NL2021403B1 - A method of producing a door body, and a door body or door - Google Patents

A method of producing a door body, and a door body or door Download PDF

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Publication number
NL2021403B1
NL2021403B1 NL2021403A NL2021403A NL2021403B1 NL 2021403 B1 NL2021403 B1 NL 2021403B1 NL 2021403 A NL2021403 A NL 2021403A NL 2021403 A NL2021403 A NL 2021403A NL 2021403 B1 NL2021403 B1 NL 2021403B1
Authority
NL
Netherlands
Prior art keywords
door
plate
door frame
plate structure
insulation plate
Prior art date
Application number
NL2021403A
Other languages
Dutch (nl)
Inventor
Kooijman Mark
Original Assignee
Mk Doors Holding B V
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mk Doors Holding B V filed Critical Mk Doors Holding B V
Priority to NL2021403A priority Critical patent/NL2021403B1/en
Application granted granted Critical
Publication of NL2021403B1 publication Critical patent/NL2021403B1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70—Door leaves
    • E06B3/82—Flush doors, i.e. with completely flat surface
    • E06B3/822—Flush doors, i.e. with completely flat surface with an internal foursided frame
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/007—Manufacture of substantially flat articles, e.g. boards, from particles or fibres and at least partly composed of recycled material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70—Door leaves
    • E06B3/7015—Door leaves characterised by the filling between two external panels
    • E06B2003/7025—Door leaves characterised by the filling between two external panels of cork; of wood or similar fibres
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70—Door leaves
    • E06B3/7015—Door leaves characterised by the filling between two external panels
    • E06B2003/7038—Door leaves characterised by the filling between two external panels made from a slurry
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70—Door leaves
    • E06B3/7015—Door leaves characterised by the filling between two external panels
    • E06B2003/704—Door leaves characterised by the filling between two external panels of mineral material which is not further specified
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70—Door leaves
    • E06B2003/7049—Specific panel characteristics
    • E06B2003/7051—Specific panel characteristics of layered construction involving different materials

Abstract

Title: A method of producing a door body, and a door body or door Abstract The invention relates to a method of producing a door body, comprising the step of providing a door frame having a front side, a back side and at least one open interior volume, a step of providing at least one isolation plate, inserting the isolation plate in the open interior volume of the door frame, and a step of mounting a front plate structure to the front side of the door frame, and a back plate structure to the back side of the door frame. The step of providing at least one isolation plate includes the step of feeding a cellulose material and a binder material into a mould having a box shaped interior, a step of curing the cellulose material With the binder material in the mould, forming a isolation plate, and a step of releasing the isolation plate from the mould.

Description

Title: A method of producing a door body, and a door body or door
The invention relates to a method of producing a door body. Typically, insulated door bodies are produced by providing a door frame having a front side, a back side and at least one open interior volume, providing at least one isolation plate, inserting the isolation plate in the open interior volume of the door frame, and mounting a front plate structure to the front side of the door frame, and a back plate structure to the back side of the door frame, sandwiching the isolation plate between the front plate structure and the back plate structure.
It appears, however, that a process of providing a door body or door with a desired thermal isolation, sound isolation and/or flame retarding functionality is no sinecure. Further, a door manufacturing process can be an environmental impact.
It is an object of the present invention to provide a method for producing a door body according to the preamble having a reduced environmental impact. Thereto, according to the invention, the step of providing at least one isolation plate includes the steps of feeding a cellulose material and a binder material into a mould having a box shaped interior, curing the cellulose material with the binder material in the mould, forming a isolation plate, and releasing the isolation plate from the mould.
By curing a mixture of cellulose material, e.g. from paper or cardboard material, with a binder material, isolation plates can be obtained that have a minimal ecological footprint, while, on the other hand, advanced insulation properties can be achieved, both in terms of thermal and sound insulation.
Advantageously, a flame retardant can be added to obtain a desired fire retarding property as well.
The invention also relates to a door body or door.
Further advantageous embodiments according to the invention are described in the following claims.
It should be noted that the technical features described above or below may each on its own be embodied in a system i.e. isolated from the context in which it is described, separate from other features, or in combination with only a number of the other features described in the context in which it is disclosed. Each of these features may further be combined with any other feature disclosed, in any combination.The invention will now be further elucidated on the basis of a number of exemplary embodiments and an accompanying drawing. In the drawing:
Fig. 1A shows a schematic perspective view of a door frame of a door body according to the invention;
Fig, IB shows a schematic cross sectional view of a door body according to the invention, and
Fig. 2 shows a flow chart of a method according to the invention.
It is noted that the figures show merely a preferred embodiment according to the invention. In the figures, the same reference numbers refer to equal or corresponding parts.
Figure 1A shows a schematic perspective view of a door frame 1 of a door body according to the invention. The door frame 1 has a bottom frame portion 2 and a top frame portion 3, opposite to each other. The door frame 1 also has a first side frame portion 4 and a second side frame portion 5, opposite to each other, and interconnecting the bottom frame portion 2 and the top frame portion 3 to each other, thus forming a generally rectangular shaped door frame 1 extending in a door frame plane P.
The door frame 1 has a front side FS, a back side BS and an open interior volume V. In the shown embodiment, the open interior volume V is bounded, in the frame plane P, by frame portions. Further, the open interior volume V is accessible via at least the front side FS and/or the back side BS of the door frame 1. During a process of manufacturing a door body, the open interior volume V is at least partially filled with an isolation plate.
Figure IB shows a door body 10, in a schematic cross sectional view through a cross section plane CS through the first and second side frame portions 4, 5 or stiles of the door frame 1, and through the door frame plane P. The door body 10 is provided with an isolation plate 11 located in the interior volume V of the door frame 1. Further, the door body 10 includes a front plate structure 12 mounted to the front side FS of the door frame 1 and a back plate structure 13 mounted to the back side BS of the door frame 1. The isolation plate 11 is located, in a layering direction LD, between the front and back plate structure 12, 13, respectively, and, in directions in the door frame plane P, transverse to the layering direction, between the bottom frame and the top frame portions 2, 3, and the first and second side frame portions 4, 5. By sandwiching the isolation plate 11 between the front and back plate structure 12, 13, generally a layered structure is obtained with front and back plate structures 12, 13 covering both the front side FS and the back side BS of the door frame 1.
The front plate structure 12 may include a multi layer structure provided with wood based plates and a metal plate sandwiched therebetween. As an example, the multi layer structure may include a first wood based layer 14 facing towards the front side FS of the door frame 1, an intermediate metal plate 15 and a second wood based layer 16 facing away from the front side FS of the door frame 11 such that the first and second wood based layers 14, 16 sandwich the intermediate metal plate 15, as shown in Fig. 2. However, the multi layer structure may include further layers, e.g. a top layer on top of the second wood based layer 16. At least one of the wood based layers may include medium density fibre board or acetylated wood. Further, the metal layer 15 may include aluminum or another metal such as stainless steel.
As an alternative, the front plate structure 12 may include a single layer such as a metal layer.
Similarly, the back plate structure 13 may include a multi layer structure provided with wood based plates sandwiching a metal plate. In the embodiment shown in Fig. 2, the back plate structure 13 includes another first wood based layer 17 facing towards the back side BS of the door frame 1, another intermediate metal plate 18 and another second wood based layer 19 facing away from the back side BS of the door frame 11 such that the first and second wood based layers 17, 19 of the back plate structure 13 sandwich the intermediate metal plate 18 thereof.
In the shown embodiment, the interior volume V of the door frame 1 is completely filled with the isolation plate 11. However, as an alternative, the isolation plate 11 fills said interior volume V partially, e.g. up to circa 50%, up to circa 80% or up to circa 95%, or even more.
The isolation plate 11 comprises a cellulose material that has been cured with a binder material as specified in more detail below. Advantageously, the isolation plate comprises also a fire retardant to improve a fire durability of the door body 10. In principle, however, the isolation plate 11 may be implemented without a fire retardant.
Figure 2 shows a flow chart of a method according to the invention. The method is used for producing a door body 10. The method 100 comprises a step of providing 110 a door frame having a front side, a back side and at least one open interior volume, a step of providing 120 at least one isolation plate, a step of inserting 130 the isolation plate in the open interior volume of the door frame, and a step of mounting 140 a front plate structure to the front side of the door frame, and a back plate structure to the back side of the door frame, sandwiching the isolation plate between the front plate structure and the back plate structure. The step of providing 120 at least one isolation plate includes a step of feeding 122 a cellulose material and a binder material into a mould having a box shaped interior, a step of curing 124 the cellulose material with the binder material in the mould, forming a isolation plate, and a step of releasing 126 the isolation plate from the mould.
It is noted that the door frame 1 can be provided with a single or a multiple number of open interior volumes V. As an example, the door frame 1 may including an additional frame portion interconnecting the first and second side frame portions 4, 5, e.g. somewhere halfway between the bottom and top frame portions 2, 3. Then, the single open interior volume V shown in Fig. 1 is divided into two open interior volumes surrounded by frame portions. At least one of these multiple number of open interior volumes V can at least partly be filled with an isolation plate.
It is further noted that it is generally preferred to fill all open interior volumes V, preferably completely, with corresponding isolation plates 11 to optimize sound and thermal isolation properties of the door body 10.
The isolation plate is preferably made from cellulose material, e.g. from paper or cardboard such as paper and/or cardboard waste having cradle to cradle properties. The isolation plate may further have an excellent insulating functionality, both in terms of heat and acoustics. In addition, the isolation plate is flame retardant.
A process of providing high-quality, high-grade isolation plates may include the following.
Cellulose material may be collected and preferably pulverized or crushed, preferably using a motor driven device such as an agitator or stirrer device.
The process includes the step of feeding 122 the cellulose material and a binder material into a mould having a box shaped interior. Preferably, prior to feeding the material into a mould, the cellulose material and binder material are be pre-mixed to obtain a degree of uniformity in distributing the binder material through the cellulose. In principle, the process can be performed without a step of pre-mixing, e.g. if the binder material is added to the cellulose material in a distributed manner. Preferably, the binder material is degradable or bio-degradable.
Also a fir retardant can be added to the cellulose material.
The process further includes the step of curing 124 the cellulose material with the binder or curing material in the mould or dosing box, forming an isolation plate. Subsequently, the isolation plate is released 126 from the mould. Optionally, the isolation plate is dried, e.g. in a dryingdevice, after being removed from the mould.
At least one dimension of the isolation plate can be reduced to a pre-defined dimension value, preferably cutting the isolation plate. As an example, the isolation plate is cut to a smaller and/or shorter plate to fit into the corresponding interior volume V of the door frame 1. Preferably, material that is removed from the isolation plate is re-used in a novel cycle of making an isolation plate, preferably after pulverizing the material, so that no material is lost.
The cellulose material can be resilient such that the isolation plate is flexible, also after curing.
After mounting the front and back plate structure 12, 13 the door body 10 can be provided with a primer or undercoating.
For the purpose of providing a door, the door body can be subjected to a milling process. Also, hinges or other accessories for a suspension structure of the door can be provided, as well as locking elements. Further, sealing strips can be mounted on the door.
The invention is not restricted to the embodiments described above. It will be understood that many variants are possible.
These and other embodiments will be apparent for the person skilled in the art and are considered to fall within the scope of the invention as defined in the following claims. For the purpose of clarity and a concise description features are described herein as part of the same or separate ί
embodiments. However, it will be appreciated that the scope of the invention may include embodiments having combinations of all or some of the features described.

Claims (10)

ConclusiesConclusions 1. Werkwijze voor het produceren van een deurromp, omvattende de stappen van:A method for producing a door hull, comprising the steps of: - het verschaffen van een deurframe met een voorzijde, een achterzijde en tenminste één open binnenruimte,- providing a door frame with a front side, a rear side and at least one open interior space, - het verschaffen van een tenminste één isolatieplaat,- providing an at least one insulation plate, - het invoegen van de isolatieplaat in de open binnenruimte van het deurframe, en- inserting the insulation plate into the open inner space of the door frame, and - het bevestigen van een voorplaatstructuur op de voorzijde van het deurframe, en een achterplaatstructuur op de achtezijde van het deurframe, waarbij de isolatieplaat tussen de voorplaatstructuur en de achterplaatstructuur wordt geplaatst, waarbij de stap van het verschaffen van tenminste één isolatieplaat de stappen omvat van:- attaching a face plate structure to the front of the door frame, and a rear plate structure to the rear side of the door frame, the insulation plate being placed between the face plate structure and the rear plate structure, the step of providing at least one insulation plate comprising the steps of: - het in een matrijs met een doosvormige binnenruimte invoeren van cellulosemateriaal en een bindmiddelmateriaal,- introducing cellulose material and a binder material into a mold with a box-like interior, - het in de matrijs uitharden van het cellulose materiaal met het bindmiddelmateriaal, encuring the cellulose material with the binder material in the mold, and - het uit de matrijs loshalen van de isolatieplaat.- removing the insulation plate from the mold. 2. Werkwijze volgens conclusie 1, voorts omvattende een stap van het mixen van het cellulose- en bindmiddelmateriaal voorafgaand aan het in de matrijs invoeren van het materiaal.The method of claim 1, further comprising a step of mixing the cellulose and binder material prior to introducing the material into the mold. 3. Werkwijze volgens conclusie 1 of 2, voorts omvattende een stap van het toevoegen van een brandvertrager aan het cellulose- en bindmiddelmateriaal voorafgaand aan het in de matrijs invoeren van het materiaal.The method of claim 1 or 2, further comprising a step of adding a fire retardant to the cellulose and binder material prior to introducing the material into the mold. 4. Werkwijze volgens één der voorgaande conclusies, voorts omvattende een stap van het drogen van de isolatieplaat na het uit de matrijs loshalen van die plaat.4. Method as claimed in any of the foregoing claims, further comprising a step of drying the insulation plate after removing said plate from the mold. 5. Werkwijze volgens één der voorgaande conclusies, voorts omvattende een stap van het reduceren van een dimensie van de isolatieplaat tot een vooraf gedefinieerde climensiewaarde, bij voorkeur door de isolatieplaat te snijden.A method according to any one of the preceding claims, further comprising a step of reducing a dimension of the insulation plate to a predefined climatic value, preferably by cutting the insulation plate. 6. Werkwijze volgens conclusie 5, voorts omvattende een stap van het hergebruiken van materiaal dat is verwijderd van de isolatieplaat.The method of claim 5, further comprising a step of reusing material removed from the insulating plate. 7. Werkwijze volgens één der voorgaande conclusies, waarbij een meervoudig aantal isolatieplaten in corresponderende open binnenruimtes van het deurframe worden ingevoerd.A method according to any one of the preceding claims, wherein a plurality of insulating plates are introduced into corresponding open interior spaces of the door frame. 8. Werkwijze volgens één der voorgaande conclusies, waarbij de voorplaatstructuur en/of de achterplaatstructuur een meerlaagsstructuur bevat die is voorzien van op hout gebaseerde platen en een metaalplaat die daartussen is geplaatst.A method according to any one of the preceding claims, wherein the front plate structure and / or the back plate structure comprises a multi-layer structure which is provided with wood-based plates and a metal plate placed between them. 9. Deurromp of deur, omvattende een deurframe met een voorzijde, en achterzijde en tenminste één open binnenvolume die tenminste gedeeltelijk is gevuld met een isolatieplaat, waarbij de deurromp of deur voorts een voorplaatstructuur bevat die op de voorzijde van het deurframe is bevestigd en een achterplaatstructuur die op de achterzijde van het deurframe is bevestigd, waarbij de isolatieplaat cellulosemateriaal omvat dat met een bindmiddelmateriaal is uitgehard.A door hull or door, comprising a door frame with a front side, and rear side and at least one open inner volume that is at least partially filled with an insulating plate, the door hull or door further comprising a face plate structure mounted on the front side of the door frame and a rear plate structure which is mounted on the rear side of the door frame, the insulation plate comprising cellulose material cured with a binder material. 10. Deurromp of deur volgens conclusie 9, waarbij de isolatieplaat een brandvertrager bevat.The door hull or door according to claim 9, wherein the insulation plate comprises a fire retardant.
NL2021403A 2018-07-27 2018-07-27 A method of producing a door body, and a door body or door NL2021403B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
NL2021403A NL2021403B1 (en) 2018-07-27 2018-07-27 A method of producing a door body, and a door body or door

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
NL2021403A NL2021403B1 (en) 2018-07-27 2018-07-27 A method of producing a door body, and a door body or door

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NL2021403B1 true NL2021403B1 (en) 2020-01-31

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU651285B2 (en) * 1992-10-12 1994-07-14 Foong Intellectual Properties Sdn Bhd Cellulosic bodies
WO2000004249A1 (en) * 1998-07-16 2000-01-27 Therma-Tru Corporation Compression molded door assembly
US9080372B2 (en) * 2012-06-29 2015-07-14 Intellectual Gorilla B.V. Gypsum composites used in fire resistant building components
US9816313B2 (en) * 2015-07-30 2017-11-14 Aadg, Inc. High performance acoustical wood door

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU651285B2 (en) * 1992-10-12 1994-07-14 Foong Intellectual Properties Sdn Bhd Cellulosic bodies
WO2000004249A1 (en) * 1998-07-16 2000-01-27 Therma-Tru Corporation Compression molded door assembly
US9080372B2 (en) * 2012-06-29 2015-07-14 Intellectual Gorilla B.V. Gypsum composites used in fire resistant building components
US9816313B2 (en) * 2015-07-30 2017-11-14 Aadg, Inc. High performance acoustical wood door

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Effective date: 20230801