EP4237648A1

EP4237648A1 - Door leaf with metal box profile

Info

Publication number: EP4237648A1
Application number: EP22710768.7A
Authority: EP
Inventors: Tomo PEKLENIK
Original assignee: Pirnar Trzenje Proizvodnja In Razvoj d o o
Current assignee: Pirnar Trzenje Proizvodnja In Razvoj d o o
Priority date: 2022-01-14
Filing date: 2022-01-14
Publication date: 2023-09-06
Also published as: WO2023136782A1

Abstract

Door leaf with metal box profile solves problem of insufficient resilience of the door leaf on one side, as well as manufacturing issues by constructing the door leaf frame of metal box profile onto which two plastic essentially U profiles are attached either with shared U-leg or two different U-legs.

Description

DOOR LEAF WITH METAL BOX PROFILE

Field of technology

Building and construction; doors; door frames; door leaf.

Technical problem

Technical problem addressed in these specifications is insufficient resilience of the door leaf on one side, as well as manufacturing issues.

State of the Art

EPO 125462 describes the composite profiles from which the frames of a window or door are made or which are used to build a facade consist of a profile rail made of plastic and a profile rail made of metal. When the composite profile is used to build a window or a door frame, the profile rails made of metal face the inside of the room, while the profile rail made of plastic forms the outer shell. The profile rail made of plastic is provided with anchoring webs, which engage with their free longitudinal edges in grooves of the profile rail made of metal. The anchoring webs are fixed in the grooves by molding the outer groove webs and / or the inner groove webs onto the anchoring webs. The profile rails made of plastic are designed with an angular cross section and have outer legs that, in the case of a window or door, stop webs or Form glass retaining strips. The connecting fittings between the sash and the frame and the anchoring fittings for the frame are only attached to the metal profile rails.

EP0022167 describes the door-leaf comprising an outer panel and an inner panel, a body of synthetic material, and also a peripheral frame. For rapid and inexpensive manufacture, a number of these elements are stacked into a press alternately with separation plates, and the insides of the separation plates and the frames are injected with the synthetic material intended to form the body after expansion. Closest to current specification is EP2581542. It describes the doorstep door leaf has a door leaf frame and door leaf broad sides forming panels. An isolator is arranged between the panels. The door leaf frame is formed to form a metal box profile and a plastic halfshell attached thereto. The door leaf frame is comprised of frame spars having frame spar as metal profile and plastic profile respectively.

EP 1568842 shows different manufacturing methods for known wing-covering designs. In the embodiment shown therein, the insulation and the inner panel of the sandwich panel door panel is cut out, while the motif panel is essentially left as large as the outer broad side of the door leaf, so that only the motif panel rests on the outside of the door leaf frame.

EP1918501 describes inner and outer metallic panels respectively turned towards interior and exterior of a premise, and coupled to a chassis which is formed of two parts movable with respect to each other. The movable parts are coupled together by a thermal bridge rupture unit. The rupture unit has two degrees of freedom along a plane parallel to the panels, and has a plastic profile whose one end is coupled with a guiding clearance in a housing realized on one of the movable parts. An additional part acts as an interface between the rupture unit and an aluminum frame.

Description of new invention

For purposes of these specifications metal refers to any kind of metal, for example steel, aluminum, titanium, and further, refers to metal alloys, regardless of coating or covering, and further refers to combination of metals, alloys, or combination thereof. For purposes of these specifications plastic refers to any type of artificial material such as polypropylene, polyamide, PVC, as well as their combination, and further, regardless of coating or covering.

Subject of this invention is door leaf having a door leaf frame and panels forming the door leaf broad sides and having an insulation between said panels, wherein the door leaf frame is formed of a metal essentially box profile, preferably essentially square or rectangular profile, and at least two plastic half-shells, wherein said at least two plastic half-shells are interconnected with or attached to said metal essentially box profile, wherein the first one of said panels is arranged on at least one of said at least two plastic half-shells while overlapping a major part thereof, and the second panel is arranged on the metal essentially box profile while overlapping a major part thereof, wherein both of said plastic half-shell are substantially U-profiles shaped each with at least one separate U-leg, further each with additional U-leg wherein said U-leg serves either one, or both of said at least two plastic half-shells, and a U-web interconnecting U- legs of each of said at least two plastic half-shells.

Subject of this invention is further at least two plastic half-shells (15, 16) comprised of outer U-legs (41, 42), common U-leg (49), and interconnecting U-web (50).

Subject of this invention is further at least two plastic half-shells (17, 18), the first one of which is comprised of U-legs (43, 44), and interconnecting U-web (45), and the second one of which is comprised of U-legs (46, 47), and and interconnecting U-web (48).

Subject of this invention is further insulation arranged between said panels or inside said profiles, or both.

Subject of this invention is further panel, said panel covering entire door leaf, or cover door leaf partially, the rest of door leaf comprising elements chosen from the group consisting of window, glass pane, filling, empty space. Subject of this invention is further panel, said panel made of metal, sheet metal, smooth metal, wood, simulated wood, plastic, having recesses, having protrusions, or combination thereof.

Subject of this invention is further method for manufacturing of said door leaf profile as described comprising the following steps: providing at least four door leaf frame spars, each door leaf frame spar comprised of at least three door leaf frame spar profiles,

- the first of at least three door leaf frame spar profiles is a metal essentially box profile,

- the second, and the third of at least three door leaf frame spar shells are plastic half-shells, forming each door leaf frame spar by connecting said plastic half-shells to said metal essentially box profile, attaching said door leaf frame spars to each other to form door leaf frame, attaching panels to said door leaf frame spars.

Subject of this invention is also method comprised of further step of filling in at least one profile, at least partially with insulation.

Subject of this invention is also method comprised of further step of reinforcing the corners of said door leaf frame with comer brackets of arbitrary material, preferably either metal or plastic, depending on the situation and decision of the designer.

The invention provides for doors having door leaf, said door leaf provided with side panels attached to door leaf frame. This door leaf frame is comprised of door leaf frame spars, and they are in turn comprised of at least three profiles, the first of which is metal profile of essentially box cross section and the second, and third of which are a plastic half-shells attached to said metal profile.

It is customary in state of the art that the door leaf frame is comprised of either two box profiles or two half-shells. Two box profile is problematic as they are hard to attach, or even hard to slide one onto another. Two half-shell is problematic as it is less rigid than two box profiles causing the doors to buckle under specific loads. Further, two half-shell system is problematic during manufacturing requiring sliding both half-shells one to another if tongue-and-groove attachment is provided.

The solution is to create one box profile connecting to at least two plastic half-shells.

Preferably, said plastic half-shells are attached to said metal box profile with one U-leg each, preferably having middle U-leg or middle U-legs (i.e. U-legs forming border between both said plastic half-shells) simply lean against said metal box profile. Of course, all U-legs can be attached to said metal box profile using attachment means as known in state of the art such as tongue-and-groove, snap-on, slide-in, rivets, screws, adhesive or similar attachment means.

It is advantageous to have metal box profile which may be equipped with tongues, attachment points or similar to provide for snap-on or slide-in connections between said metal box profile and said at least two plastic half-shells. Once tool for plastic moulding is created, the cost no longer depends on complexity of the plastic half-shell profiles.

On the other hand, two plastic half-shells are flexible and provide for appropriate snap- on or slide-in connection to tongues, recessions, attachment points or similar hence sliding one profile onto another is no longer necessary.

Plastic half-shells are therefore formed in such a way that each of plastic half-shell is separated from the other, or alternatively, that both of said at least two plastic half-shells share common U-leg. Thus, each of said plastic half-shells therefore form essentially U profile with two U-legs wherein at least one of U-legs attaches to said metal essentially box profile, and with reinforcing U-web interconnection between both U legs of each of said at least two plastic half-shells. Points of attachment can be continuous, or intermittent depending on connection type. It is also possible to attach all profiles one onto another with other types of attachment such as screws, rivets, adhesives or similar but snap-on attaching is preferred. Not only that, tongue-and-groove arrangement can be provided for conventional sliding the profiles one onto another if existing manufacturing facilities are to be used, and converted.

The panels can be attached to said profiles, first of said panels arranged onto said metal box profile, and second of said panels arranged onto said metal profile, said panels largely covering each of respective profiles. Form of attachment can vary from applying adhesive to using screws, rivets, welding, spot welding or other type of attachment as known in state of the art.

It is also advantageous to have said door leaf with improved insulation. The energy prices increasing, and entry into building forming more and more livable part of the living quarters it is advantageous to have inner panels at as close as temperature to other inner parts of the living quarters as possible. This can be made possible by insulating the door leaf. If the door leaf is to be comprised also of a window, only space between the panels will be insulated.

The insulation further improves the stability and the rigidity of the door leaf.

The panels can be made of plastic, metal, wood, artificial wood, or any other material suitable for dressing-up the door leaf.

The doors in question can be equipped with magnetic holder, magnetic strip or similar magnetic device in order to provide for attachment point for Christmas decorations or similar, on the inside of said panels if said panels are made of non-magnetic metal or non- metal materials.

The panels can be either smooth, or made with protrusions and depressions as to mimic naturally rough surfaces or to provide for coverings of said panels. Below, the invention is further described with help of the figures, said figures forming part of this application and describing:

Figure 1 shows partial cut view of a door showing a door frame (1), door leaf (2), panel (5), door leaf frame (9).

Figure 2 shows state of the art profile comprised of two box profiles, showing door frame (1), door leaf (2), first essentially box profile of metal (3), door glass (4), panel (5), second essentially box profile of plastic (6), panel (7).

Figure 3 shows state of the art profile comprised of two half-shells, one of metal, and one of plastic.

Figure 4 shows profiles according to this invention showing door frame (1), door leaf (2), first essentially box profile of metal (14), door glass (4), panel (5), second half-shell of plastic (15), third half-shell of plastic (16), panel (7).

Figure 5 shows profiles according to this invention showing first essentially box profile of metal (14), second half-shell of plastic (15), third half-shell of plastic (16), first U-leg of the first plastic half-shell (41) first U-leg of the second plastic half-shell (42), common U-leg of both plastic half-shells (49), interconnecting U-web (50).

Figure 6 shows profiles according to this invention showing door frame (1), door leaf (2), first essentially box profile of metal (14), door glass (4), panel (5), second half-shell of plastic (15), third half-shell of plastic (16), panel (7).

Figure 7 shows profiles according to this invention showing first essentially box profile of metal (14), second half-shell of plastic (17), third half-shell of plastic (18), first U-leg of the first plastic half-shell (43), second U-leg of the first plastic half-shell (44), interconnecting U-web (45), first U-leg of the first plastic half-shell (46), second U-leg of the first plastic half-shell (47), interconnecting U-web (48). Figure 8 shows profiles according to this invention showing door frame (1), door leaf (2), first essentially box profile of metal (14), door glass (4), panel (5), second half-shell of plastic (15), third half-shell of plastic (16), panel (7), insulation (31).

Figure 9 shows profiles according to this invention showing door frame (1), door leaf (2), first essentially box profile of metal (14), door glass (4), panel (5), second half-shell of plastic (17), third half-shell of plastic (18), panel (7), insulation (31).

Figure 10 shows profiles according to this invention showing door frame (1), door leaf (2), first essentially box profile of metal (14), door glass (4), panel (5), second half-shell of plastic (15), third half-shell of plastic (16), panel (7), insulation (31).

Figure 11 shows profiles according to this invention showing door frame (1), door leaf (2), first essentially box profile of metal (14), door glass (4), panel (5), second half-shell of plastic (17), third half-shell of plastic (18), panel (7), insulation (31).

The preferred embodiment of this invention is a door leaf (2) comprised of a door leaf frame (9), which in turn is comprised of plurality, preferably four, door leaf frame spars having at least three profiles, the first of which has essentially box profile of metal (14), and the second and the third having half-shells of plastic (15, 16, 17, 18).

There are two embodiments of this invention.

The first embodiment features both half-shells of plastic (15, 16) sharing common U-leg (48). Conceptually, this can be seen as having two half-shells of plastic (15, 16) with “inner” U-legs fused. Such arrangement provides for high rigidity in direction lateral to main door leaf direction (i.e. direction normal to said panel surface), and provides for resilient, flexible, behavior in direction of plane in which said panel surface lies. In this case both half-shells of plastic (15, 16) are essentially U-profiles comprised of “outer” U- legs (41, 42), and “inner” U-leg (49) serving both U-profiles and counted toward each of aid U-profiles leg count. In order to complete the profile, interconnecting U-web (50) is provided joining all U-legs (41,42, 49). If even more flexibility is needed, the second embodiment is used. Therein, both shells of plastic (17, 18) are separated one from another. This provides for possible relative movement of one half-shell compared to the other thus decreasing rigidity in lateral direction of door frame direction (i.e. direction normal to said panel surface) and provides for even more resilient, flexible, behavior in direction of plane in which said panel surface lies. In this case both half-shells of plastic (17, 18) are essentially two separate U-profiles, first of which is comprised of U-legs (43, 44) and interconnecting U-web (45), and the second of which is comprised of U-legs (46, 47), and interconnecting U-web (48).

Onto all door leaf frame spars panels (5, 7) are mounted forming both sides of door leaf. The panels (5, 7) are arranged on said door leaf frame spars, in particular on each profile forming part of said leaf frame spar (14, 15, 16, 17, 18). The panels (5, 7) are overlapping major part of respective essentially box profile of metal (14) and at least one of at least two half-shells of metal (15, 17).

The doors may be equipped with either panels which cover entire door leaf, or part thereof, the rest of the doors being either in form of a window, filling, empty, or any other combination.

In order to provide for better heat transfer properties, and also to improve stability, and rigidity, insulation can be injected inside said door leaf frame spars, and also in between said panels (31). The position of said insulation is not fixed, it varies according to desired door properties, and also desired increase in stability and rigidity.

Claims

PATENT CLAIMS

1. Door leaf having a door leaf frame and panels forming the door leaf broad sides and having an insulation between said panels, wherein the door leaf frame is formed of a metal essentially box profile, preferably essentially square or rectangular profile, and at least two plastic half-shells, wherein said at least two plastic half-shells are interconnected with or attached to said metal essentially box profile, wherein the first one of said panels is arranged on at least one of said at least two plastic half-shells while overlapping a major part thereof, and the second panel is arranged on the metal essentially box profile while overlapping a major part thereof, wherein both of said plastic half-shell are substantially U-profiles shaped each with at least one separate U-leg, further each with additional U-leg wherein said U-leg serves either one, or both of said at least two plastic half-shells, and a U-web interconnection between U-legs of each of said at least two plastic half-shells.

2. Door leaf according to claim 1, further comprising at least two plastic half-shells (15, 16) comprised of outer U-legs (41, 42), common U-leg (49), and interconnecting U-web (50).

3. Door leaf according to any of previous claims, further comprising at least two plastic half-shells (17, 18), the first one of which is comprised of U-legs (43, 44), and interconnecting U-web (45), and the second one of which is comprised of U- legs (46, 47), and and interconnecting U-web (48).

4. Door leaf according to any of previous claims further comprising insulation arranged between said panels or inside said profiles, or both. Door leaf according to any of previous claims, further comprising panel, said panel covering entire door leaf, or cover door leaf partially, the rest of door leaf comprising elements chosen from the group consisting of window, glass pane, filling, empty space. Door leaf according to any of previous claims, further comprising panel, said panel made of metal, sheet metal, smooth metal, wood, simulated wood, plastic, having recesses, having protrusions, or combination thereof. Method for manufacturing of door leaf according to claims 1 to 4 comprising the following steps:

- providing at least four door leaf frame spars, each door leaf frame spar comprised of at least three door leaf frame spar profiles,

- the second, and the third of at least three door leaf frame spar shells are plastic half-shells,

- forming each door leaf frame spar by connecting said plastic half-shells to said metal essentially box profile,

- attaching said door leaf frame spars to each other to form door leaf frame,

- attaching panels to said door leaf frame spars. Method for manufacturing of door leaf according to claim 7 further comprising step of filling in at least one profile, at least partially with insulation. Method for manufacturing of door leaf according to any of claims 7 to 8 further comprising step of step of reinforcing the comers of said door leaf frame with corner brackets of arbitrary material, preferably either metal or plastic, depending on the situation and decision of the designer.