FR2549521A1 - Method for the modular manufacture of joinery items, and joinery item, a door in particular, manufactured according to this method - Google Patents

Abstract

The invention principally relates to a method for the modular manufacture of a joinery item, and in particular of a door 1. The latter is constituted by a rectangular central panel 3 surrounded by a stiffening and supporting frame 2, comprising two uprights 5 and 6 and two cross-pieces 7 and 8 forming the edge pieces. The method is noteworthy in that each of the edge pieces 5, 6, 7, 8 of the joinery item 1 are made by stacking in the plane of the said central panel 3 and in directions aa' and bb' perpendicular to each of the four edge parts 5, 6, 7, 8 at least two wooden strips 10, 11, 12 ... per edge piece. According to an advantageous variant of the invention, the strips 11, 10, 12 have a length which decreases towards the centre of the door 1 such that staircase-like fittings are produced at each of the corners. The method according to the invention makes it possible to obtain joinery items (doors and windows) which are solid, non-deformable, new in style, of solid appearance and of low cost price.

Description

 The present invention is in the field of manufacture of joinery.

It mainly relates to a modular method of manufacturing the uprights and crosspieces of the frame surrounding and stiffening the frame of a carpentry, such as an interior door.

 Various processes for manufacturing doors are currently known.

 The most commonly used solution in modern construction, called an isoplane door, consists first of all in making a rectangular frame using flat rods, of small thickness, placed on the field. Inside the frame, we come to house a network, either of other very thin strips of wood, or of honeycombed cardboard. This network occupies the interior volume delimited by the frame. The whole is then covered, frame and network, on each of its two faces, with a plywood panel or a wood fiber panel a few millimeters thick.

 This type of door is of very light design, easily industrializable and, therefore, of a low cost price. In addition, it requires only a weakly resistant fixing frame because of its low weight.

 On the other hand, its alveolar character makes the isoplane doors very vulnerable to shocks. In addition, their successive handling, on construction sites, often cause numerous degradations and holes on the lateral faces during handling as well as very large rejects.

 Another defect of this honeycomb structure is to limit the possibilities of including a rectangular glass or other panel, of large surface area, inside the door. In fact, it can be seen that this type of door with a light structure is poorly resistant to torsional forces if it is pierced with a large central opening. This quickly results in curtains, deformations and a brittleness of the uprights surrounding the opening.

 Finally, the current embodiment of these doors hardly makes it possible to decorate them in an original way. They are presented in a united form, of a very monotonous aspect.

 In addition, a very old solution consists in manufacturing the doors out of solid wood; that is to say by assembling solid wood panels in broad band. However, this solution has numerous drawbacks of use; indeed, as everyone knows, wood is a living material which, under the action of humidity or temperature (overheated parts), becomes veiled, shrinks or splits. These defects are of course accentuated by the size of the wooden panels used. This is the reason why solid wood doors are generally only used for entrance doors. When they are for interior doors, they are made from very high quality wood, having undergone very thorough heat treatments (in particular steaming). Their cost price is very high.

 The object of the present invention is to globally solve these problems.

 The first object of the invention is to make it possible to considerably reduce the cost of the raw materials used in the production of doors and windows while giving the latter mechanical qualities and durability much superior to current solutions.

 Another object of the invention is to propose a process for producing such joinery which allows industrialization and very mechanized assembly and at low cost due to the great modularity of the elements used.

 The third object of the invention is to allow a widening of the standards of joinery without substantially increasing their unit cost.

 The fourth object of the invention is to allow the production of door frames whose uprights and crosspieces can be of very small section vis-à-vis the inner surface of the frame, which can thus contain a light panel such as a window without harm the rigidity and mechanical strength of the assembly.

The fifth object of the invention is to propose a sequence
- manufacturing of the components of carpentry and more
particularly of its setting
- grouped transport of its elements
- and assembly of the joinery on its place of assembly.

This allows amateur carpenters and do-it-yourselfers to transport the elements essential to the manufacture of a door in a reduced volume, in particular inside the passenger compartment of their vehicle and, subsequently, to assemble and put them in place. using rudimentary equipment and in a very limited time.

 Finally, a final object of the invention is to propose a manufacturing method which allows a wealth and a variety of almost infinite aspects in the manufacture of carpentry while using a small number of basic materials.

To this end, the invention provides a modular manufacturing process
carpentry. Which carpentry is of the type so constituted
usual of a rectangular central panel surrounded by a frame
stiffener and carrier with two uprights and two crosspieces
forming the four edge pieces of the panel.

This process is remarkable by the fact that each of the
four pieces of carpentry edge
- by stacking, in the plane of the central panel and according to the four
directions perpendicular to each of the four edge pieces
- at least two strips of wood per piece of riVe.

Admittedly, it is known in the prior art (French patent FIMA) to
realize the closing leaf of a door by juxtaposition of three oblong pieces of wood oriented in fiber directions
different.

However, it has never been suggested to extend these features to the
production in strips of each of the edge pieces of a frame
carpentry surrounding a central panel.

 In addition, the properties attached to joinery of the type described in the document cited above relate only to the increase in the resistance of the closing amount to deformation.

 Of course, the four edge parts of the frame, produced according to the invention, by stacking the strips, will have the characteristics of resistance to deformation mentioned above; but, moreover, they will have new characteristics specific to the invention.

 Thus, the invention recommends making, according to this method, frames having edge pieces of very varied widths and lengths from a single section of strips.

 In fact, according to a particularly advantageous embodiment of the invention, each of the four modular edge pieces is produced, independently of one another - by fastening their constituent slats in the factory in their final relative position.

A first manufacturing method consists in choosing the size of wooden strips constituting the edge pieces and stacking them in such a way that, once fitted at their ends, the constituent strips of the edge pieces are seated in a rectangular quarter. formed in the adjacent perpendicular edge piece. That is to say that the assembly of the slats at the right of a corner of a joinery is carried out,
according to this method, in the form of stairs whose height each step is equal to the width - of the strip of the perpendicular edge piece, seated on this step.

 Of course, preferably choose an equal number of blades for each of the edge pieces.

 Furthermore, it will impose on the constituent slats of each edge piece an increasing length equal to the sum of the previous length incremented by the width of each strip intended to fit into the rectangular quarter which it delimits.

 According to a first variant of the invention, the mounting of the chassis is carried out entirely in the factory.

 In particular, the four groups of each of the wooden strips constituting each of the edge pieces are assembled inside the plate of a framing machine in four perpendicular directions, each of the four groups being somewhat separated from the others. Then, the four groups of lamellae are brought together in the four perpendicular directions, so as to carry out the assembly.

 Preferably, the connection between two lamellae constituting each edge part is effected by an assembly of the grooves and tongues type.

 Prior to assembly, the various strips are pre-glued to allow their final relative fastening.

 However, according to another variant recommended by the invention, the chassis is produced in two stages.

 First of all, each of the four edge pieces is manufactured in the factory, independently of each other, by assembling their constituent lamellae. Furthermore, each of said edge pieces is provided with two-by-two assembly means capable of subsequently enabling them to be joined. Then these four edge pieces are assembled, notably inside the carton, in the form of a unitary oblong monolithic assembly which is easy to transport, handle and store. Finally, this assembly is routed to the place of assembly of the joinery where the frame can be formed by assembling each of the edge pieces.

 We understand that this solution is particularly suitable for the installation of carpentry by a handyman. Indeed, the edge pieces arranged in parallel, almost contiguously inside the carton, will occupy a very small volume and will therefore be easily transportable in a reduced volume.

Furthermore, as will be seen below, the chassis can be mounted
at its place of use in a few minutes using rudimentary equipment.

 Other characteristics and advantages of the invention emerge from the description which follows with reference to the appended drawings, which description and drawings being given only by way of nonlimiting examples.

On these drawings
Figure 1 shows in elevation a first alternative embodiment
according to the invention of a multi-section door, for example
assembly of tongue and groove wooden slats
Figure 2 describes a detail one of the corners of the door of Figure 1 and
especially the assembly between uprights and lower crosspieces of the door
shown in figure 1
FIGS. 3 and 5 represent in section, along A and along B,
stacking of modules constituting the uprights and crosspieces of a
door centrally fitted with a melamine panel
Figure 4 also shows a door variant of the type of
figure 1 fitted with a central glass panel
Figure 6 shows schematically another alternative embodiment according to
the invention of a door, the edge parts of which consist of a
glued laminated wood assembly;
Figures 7 and 9 represent this me carries me with a panel
melamine in section AA 'and BB'
FIG. 8 relates to a door of the same type fitted with a
lightweight glass panel
Figure 10 schematically shows a process advised by
the invention of manufacture, transport and installation, by a
amateur with little equipment, modular carpentry according to the invention
finally the figure he describes in more detail the assembly method described
figure 10.

 On board 1, FIGS. 1 to 4, the first variant of a modular door 1 according to the invention appears in the form of a frame 2 with multiple sections and a central panel 3.

Frame 2 is broken down into four elements
two vertical uprights 5 and 6 which do not make sense, the upright upright
5 being identical to the left upright 6,
a high cross member 7 of the same section as the uprights 5 and 6
and a low cross member 8 of double height of the high cross member 7.

 The uprights and crosspieces are each formed by elementary modules 10 of oblong cylindrical shape, each module 10 has a cross section of substantially square shape. This appears in more detail in FIG. 3. The fitting of the modules 10 with neighboring and parallel modules 11 and 12 produce the corresponding upright or cross-member.

 To this end, the central modules 10 are provided on one of their sides 10a with a tongue 13 and on the opposite side 10b with a groove 14 complementary to the tongue 13, the interior module 11 only has a groove 15. Similarly, the external module 12 has a tongue 16. The assembly is thus carried out by fitting one into the other, in the directions aa 'and bb' perpendicular to the crosspieces and uprights, of the grooves and tongues of the adjacent modules glued. between them.

 Referring again to FIG. 1, it is noted that the modules 10, 11, 12 constituting the uprights, as well as those 18, 19, 20 constituting the crosspieces 7 and 8, are of different lengths, the latter narrowing to against the center of the door. This results in each corner 25 of the door 1 a staircase assembly very effective in terms of the strength and quality of the assembly of the uprights 5 and the crosspieces 8 and, moreover, a pleasant decorative effect.

 According to the technique represented in FIG. 2, the assembly between the uprights 5 and the crosspieces 8 of the door 1 is ensured by rebates 27 extending at their end the modules 18 and coming to nest by stuck gluing in a groove 28 of the perpendicular modules the corresponding amount 5.

 The design of the four elements 5, 6, 7, 8 making up the frame 2 of the modular door 1, produced by gluing side by side of multiple modules, ensures high rigidity of these parts and prevents any deformation and warping of the door. Indeed, by assembling with bonding several modules 10, 11, 12 by tongue 13 and groove 15, the possible tendency to deformation of one of the modules, in one direction, is compensated by the resistance of the neighboring module. This feature is reinforced if, as shown for the upright 5 (Figure 3), the orientation of the wood fibers making up the modules 10, 11, 12 is placed in a different direction. This avoids any deformation of the uprights and crosspieces after assembly, any effort in the corners 25 and any bending or warping from there door 1.

 It will also be noted, with reference to FIGS. 3 and 5, that for reasons of decorative effect, each of the modules 10, 11, 12 constituting the uprights 5, 6 as well as the crosspieces 7, 8, have their rounded corners.

The production, according to the invention, of joinery, and in particular of doors or windows, in the form of a stacking in the four directions of the uprights and crosspieces of multiple modules 10, 11, 12 of small section, have the following advantages
- it allows a very resistant and rigid construction of door 1
- it presents a new aspect and a variation of colors
- last but not least, it provides significant savings in wood.

 Indeed, it is easily understood that it is easier, when the elements constituting a door are being delivered, to produce multiple modules of small section and of variable length, than a single upright or a single cross-member. This allows maximum use of the wood because a small dimension can be located more easily between two natural defects (knots, heart, cracks, ...) which must be eliminated. Of course, the frame can be manufactured in different wood species which can also be alternated according to the modules for reasons of mechanical strength or simple aesthetic effect (hardwood, softwood, exotic,...).

 FIG. 3 represents a first alternative embodiment of the door 1 with multiple sections, the central panel of which consists of a panel 3 of melamine particles. This panel 3 consists in a known manner of a core 30 of wood fibers distributed in three layers, the two surface layers 31 and 32 of which are composed of very fine particles.

For each of the surface layers 31 and 32, melamine resins and first quality cellulose sheets are used. A central panel with exceptional light fastness and high resistance is thus produced. In addition, these panels 3 are currently made in many colors and in a very wide range of wood tones, which makes it possible to match the frame and the panel.

 According to the variant of FIG. 3, the panel 3 is placed in the factory at the center of the uprights 5 and 6 and of the crosspieces 7 and 8 during the mounting of the door 1. To do this, grooves 35 and 36 are provided on the interior sides 37 and 38 of the interior modules of the uprights and crosspieces.

As shown in FIG. 4, the central panel 3 can be replaced by a window 40. In this case, each of the interior modules 12 is provided with a rebate 42 hollowed out in an L shape on its interior side 37. The glass plate comes resting against the flat central part 44 of the angle thus formed. It is then covered by glazing beads 45 fitted with foam rubber shock absorbers 46.

Once the door is perfectly made and glued and after a drying and flat stabilization time, the door is mechanically stabilized, it can be transported and used.

 Doors 1 can be built to current standard dimensions. But it is also understood that their manufacture, in the form of assembly of modules in four directions, makes it possible to easily vary the shapes of the door without requiring large modifications in the production lines.

 The door described on board 2, FIGS. 6 to 9, was designed in the same spirit as that of board 1, but using a glulam technique.

 Like the previous one, the door 60 consists of a frame 61 and a central panel 63. The difference lies in the method of manufacturing the elements constituting the frame 61. The uprights 65 and 66, as well as the crosspieces 67 and 68 , are made of glulam, according to a technique used mainly in framework and for a few years for the arrangement of furniture. This consists of making each element 65 of the frame, whatever its shape, from thin strips 70, 71, ..., 74 stacked on top of each other and assembled to one another by gluing and pressing . The strips 70 to 74 are put in place, as shown in FIG. 7, according to different orientations of their fibers. Given the number of strips 70 to 74 assembled to make each upright 65 or cross member 68, the pieces 65 to 68 making the frame 61, are practically non-deformable, each strip being held by the adjacent strips against all deformation forces.

As for door 1, the central part of door 60 can be fitted
- either by a panel 63, and in this case the central strips 74 are
provided on their inner face with a groove 75 inside
which comes to fit the panel 63,
- Either a window 80, and in this case the internal strips 74 are
fitted with a rebate system on which the glass rests.

 The assembly of the strips 70 to 74 against each other is of a beautiful decorative effect. This is reinforced by alternating, during manufacturing, the colors of the different wood species used.

 Given the extreme stability of the joinery produced according to the two previous processes, the transport and marketing of doors 1, 60 can be carried out in two ways.

 Conventionally, the glued modules or strips constituting the frame can be assembled in the factory, in particular by tenons and mortises.

 However, a method of packaging in spare parts, recommended by the invention, is described on board 3, FIG. 10. According to this variant, each cross member 67 is provided in the vicinity of each of its ends 81 with a recess 82 perpendicular to its axis xx '.

 Inside this recess 82, is introduced along yy 'a nut rod 83 which appears in more detail through the recessed part 85 formed on the crosspiece 67 shown in Figure 10. The nut rod 83 is pierced perpendicular to its axis yy '(ie according to xx') of a tapped hole 90 (which does not appear in figure 10). Each cross-member 67 is extended along xx ′ by a tenon 91. At each of the ends 92 of an upright 65 is, of course, a mortise complementary to the tenon 91 (not shown in FIG. 10) arranged along xx ′, parallel to the axis of the upright 65 so as to cooperate with the tenon 91 in the extension of the mortise. Always along xx ', is drilled, at the end of the upright 65, a hole 94 arranged in such a way that, when the upright 65 and cross-member 67 are assembled perpendicularly (as shown in FIG. 10), the hole 94 is extended by a hole 95 made in the cross-member 67 which opens facing the tapped hole 90 of the nut rod 83.

 After fitting the pin 9l of each cross member and the corresponding mortise of the uprights 92, a return screw 96 is introduced inside the holes 94, 95. The latter cooperates and is screwed through the tapped hole 90 of the rod nut 83.

 The lower cross member 68 of the door is fixed to the upright 65 according to the same principle. Simply, because of the greater height of the lower cross member 68, it is recommended to make two transverse holes in the corresponding nut rod and to use two return screws 97 and 98.

 It is easy to understand that this assembly can be carried out with a minimum of material on the very places where the door is installed. We can increase the strength of the assemblies between the uprights 65 and the crosspieces 67 by coating the glue between the tenons and the mortises before fitting them.

 After blocking each screw 96, the head of which is then embedded in the upright 92, the hole left by the screw 96 is closed using a plug 99.

 To market and transport this type of door, it is recommended to practice as described in Figure 11.

 The assembly of the two uprights 65 and 66 of the door as well as the crosspieces 67 are introduced longitudinally side by side, as well as the return screws 95, 97 and 98 inside a carton 100. A simple label, recalling the dimensions and the type of wood of the door, is placed on the cardboard 100 to identify it. Panel 63 is delivered in a separate carton.

 The uprights 102 and 103 of the frame 101, as well as the upper crosspiece 104, can likewise be assembled inside an oblong cardboard 105. It will be appreciated that, in this way, it is particularly easy for a business carpentry installation, a craftsman or a handyman, to transport from the point of sale to the place of installation the components of a door.

 Likewise, the reduced dimensions of the door in this form make it possible to limit the storage volumes at merchants or large sales areas.

 A particularly easy method of installation appears in figure 11. It is first of all necessary to mount, according to the same principle as above, and to assemble the uprights 102 and crosspieces 104 of the frame using a system with nut rod 108 and return screw 109. The frame 101 is placed vertically, surrounded and fixed to a partition 110. The door 60 is then assembled using different elements placed in the carton 100, according to the method described above, and appearing in the central part of FIG. It only suffices to adapt the pomelles 120 as well as the lock 121 to fix the door 60 on its frame.

 The invention having now been explained and its interest justified in detailed examples, the applicants reserve the exclusivity for the entire duration of the patent, without limitation other than that of the terms of the claims below.

Claims (17)

 constitute the chassis.  - then, we assemble the four modular edge pieces for  each of the four edge pieces  each of the lamellae (10,11,12) (70, ... 74,) constituting  assembling and joining in their final relative position  four modular edge pieces (5,6,7,8) (65,66,67,68), in  - each of the following is carried out independently of each other  carpentry, (1.60) characterized in that  rectangular center panel) (3.63) 2. Method according to claim 1 preceding modular manufacturing  edge piece (length close to that of the adjacent side of the  - at least two strips of wood (10,11,12), (70, ..., 74) per said  each of the four so-called shore pieces,  and in the perpendicular directions (a, a '), (b, b') to  in the plane of said central panel (3.63)  - by stacking  edge (5,6,7,8), (65,66,67,68) of the joinery  said process being characterized in that each piece is produced  (66),  frame (101) via one of its uprights  and intended to be suspended and articulated vertically to a  uprights (5,6), (65,66) and two crosspieces (7,8), (67,68)  joined two by two by their ends (81,92) (two  consisting of four edge pieces (5,6,7,8), (65,66,67,68)  - surrounded by a stiffening and carrying frame (2.61),  - a central panel (3.63) rectangular)  1. Modular manufacturing process for joinery (1.60) consisting of: 3. Method according to one of claims 1 and 2 above, of  modular manufacture of carpentry, characterized in that  - we stack  according to each of the four edge pieces (5,6,7,8)  a series of at least two strips (10,11) of wood  increasing length  - and we fit the ends of each of the slats (12,10,11)  constituting said edge pieces (5) inside a  rectangular quarter formed in the edge room (8)  adjacent perpendicular,  - so that the assembly of the wooden strips (10,11,12) to the right  corners are in the form of stairs, the height of which  steps is equal to the width of the lamella of the edge piece  perpendicular sitting on it. 4. Method according to claim 3 preceding modular manufacturing  a carpentry, characterized in that one performs by  straddle (27,28) the assembly of the slats (12) in said staircase  formed by said adjacent perpendicular edge piece (5). 5. Method according to one of claims 3 and 4 above  modular manufacture of carpentry, characterized in that the number  stacked strips (10,11,12) constituting each edge piece (5)  is the same, so that said rectangular quarters on which  sit the ends of the slats (18) are provided by the  length difference between two stacked slats (10,12)  successively from the same edge piece. (5) this difference of  length between the two strips (10,12) being equal to the sum of  widths of the two strips (18) seated perpendicular to the  housed rectangular quarters 6. Method according to one of the preceding claims 1 to 5 for manufacturing  modular carpentry, (60) characterized in that  - all of the wooden slats making up the  frame  according to four groups (65,66,67,68) each corresponding to å  one of said edge pieces,  each of said groups being divided into four  perpendicular directions, (a a 'b b'),  and somewhat removed from other groups,  - then, we bring together one. towards each other the four  groups (65,66,67,68) of lamellae 70, ... 74,) according to said four  perpendicular directions so as to carry out their assembly. 7. Method according to one of the preceding claims 1 to 6 for manufacturing.  modular carpentry, (1) characterized in that it is secured  two by two the integral strips (10,12) constituting each of the  four said edge pieces (5) by assembly of the groove type (15) and  tongue (13). 8. Method according to claim 2 for manufacturing, transporting and  installation of modular joinery, (60) characterized in that  - in the factory, we manufacture independently of each other  each of the four said edge pieces, (65,66,67,68) by  assembly and joining of their strips (70, ... 74,)  constitutive and each of said edge pieces is provided with  means (83, 94, 95, 96) of assembly two by two allowing  subsequently of their joining together for the constitution of said  chassis (61),  - these four edge pieces are brought together in independent form  (65,66,67,68) and their means of assembly in the form of a  unitary set,  - said unitary unit (100) is transported to the place of placing  definitive place of said carpentry (60)  - And, finally, on the place of installation of the joinery (60) we  assembles said edge pieces (65,66,67,68) to constitute the  chassis (9). 9. Method according to claim 8 above, characterized in that one  brings together and lton has parallel and almost jointly, in particular  using oblong packaging, such as a carton (100), said edge pieces  inside their said unitary set. 10. Method according to 11 one of claims 8 and 9 above, characterized  in that said edge pieces are produced (65,66,67,68)  - using a stack of wooden strips, (70. .74) all of  same length for each edge piece, (65,66,68,69)  - the length of at least one of said edge pieces (68) being  equal to the development in its direction of said panel  rectangular (63) incremented by the sum of the widths of the two  joined edge pieces,  so that each of the four edge pieces comes under the  form of a compact rectangular parallelepiped element.  11. Modular joinery frame (61) (1.60) produced according to the  claim 1 and constituted by the perpendicular assembly of  four edge pieces, (5,6,7,8,) (65,66,67,68), said frame being  characterized in that each of the four edge pieces is produced by  assembly in the plane of the joinery of at least two strips of  wood (10,11,12) contiguous. 12. Frame (2) of modular carpentry according to claim 11  previous, characterized in that the end-to-end assembly of two  strips of wood (11,18) belonging to two adjacent pieces (5,25)  are carried out in staircase, each step being constituted by the  difference in length between two lamellae constituting the same  edge piece (10,12). 13. Group of four edge pieces (assembled using such packaging  a carton (100), intended to produce a frame (61) of joinery according to  one of claims 11 and 12 above, characterized in that  - each of the four edge pieces (65,66,67,68) is made up  by assembling at least two strips of wood (70, .. 74,)  - and all four edge pieces (65,66,67,68) are fitted with  means (83,94,95,96) able to allow relative assembly  perpendicular to these two by two. 14. Group of four edge pieces (65,66,67,68) according to claim  13 previous, characterized in that each of them is constituted by  a glued-laminated assembly of wooden strips (70, .. .74) similarly  length.  15. Group of four edge pieces according to claim 14 above,  typically provided with a relative securing system of the  return screw type (96). 16. Modular carpentry frame according to one of claims 11 and 12  previous, and / or group of four edge pieces (65,66,67,68) according to  one of claims 13 to 15, characterized in that the lamellae  (70, ... 74,) constituting at least one of the edge pieces (65) are  of different shade. 17. Modular carpentry frame or group of four edge pieces  (65,66,67,68) according to the preceding claim 16, characterized in that  that the lamellae constituting at least one of said edge pieces  are of different wood species.