of a self-centering projection-recess formation (72). Method according to one of claims 4 to 9,
characterized in that the frame profiles (48) are formed of fiber reinforced plastic (49). Method according to one of the preceding claims,
characterized,
in that the plate elements (42) are formed from metal. Method according to one of claims 5 to 11,
characterized,
that the wedge profile (56) is formed on the based on polyurethane (82). Method according to one of the preceding claims,
characterized in that the door leaf cavity (50) is foamed with an insulating material (52) with polyurethane foam. Door leaf frame profile for use in a method according to any one of the preceding claims,
with a door leaf frame profile bar (54) and a spline (56). Door leaf, in particular front door door leaf,
obtainable by a method according to one of claims 1 to 13.

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