GB2109449A - Pannelled door - Google Patents

Abstract

A panel particularly for a door leaf comprises a sheet 8 of synthetic material e.g. chip board having grooves 9 in which wood strips 7 are adhesively secured, the strips 7 comprise a continuous groove 5, veneers 18,20 cover the remainder of the surface giving the whole a panelled appearance. The door leaf is fabricated by milling out grooves 9 across the sheet 8, inserting the strips 7, grinding the whole surface smooth, applying a veneer to cover the entire sheet and then milling out the continuous groove 5. <IMAGE>

Description

SPECIFICATION Panel element having set off panelling or panellings The invention relates to a panel element, such as a panelled door and of the kind stated in the introductory part of claim 1. In the following description the term synthetic sheet material should include sheet materials from fibres or particles joined by means of a binder, or sheets having an open or closed cell structure, whereby the material may be foamed or filled with air bubbles. Examples of these materials will follow later.

The panel element according to the invention is characterized by the measures stated in the characterizing part of claim 1. Thus, a panel element is obtained in a simple manner, which element is not inclined to buckle or warp and which by veneering upon the fixing of the panelling lists in the grooves and a subsequent milling of the frieze or the friezes inside the list area appears as a massive panel element with an uninterrupted smoothly extending panelling frieze or friezes, i.e. the synthetic sheet material is concealed. The location of the lists provides the element with a uniform stiffness in two intersecting directions so that the panel element is not tending to buckle and furthermore the form of the frieze present a hitherto unknown aesthetic impression.

By the measures of claim 2 the possibility of a voluntary placing of the friezes is achieved because the extension of the panelling lists and the grooves arbitrarily may be adapted to the desired courses of the friezes.

By the measures of claim 3 a preferred, maximum groove depth is defined for minimizing the buckling tendency of synthetic materials.

By the measures of claim 4 the influence of humidity expansion differences in the materials used for lists and synthetic sheet material is reduced.

By the measures of claim 5 a second measure for the reduction of the effects of the humidity expansion differences is defined.

The invention will now be further explained in connection with some embodiments by way of example and with reference to the drawing in which Fig. 1 shows a panel element in the form of panelled door according to the invention and having a set off panelling, Fig. 2 a section along I-I of fig. 1, Fig. 3 a section along Il-Il of fig. 1, Fig. 4 a section along Ill-Ill of fig. 1, Fig. 5 a section along Il-Il of fig. 1 of a second embodiment having rounded groove terminals, Fig. 6 a chip board with panelling lists inserted therein, Fig. 7 a section along lV-lV of fig. 6, Fig. 8 a section along V-V of fig. 6, Fig. 9 a section along lV-lV of fig. 6 through the door after veneering but before milling of the frieze, Fig. 10 a chip board with inserted curved panelling lists in discontinuous longitudinal and transverse grooves, Fig. 11 a chip board with inserted panelling lists, the ends of which are terminated by chip board blocks, and Fig. 12 a front view of a panel element, e.g. of a panelled door.

Fig. 1 shows a panelled door 1 comprising a single set off panelling 2, performed on the basis of a compressed fibre board or sheet, such as a chip board. The panelling 2 is veneered similarly to the frame parts 3 by being veneered in a certain pattern e.g. as shown, and an endless frieze 5 extends between the panelling 2 and the frame parts 3. The rear part of the door 1 is also veneered and smooth or may be provided with a similar panelling on the rear side. Edge coating lists 6 are here mounted by a butt joint along the edges of the door 1.

Fig. 2 shows a section along I-I of fig. 1 showing the synthetic board or sheet material core 8 of the door 1, such as fibre plate or plates of an open or closed pore structure. The fibre plates may e.g. be chip boards, sawdust boards, straw boards, mineral wool boards or plates, such as rock or glass wool plates, metal wool plates, such as steel wool or aluminium wool plates, and the boards of plates having an open or closed pore structure may e.g. be boards of cell stone materials.

The frieze 5 is formed in a list 7 made of massive wood or of a material, the superficial structure of which is similar to that of massive wood. In this example the list 7 with its frieze 5 is inserted in a groove 9 in the core 8, and the frieze 5 has a cross section comprising two corners 12 each abutting a convex side part 14. The grooves 9 are performed with outwardly inclining side walls. The rear side of the door 1 comprises a veneered cover 16, and the panelling 2 and the frame parts 3, 4 comprise veneered covers 18 and 20 respectively.

Fig. 3 shows the longitudinal friezes 5 as well as a transverse frieze 5 having the same level and cross sectional shape as the longitudinal friezes 5, and similarly to the longitudinal frieze 5 the transverse frieze 5 is performed in the list 7 being inserted in the core 8.

Fig. 4 shows that the lists 7 inserted completely fill the grooves 9 below the frame parts 3.

Fig. 5 shows a section through another embodiment in which the longitudinal and transverse grooves 9 are performed with a rounded terminal form 30, and that the panelling lists 7 are performed complementarily to the grooves 9. In case massive wood is used for the panelling lists 7, the influence of the differences in expansion between the massive wood and the synthetic sheet material 8 by changes in the relative humidity in the two materials is reduced.

According to the invention a panelling door 1 may e.g. be manufactured by cutting a plate in synthetic sheet material, such as chip board.

Thereupon transverse grooves 9 are milled by a surface milling cutter in the plate, and transverse lists 7 of a complementary shape to the transverse grooves 9 are provided with an adhesive and are inserted in the grooves 9, possibly during performance of a pressing force. When the transverse lists 7 so being adhered to the grooves, longitudinal grooves 9 of same depth as the transverse grooves are milled by the surface milling cutter in the board or plate 8, and longitudinal lists 7 of a complementary shape to the longitudinal grooves provided with adhesive and likewise possibly under performance of a pressing force are inserted therein. The board 8 with panelling lists 7 is now as shown in fig. 6.

Thereupon the protruding ends of the panelling list 7 are removed, and edge covering lists 6 are by butt joints mounted as shown in figs. 7 and 8. The surface of the plate 8 with the lists 7 is surfaced and is veneered in veneering pattern dependent on the location of the panelling lists 7, and surfacing and veneering are also performed on the opposite surface of the plate 8 in the full extension thereof.

Then the veneer is cut off at the edges of the plate, whereupon an outer wood moulding is performed.

A surface milling cutter then mills the internal cross section of the frieze 5 inside the area of the veneered panelling lists to below the surface of the veneer whereupon the panel element is surface treated by grinding and finishing.

The door thus manufactured thereby obtains an appearance as a frame door of massive wood but at essentially lower material and production costs, and the panelling door obtained is stiffer and consequently less inclined to warp or buckle than a panelling door manufactured of massive wood.

The rounded transition zones made by the surface milling cutter between the rectilinear parts of the frieze 5 provide an aesthetic impression.

Fig. 10 shows the plate for the panelled door 1 before veneering with curved panelling lists 7 inserted and having a rounded terminal form 30 of the grooves 9 in the core 8 as shown in fig. 5.

Thus, panellings in the panelled door 1 of essentially an arbitrary shape may be manufactured.

Fig. 11 also shows a plate for a panelled door before veneering, whereby blocks 32 are glued to the ends of the panelling lists 7, said blocks 32 being made of the synthetic sheet material in order to reduce the influence of humidity expansion differences in the materials used.

Fig. 12 shows a characteristic corner section of the panel element according to the invention from which is appears that the longitudinal and the transverse friezes 5 meet each other in a corner whereby the corners 12 of the frieze and its side parts 14 are rectangular at one edge of the frieze and smoothly rounded at the opposite edge of the frieze.

Compared to known panelled doors manufactured on the basis of synthetic sheet material it is possible by the panelled door according to the invention to achieve sharper mouldings and, besides, also mouldings of an arbitrary cross sectional shape, seeing that the frieze is performed in a massive material. In case the panelling lists are made of wood, the shaping thereof may take place by means of a surface milling cutter.

In case the inserted panelling lists are prefabricated in a predetermined cross sectional shape, grooves with a shape complementary to the prefabricated panelling lists are formed in the synthetic sheet material, whereupon said lists are inserted in the grooves, the plate is veneered, and the veneer is removed after setting of the adhesive in the area of the inserted panelling lists either by a cutting operation, by surface milling or by a punching operation. The panelling lists may here be manufactured of an arbitrary suitable plastic which may be provided with an arbitrary, desired surface structure, and among the plastics may be mentioned moulding pressed paper mass or the like moulding pressed material.

Claims (5)

1. Panel element from mainly synthetic board or sheet material (8) and having a set off panelling or panellings (3), whereby at least one panelling frieze (5) is performed in panelling lists (7) which are fixed in grooves (9) in the sheet material (8), characterized in that the panelling lists (7) and the grooves (9) cross each other in the same level, and that each panelling frieze (5) by a surface milling is milled endlessly or is forming a closed loop.

2. Panel element according to claim 1, characterized in that the panelling lists (7) and the corresponding grooves (9) have the same arbitrarily chosen course along the surface of the panel element.

3. Panel element according to claims 1 or 2, characterized in that the depth of the grooves (9) does not exceed 50% of the thickness of the sheet material (8).

4. Panel element according to claim 1, 2 or 3, characterized in that at least one panelling list (7) inside the sheet material area comprises an extension (32) of a material having the same characteristics as to humidity and temperature as the sheet material (8).

5. Panel element according to claim 1, 2, 3 or 4, characterized in that the grooves (9) are performed with rounded terminal form (30) from the groove bottom to the surface of the sheet material (8).