PL229642B1 - Method for manufacturing the door system - Google Patents

Abstract

The application relates to a method of manufacturing a door assembly, the assembly comprising a door leaf panel with a frame structure composed of stiles made of moisture-resistant MDF, faced on both sides with a moisture-resistant HDF board, having a structured lightweight fill, and a frame assembly made of moisture-resistant MDF, the facing surfaces of the door assembly is covered with veneer using hot melt glue. The method consists in using a moisture-resistant MDF and a board made of moisture-resistant HDF, containing a melamine-urea-formaldehyde resin as an adhesive for wood fibers, and containing the addition of a wax emulsion, a raw door leaf panel with a frame structure made of stiles made of moisture-resistant MDF is assembled. glued on both sides with a moisture-resistant HDF board with the use of dispersion glue, after placing a light structured filling in the form of an LDF board with a density not exceeding 300 kg / m3 in the space between the rails, raw elements of the door frame set milled from moisture-resistant MDF are delivered, d) glued independently replaced the panel and the posts and the beam of the frame set with a veneer that is essentially water-repellent using a hot-melt, reactive polyurethane adhesive applied with a glue nozzle assembly in the amount of 60 - 80 g / m2, at a temperature of 110 - 130 ° C, and the glued panel and posts are left and b a door frame assembly for cross-linking polyurethane adhesive, producing a door assembly with increased water resistance, showing no deformation of shape or substantially detachment of the veneer from the MDF / HDF material surface under conditions of high humidity, variable humidity and / or at least 24 hours exposure to liquid water.

Description

Description of the invention

The invention relates to a method of manufacturing a door assembly, comprising a door leaf panel with a frame structure made of stiles made of moisture-resistant MDF, covered on both sides with a moisture-resistant HDF board, having structured light filling, and a frame set made of moisture-resistant MDF, in which the facing surfaces of the door assembly are then taped veneer with hot melt glue. The door unit made according to the invention, made only of typical wood-based materials veneered with a typical veneer, shows increased resistance to significant changes in humidity, high humidity, and also to liquid water under conditions of at least 24-hour exposure.

In the field of wood and wood-based materials technology, it is generally known that wood and wood-based (lignocellulosic) materials collect or release moisture from the environment, depending on the prevailing humidity conditions (humidity and / or air temperature). For example, in non-air-conditioned indoor rooms, in Central European conditions, the humidity of items made of lignocellulosic materials ranges from approx. 5% in winter to approx. 19% in summer.

In contact with moisture, wood and wood-based materials tend to change dimensions, which directly translates into the stability of the shape and finish of finished products made of such materials. Exposing wood materials in extreme values of relative air humidity results in a decrease in mechanical properties, dimensional changes (due to, among others, shrinkage and swelling in three sections), the occurrence of an unbalanced state of internal stress, as a result of which changes in the shape of the elements occur (especially the possibility of the so-called twisting), the appearance of desorption cracks, disturbance of the cohesion of the material (in relation to chip and laminate materials) associated with the weakening of the adhesion forces (adhesion) between the wood particles and the adhesive joints; breaking the continuity of the coating system (mainly made in wet technology), which finishes and makes the surfaces of wood materials resistant to physical factors, as well as the development of biological corrosion.

US 6,620,459 relates to polyisocyanate-impregnated lignocellulosic materials and discloses a method of producing a frame beam and posts and door leaf skins with increased strength and water resistance. The inventive product has a top beam, a bottom beam and two posts constituting the door jamb, and a door leaf frame and two door panels arranged on both sides of the frame. The beams and posts of the frame are made of MDF board, impregnated with polyisocyanate. The excess polyisocyanate is removed, the impregnated surface is treated with a liquid such as water and the excess liquid is removed. The leaf sheathing is made of HDF board, analogically impregnated with polyisocyanate. In an exemplary embodiment of the method (using 1 inch [25.4 m] thick MDF samples and studs with a 7/8 inch x 1 5/8 inch [22.2 x 41.3 mm] cross section), it was shown that MDF material largely absorbs polyisocyanate, which was demonstrated by the weight gain of the samples expressed as the weight ratio [g / g]. Depending on the type of polyisocyanate, the proportion varied from 0.072 to 0.169 g / g. Samples impregnated with polyisocyanate (after curing) show low water absorption and dimensional stability in liquid water exposure tests.

International publication WO 2007/120037 of the invention discloses a panel composed of two boards of wood or wood material, between which there are ribs made essentially of at least wood or wood material. The wood material may be a fiber board such as MDF. Said boards are provided on a frame made of wood and at least part of the panel is treated with a water-displacing agent.

International Publication WO 2012/030310 invention discloses a method for manufacturing the door panels raised fibers formed by known methods of hot pressing the contour, which side panels have a density of 950-1100 kg / m ^3, a thickness of 3.2 ± 0.2 mm exhibiting resistance heat, moisture, cracking and scratching, easy to clean, which are covered with patterned paper veneer, in which the outline is covered with melamine decorative paper or paper finishing foil.

The object of the invention is to provide a method for manufacturing a door assembly, the assembly comprising a door leaf panel with a frame structure composed of moisture-resistant MDF, covered on both sides with a board of moisture-resistant HDF, having a structured lightweight filling, and

The PL 229 642 B1 is comprised of a moisture-resistant MDF door frame assembly, in which method the facing surfaces of the door assembly are then veneered using hot-melt adhesive, and the door assembly would not exhibit any deformation of the shape or substantially detachment of the veneer from the surface of the wood-based material under high humidity conditions. , variable humidity and / or at least 24-hour exposure to liquid water.

A method of manufacturing a door assembly, including a door leaf panel with a frame structure composed of stiles made of moisture-resistant MDF, covered on both sides with a moisture-resistant HDF board, having structured light filling, and a frame set made of moisture-resistant MDF, in which the facing surfaces of the door assembly are then covered with veneer with using the hot-melt adhesive, according to the invention, is characterized in that in the following stages: a) a moisture-resistant MDF board and a board made of moisture-resistant HDF containing a melamine-urea-formaldehyde resin as an adhesive for wood fibers and containing the addition of a wax emulsion are used, b) a door leaf panel with a frame structure made of stiles made of moisture-resistant MDF, veneered on both sides with a moisture-resistant HDF board with the use of dispersion adhesive, after placing a light structured filling in the space between the rails in the form of an LDF board with a density of no exceeding 300 kg / m ³ , c) raw elements of the door frame set are delivered milled from moisture-resistant MDF, including two posts and a transverse beam,

d) the above-mentioned panel, posts and a beam of the frame set are glued with a veneer that is substantially water-impermeable with the use of a hot-melt, reactive polyurethane adhesive applied with the use of a glue application nozzle in the amount of 60-80 g / m ² , at a temperature of 110-130 ° C, and

e) the veneered panel and the posts and the frame of the jamb are left to cross-link the polyurethane adhesive, producing a door assembly with increased water resistance, showing no deformation of the shape or substantially detachment of the veneer from the MDF / HDF material surface in conditions of high humidity, variable humidity and / or what at least 24 hours of exposure to liquid water. Preferably, a moisture-resistant MDF and a moisture-resistant HDF board with a melamine-urea-formaldehyde resin content of 14-24% and a wax emulsion of 1-3% are used. In particular, in step e) a narrow plane of the door leaf panel is glued with at least one rim made of water-repellent veneer. The substantially water-impermeable veneer is, in particular, a veneer having at least one backing layer made of organic plastic or a veneer having at least one backing layer made of cellulosic material impregnated with synthetic organic resins.

More preferably, in step d) the adhesive is applied at a temperature of 115-130 ° C. In step b), in particular, a dispersion adhesive based on polyvinyl acetate is used.

The present invention provides a door assembly (including a door leaf panel and a frame assembly) which door assembly exhibits enhanced resistance to conditions of high humidity, varying humidity and / or at least 24 hours of exposure to liquid water. Obtaining the aforementioned high strength and durability in conditions of high humidity, variable humidity and / or exposure to liquid water is unexpected, because in the solution according to the invention, the construction material is only typical MDF and HDF materials, which are not surface impregnated, in a moisture-resistant version, which when in contact with liquid water they absorb water and swell, which can directly translate into the stability of the shape and finish of finished products made of such materials. The said resistance to high humidity, variable humidity and / or at least 24-hour exposure to liquid water of the finished door assembly is achieved with a relatively very low polyurethane adhesive consumption of only 60-80 g / m ² , using an appropriately selected veneer.

Within the specification of the invention and the claims, an exposure to liquid water of at least 24 hours is assumed to be at least 24 hours of contact of the door assembly with drops of liquid water retained on the surface of the door leaf panel and / or jamb during normal use of the panel and / or the door frame. By normal use is meant use of the door assembly typically seated in a structural opening (i.e., substantially vertical).

In a typical solution according to the state of the art, the door leaf panel is a frame structure composed of vertical and horizontal stiles made of wood-based material, faced with wood-based panels on both sides. The space between the stiles is filled with structured light filling. The door leaf panel is covered with a veneer that gives it the target aesthetic appearance and resistance to dirt. The panel is then fitted with fittings

PL 229 642 B1 (hinges, locks), with the preparation of the door leaf intended to partition the vertical building opening (door opening).

The casing enables the installation of the door leaf in the construction opening intended to be partitioned with the door. It is a frame that is inserted into the above-mentioned hole and fixed permanently. The frame is most often delivered complete with the door leaf in order to reduce the risk of improper interaction between the frame and the door leaf. The door frame can be delivered as a whole or in the form of several elements to be combined in the opening (to be partitioned with a door leaf panel) at the installation site. For example, the frame may be provided in the form of three elements including two profiled posts and one cross beam.

In the known solutions of interior doors, the vertical and horizontal rails of the door leaf panel as well as the profiled posts and the transverse beam are made of blocks cut from MDF material, while the facing of the frame structure of the leaf panel is made of HDF board. The terms used herein: material or MDF (Medium-Density Fibreboard) and HDF (High-Density Fibreboard) have typical meanings and refer to wood-based products produced by pressing wood fibers with the addition of synthetic resins under high pressure and temperature conditions. These materials are characterized by a substantially homogeneous density and raw material composition throughout the entire cross-section.

The material density / MDF is typically in the range of from 500 kg / m ³ to 1000 kg / m ^3, more typically in the range of 650 to 800 kg / m ^3. HDF boards density usually exceeds 800 kg / m ^3.

The inner space of the door leaf panel, between the rails, is filled with structured light filling. The filling can be made in various forms, as long as the average filling density is kept at a level that does not excessively add to the weight of the entire sash panel, and that it provides stiffening support for the HDF door leaf facing.

The finishing of the door leaf panel as well as the door frame set usually depends on the expected aesthetic effect. It is most often carried out by covering individual elements with solid materials (natural veneer, "finish" foil, CPL laminates) or varnishing (one-color or with an imprint of a wood pattern). The gluing of door leaves as well as frame elements can be done in the postforming technology, which enables finishing the main (wider) surface and one or two parallel side surfaces with the same material at the same time.

MDF and HDF materials are intended to be used indoors, with moderate and relatively stable ambient air humidity (generally dry, i.e. relative humidity not exceeding 65%), and especially without contact with liquid water. Within the scope of the present specification, MDF and HDF materials intended for indoor use are referred to as MDF and HDF materials in the basic embodiment. For use in conditions of increased exposure to moisture, wood-based materials such as MDF and HDF in moisture-resistant execution are provided, which are essentially made like MDF and HDF in the basic version, i.e. standard pulp obtained in the process of defibrating pressed wood material with the addition of resins synthetic resins, while the effect of resistance to moisture is obtained by using resins other than urea-formaldehyde as binding materials (because urea-formaldehyde resins have limited resistance to moisture), for example, phenol-formaldehyde, resorcinol-formaldehyde, melamine-formaldehyde, urea resins -melamine-formaldehyde. Polyisocyanates can also be used as binders. The water resistance is improved by incorporating the addition of liquid emulsions or otherwise liquefied waxes into the pulp.

Yet another type of MDF and HDF materials that show increased resistance to liquid water are lignocellulosic materials which, in addition to the synthetic resin contained in the bulk of the material and gluing the wood fibers together, are additionally impregnated with polyisocyanates, e.g. 6,620,459. However, the preparation of materials of this type, as well as the impregnation of individual elements of the frame and door leaf of MDF / HDF according to US 6,620,459, requires an additional step of treatment with polyisocyanates, said impregnation being complicated and characterized by a very high consumption of polyisocyanate per unit area of the impregnated material / item.

PL 229 642 B1

The use of typical moisture-resistant MDF and HDF boards (i.e. made by pressing wood fibers using synthetic resins that stick the fibers, essentially evenly dispersed in the material, and with the addition of wax emulsions) for the production of door units does not ensure the provision of door units that would be durable under the conditions of high humidity, variable humidity, and especially exposure to liquid water for at least several hours.

The invention will be further illustrated with reference to the drawing, in which fig. 1 shows the door assembly in a rectangular front view, fig. 2 - door leaf panel in a rectangular bottom view, fig. 3 - cross-section of a beam / post in a jamb set, fig. 4 illustrates a door leaf panel cut in a practical embodiment, and Figure 5 shows a door leaf panel cut in an alternative practical embodiment.

The solution according to the invention relates to a door assembly in which neither the door leaf panel nor the elements of the frame assembly show deformation of the shape or substantially detachment of the veneer from the surface of the wood-based material, in conditions of high humidity, variable humidity and / or at least 24-hour exposure to water. liquid. Fig. 1 illustrates the general appearance of a door assembly including a door leaf panel 1 and a jamb assembly 2 including two posts 2.1 and a horizontal beam 2.2. According to the invention, the vertical and horizontal rails of the door leaf panel 1 and the profiled posts 2.1 and the transverse beam 2.2 are made of blocks cut from moisture-resistant MDF material, and the facing of the frame structure of the door leaf panel 1 is made of a moisture-resistant HDF board. The door leaf panel 1, the profiled posts 2.1 and the transverse beam 2.2 included in the frame assembly 2 (and especially their facing surfaces) are veneered.

Comparative tests carried out by the present inventors have shown that the use of typical MDF / HDF materials in the basic execution (for internal use), and even typical MDF / HDF moisture-resistant materials in the door assembly method, does not provide a door assembly with sufficient resistance to moisture and water i. e. a door assembly that would not exhibit shape deformation or substantially detachment of the veneer under conditions of high humidity, varying humidity and / or at least 24 hours exposure to liquid water. Unexpectedly, the present inventors have found that the object of the invention, i.e. to fabricate and provide a door assembly comprising a door leaf panel 1 and a frame assembly 2 with improved resistance to high humidity conditions, variable humidity and / or at least 24 hours exposure to liquid water (in which According to the invention, the construction material is only typical wood-based materials, such as MDF and moisture-resistant HDF), it can be realized if a particular combination of construction materials, binders and finishing materials are used for the production of the door unit, preferably combined in the technological conditions specified in the method according to the invention.

The construction material for the production of the door set by the method according to the invention are typical moisture-resistant MDF and HDF materials, pressed from wood fibers glued with melamine-urea-formaldehyde resin, with the addition of a wax emulsion. The resin and emulsion are added to the pulp so that they are substantially uniformly dispersed throughout the produced MDF / HDF material. According to the method, elements of the door assembly are made, including the raw door leaf panel 1 and the raw door frame assembly 2. The raw door leaf panel 1 (with a frame structure) is composed of stiles made of moisture-resistant MDF, the space between the rails is filled with structured light filling, and the frame structure is filled with is stuck on both sides with a moisture-resistant HDF board. Raw elements of the door frame set 2, after cutting out the blocks of moisture-resistant MDF with dimensions adapted to the dimensions of the door leaf panel 1, are milled to the shape adapted to the cooperation with the said panel. Then, the independently mentioned door leaf panel 1 and the elements of the frame set 2 are glued with substantially water-impermeable veneer, using a hot-melt polyurethane adhesive, applied in an amount of 60-80 g / m ² . Unexpectedly, by using the combination of construction materials, adhesives and finishing materials shown, and the veneering according to the method of the invention, a door assembly is obtained with finished faced surfaces exhibiting unexpected resistance to conditions of high humidity, varying humidity and / or at least 24 hours. hourly exposure to liquid water. The production of the door assembly is carried out under technological conditions defined by the use of a hot-melt, reactive polyurethane adhesive applied by means of a glue application nozzle in the amount of 60-80 g / m ² , at a temperature of 110-130 ° C, more

Preferably at a temperature of 115-130 ° C, leaving the bonded panel and the frame assembly elements to cross-link the adhesive.

Typical materials and wood-based panels prepared from standard pulp obtained in the process of defibrating wood raw material, with the use of melamine-urea-formaldehyde resin and with the addition of wax emulsion are used as MDF and HDF moisture-resistant materials. Preferably, the melamine urea formaldehyde resin content is 14% -24%. The wax emulsion is used in an amount of 1-3%.

Examples of MDF and HDF materials are "Medium Density Fibreboard for Use in Humid Conditions With Low Formaldehyde Content" and "High Density Fibreboard for Use in Humid Conditions With Low Formaldehyde Content" available from FINSA, Santiago de Compostela, Spain.

A lightweight wood-based material known in the art is used as a structured lightweight filling, which is suitable for filling inter-frame spaces in panel door leaves. Preferably, filling structured light, which average density (relative to the volume of the międzyramiakowej) does not substantially exceed 300 kg / m ^3. For example, the filling may be a wood-based honeycomb material, or a variously shaped (e.g. V-shaped) and spaced-apart plurality of wood-based panel moldings. The filling can also be LDF (Low-Density Fibreboard). Generally, it is assumed that the density of the LDF plates is less than 650 kg / m ^3, but in the embodiment, the panel door wing according to the invention provides the use of the LDF boards having a density of at most 300 kg / m ^3. Preferably, the plate is structured filling LDF density of approximately 120-220 kg / m ^3, such as LDF plate having a density of about 200 kg / m ³ having a low swelling ratio, such as plate Homalight® D available from Homanit GmbH & Co., KG , Herzberg am Harz, Germany.

The structured light filling can also be a filling made with the use of lightweight particle boards, possibly with the use of embossed boards, also called orifice plates (having hollow channels running inside the board). These boards are formed and pressed vertically, which results in the perpendicular arrangement of the chips to wide planes. A light structure to fill the door leaf is also provided by the DendroLight® material, which has a central part made of solid, incised spruce wood glued in layers into an openwork core. The cladding of the board can be other thin-walled wood-based board or thin-layer glued wood panels. The density of the boards is in the range of 250-300 kg / m ³ .

The solution according to the invention uses a hot-melt reactive polyurethane adhesive, i.e. an adhesive containing a polyurethane resin having isocyanate reactive groups capable of reacting further with materials having / containing free hydroxyl and / or amine groups, for example with ambient moisture and / or the moisture of the material to be glued. , and / or with a lignocellulosic material to form a cross-linked polymer. Preferably, the hot melt reactive polyurethane adhesive is an adhesive with an application temperature of 110-150 ° C having a viscosity in this temperature range of about 20,000-50,000 mPas, containing reactive 4-isocyanatophenyl moieties. An example of a hot-melt, reactive polyurethane adhesive is Jowatherm-Reaktant® hot-melt reactive adhesive (PUR), trade designation Jowat 605.60 (Jowat Polska sp. Z o.o., Sady near Poznań, Poland).

The present invention employs a substantially water-impermeable veneer, which is preferably selected from the group consisting of a veneer having at least one backing layer made of organic plastic and a veneer having at least one backing layer made of cellulosic material impregnated with synthetic organic resins.

The veneer having at least one support layer made of organic plastic is a veneer having at least a support layer of thermoplastic organic polymer covered with a decorative layer, for example a printed layer and an overlay layer. Particularly preferably, such a veneer is a PVC veneer having a wood-imitating decorative layer and an overlay, for example Golden Oak TWIN PVC.

A veneer having at least one support layer made of cellulosic material impregnated with synthetic organic resins is a veneer consisting of several (at least 3) layers of paper impregnated with synthetic organic resins pressed at elevated temperature and pressure to form a layered laminate. Preferably, this type of veneer is a laminate consisting of 3-4 hot-pressed layers of paper impregnated with resins and a decorative paper impregnated with resins. An example of a multi-layer veneer is a CPL (Continuous Pressure Laminate) laminate, which is a laminated material made by combining several layers of paper saturated with waterproof resins (melamine-formaldehyde).

PL 229 642 B1 and phenol-formaldehyde). CPL laminate consists of three or four hot pressed layers of papers impregnated with resins and covered with an overlay varnish coat with increased resistance to mechanical damage and the effects of physical factors (e.g. moisture). Examples of this type of veneer are the CPL White veneer (Folia microflex 15 morbida 8348 bianco) and the Akacja CPL - veneer (Folia microslim melaminico 15 morbida 8605) available from La-con S.p.A., Villa Santina, Italy.

Preferably, the solution according to the invention provides an additional step of gluing the door leaf panel 1, in which step at least one rim in the form of a veneer strip matching the shape of said narrow plane is applied to the narrow plane 3 of the door leaf panel 1. The rim may be made of the same veneer as used for the sash panel 1 and the frame assembly 2. The rim is superimposed on at least one narrow plane 3, on the underside narrow plane of the door leaf panel 1 (shown in Fig. 2) and possibly also onto the upper narrow plane of the door leaf panel 1, and the bonding is carried out using a hot-melt reactive polyurethane adhesive under the conditions specified above. The door leaf panel 1 with a narrow plane 3 veneered is more effectively protected against moisture absorption, because the rim is an additional barrier limiting the ingress of moisture and protecting against the effects of liquid water.

The improved water resistance of the door assemblies according to the invention has been demonstrated in the comparative tests given in the examples. Figures 3, 4 and 5 illustrate the execution of the samples used in the tests and associate the dimensions of the samples determined in the tests.

Examples

Test procedure I

General methodology for the preparation of samples of the frame kit and the liquid water exposure test.

For the embodiment of a ościeżnicowego used Water resistant MDF (Medium Density Fibreboard for Use in Humid Conditions With Low Formaldehyde Content, FINS Santiago de Compostela, Spain) having a thickness of 44 mm and a density of 675-730 kg / m ^3. The MDF material contains 68-74% wood fibers, 14-24% melamine-urea-formaldehyde resin, wax added in the form of an emulsion 1-3%. The humidity of the board is 7 ± 3%. Large-format MDF board is sliced on a multi-functional Selco panel saw, which allows for the preparation of blocks in any configuration. The cutting operation is controlled by the operator who sets the type and form of the blocks. The blocks are milled on a Wenig milling machine, and the milled elements are then covered with a finishing foil on a Barberan edgebander. A door frame set is prepared in a similar way with the use of a basic MDF board.

The following veneers are used:

- CPL white veneer (microflex 15 morbida 8348 bianco foil) and Akacja CPL veneer - (Folia microslim melaminico 15 morbida 8605) - CPL laminates (La-con SpA, Villa Santina, Italy) consisting of several hot pressed (approx. 180 -200 ° C) layers of paper impregnated with resins and decorative paper impregnated in melamine or acrylic resins, with resin hardened at a pressure of 8-10 bar on the top side, giving the CPL veneer high mechanical strength, high surface hardness and high resistance to scratching, abrasion, dirt and humidity; thanks to the wood structure imprinted on the surface, CPL laminates give the door the effect of natural wood or veneer;

- decorative greco oak dark veneer (CATAS S. p. A., S. Giovanni al Nat., Italy) - cellulose paper impregnated with resins, covered with paints and finished with a topcoat; the technical parameters of the pre-impregnated paper are compatible with the use of adhesives such as EVA (ethylene polyvinyl acetate copolymer), polyurethane adhesive;

- Złoty Oak TWIN veneer - veneer with a carrier layer made of thermoplastic organic polymer, which is PVC, covered with a decorative layer and an overlay layer.

Sticking is carried out with the use of the following adhesives:

- Jowat-Hightherm® Polyolifina polyolefin hot melt adhesive, trade designation Jowat 221.80 (Jowat Polska sp. z oo, Sady near Poznań, Poland), with nozzle application (with precise dosing of the applied adhesive, 80-120 g / m ² ) in a temperature of about 180 ° C; hereinafter referred to in the examples as polyolefin adhesive;

PL 229 642 B1

- polyurethane hot melt adhesive (PUR reactive hot melt adhesive) Jowatherm-Reaktant®, trade designation Jowat 605.60 (Jowat Polska sp. z oo, Sady near Poznań, Poland), with nozzle application (with precise dosing of the applied adhesive weight, 60-80 g / m ² ) at a temperature of about 120 ° C; hereinafter referred to in the examples as polyurethane adhesive;

and the veneer is pressed with pressure rollers with the continuous movement of the glued element. Wrapping using a polyurethane adhesive is performed at a relatively low level of adhesive application weights (60-80 g / m ^2).

Preparation of samples for testing.

Six 2.1 posts are prepared for the door frame sets. Five 30 cm long sections are cut from each post 2.1 by cutting them transversely to provide thirty samples of the jamb kit for testing.

Measurement mode.

The sample of the frame set at time t0 is immersed in the water so that the water level reaches a height of 3 cm, measured from the lower edge of the sample. Measurements of the A, B, C dimensions (shown in Figure 3) of the weight of the sample are made after 1 hour (time point t1), 2 hours (time point t2) and 24 hours (time point t3).

Test procedure II

General methodology for the preparation of samples of the door leaf and the liquid water exposure test

For the embodiment of the panel of the door leaf is used Water resistant MDF (Medium Density Fibreboard for Use in Humid Conditions With Low Formaldehyde Content, FINS Santiago de Compostela, Spain) having a thickness of 38 mm and a density of 675-730 kg / m ^3. The MDF material contains 68-74% wood fibers, 14-24% melamine-urea-formaldehyde resin, wax added in the form of an emulsion 1-3%. The humidity of the board is 7 ± 3%. The large-format MDF board is cut on a multi-functional Selco panel saw to create vertical and horizontal stiles of the sash panel, which are assembled to form a panel frame, filling the spaces between the stiles with a structured light filling (made of Homalight® D board - LDF board, Low Density Fibreboard, d = 200 kg / m ³ , Homanit GmbH & Co. KG, Germany, or honeycomb filling). A frame panel on both sides sticky Water resistant HDF (High Density Fibreboard for Use in Humid Conditions With Low Formaldehyde Content, FINS Santiago de Compostela, Spain) having a thickness of 3 mm and a density of 810-820 kg / m ^3. HDF material contains 68-74% wood fibers, 14-24% melamine-urea-formaldehyde resin and wax added in the form of 1-3% emulsions. The humidity of the board is 7 ± 3%. The sash frame is glued with HDF boards in an ORMA press with the use of Woodmax® WR 13.50 M glue (polyvinyl acetate dispersion glue, water resistance class D3, Synthos Dwory sp. Z oo SKA, Oświęcim, Poland). The raw panel of the door leaf, after formatting on the GABBIANI milling machine, is covered with a finishing foil on the BARBERAN edgebander.

Similarly, a door leaf panel is prepared using basic MDF and HDF materials.

The following veneers are used:

- CPL White veneer (Microflex 15 morbida 8348 bianco film) and CPL Akacja veneer - (Folia microslim melaminico 15 morbida 8605) (La-con SpA, Villa Santina, Italy) - CPL laminates consisting of several hot pressed (approx. 180 -200 ° C) layers of paper impregnated with resins and decorative paper impregnated in melamine or acrylic resins, with resin hardened at a pressure of 8-10 bar on the top side, giving the CPL veneer high mechanical strength, high surface hardness and high resistance to scratching, abrasion, dirt and humidity. Thanks to the wood structure imprinted on the surface, CPL laminates give the door the effect of natural wood or veneer;

- decorative greco oak dark veneer (CATAS S.p.A., S. Giovanni al Nat., Italy) - cellulose paper impregnated with resins, covered with paints and finished with a topcoat; technical parameters of pre-impregnated paper enable the use of adhesives, among others EVA, PUR;

- decorative walnut veneer (VTO-Dekor Sp.z o.o., Głogówek, Poland) - cellulose paper impregnated with resins, covered with paints and finished with a topcoat.

PL 229 642 B1

Sticking is carried out with the use of the following adhesives:

- ethylene polyvinyl acetate (EVA) hot melt adhesive, trade designation Henkel PW839, applied by roller at 170-180 ° C; hereinafter referred to in the examples as EVA adhesive;

- Jowat-Hightherm® Polyolifina polyolefin hot melt adhesive, trade designation Jowat 221.80 (Jowat Polska sp. z oo, Sady near Poznań, Poland), with nozzle application (with precise dosing of the applied adhesive, 80-120 g / m ² ) in a temperature of about 180 ° C; hereinafter referred to in the examples as polyolefin adhesive;

- polyurethane hot melt adhesive (PUR reactive hot melt adhesive) Jowatherm-Reaktant®, trade designation Jowat 605.60 (Jowat Polska sp. z oo, Sady near Poznań, Poland), with nozzle application (with precise dosing of the applied adhesive weight, 60-80 g / m ² ) at a temperature of about 120 ° C; hereinafter referred to in the examples as polyurethane adhesive;

and the veneer is pressed with pressure rollers with the continuous movement of the glued element. Wrapping using a polyurethane adhesive is performed at a relatively low level of adhesive application weights (60-80 g / m ^2).

Preparation of samples for testing.

15 panels of door leaves are prepared. Two pieces are cut from each panel (on the left side of the panel edge and on the right side of the panel side) of rectangular shape with dimensions A, B, C as shown in Fig. 4 or Fig. 5, respectively, giving 15 left-sided and 15 right hand slices for a total of 30 samples for testing.

Measurement mode.

The panel sample at time point 10 is immersed in the water so that the water level is up to a height of 3 cm measured from the lower edge of the sample. Measurements of A, B, C dimensions and sample weight are made at 1 hour (time point 11), 2 hours (time point t2) and 24 hours (time point t3).

P r z k ł a d 1

The door frame sets were prepared according to test procedure I, in the following execution: construction material - profile cut from moisture-resistant MDF board, Golden Oak TWIN veneer, polyurethane adhesive. The samples for measurement were prepared as in test procedure I, using the measurement mode as in test procedure I. The averaged measurement results (mean values from thirty measurements) are shown in Table 1.

T a b e l a 1. Test results for samples of the door frame immersed in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. T0 33.65 89.6 44.6 522.1 t1 = 1 hour 33.8 89.7 44.8 523 t2 = 2 hours 33.8 89.7 44.9 523.3 t3 = 24 hours 34.6 89.8 46.1 528.9 Relative increment, from t0 to te 2.82% 0.22% 3.36% 1.30%

Visual assessment: samples after the tests retain their original performance characteristics and there is no visible line separating the fragment of the sample immersed in water from the fragment above the water surface; in a few cases, a slight detachment of the veneer from the MDF material was observed.

P r z k ł a d 2

The door frame sets were prepared according to test procedure I, in the following execution: construction material - profile cut from moisture-resistant MDF board, Akacja CPL veneer, polyurethane adhesive. The samples for measurement were prepared as in test procedure I, using the measurement mode as in test procedure I. The averaged measurement results (mean values from thirty measurements) are shown in Table 2.

PL 229 642 B1

T a b e l a 2. Test results for samples of the door frame set immersed in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 33.4 89.35 44.4 523.2 t1 = 1 hour 33.5 89.5 44.5 524.1 t2 = 2 hours 33.8 89.5 44.7 524.5 t3 = 24 hours 34.7 89.6 45.9 531.9 Relative increment, from t0 to t3 3.89% 0.28% 3.38% 1.66%

Visual assessment: samples after the tests retain their original performance characteristics and there is no visible line separating the fragment of the sample immersed in water from the fragment above the water surface; in a few cases, a slight detachment of the veneer from the MDF material was observed.

P r z k ł a d 3 (comparative)

The door frame sets were prepared according to test procedure I, in the following execution: construction material - a profile cut from moisture-resistant MDF board, Golden Oak TWIN veneer, polyolefin glue. The samples for measurement were prepared as in test procedure I, using the measurement mode as in test procedure I. The averaged measurement results (mean values from thirty measurements) are shown in Table 3.

T a b e l a 3. Test results for samples of the door frame set immersed in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 33.7 89.7 44.7 524.7 t1 = 1 hour 33.9 89.8 44.8 525.4 t2 = 2 hours 34.1 89.9 44.9 525.7 t3 = 24 hours 35.1 90 46.3 531.2 Relative increment, from t0 to te 4.15% 0.33% 3.58% 1.24%

Visual assessment: samples after testing have a clearly visible line separating a fragment of the sample immersed in water from the fragment above the water surface, and there is also a detachment of the veneer from the MDF material.

P r z k ł a d 4 (comparative)

The door frame sets were prepared according to test procedure I, in the following execution: construction material - profile cut from MDF board (basic version), Golden Oak TWIN veneer, polyolefin glue. The samples for measurement were prepared as in test procedure I, using the measurement mode as in test procedure I. The averaged measurement results (mean values from thirty measurements) are shown in Table 4.

T a b e l a 4. Test results for samples of the door frame set immersed in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 33.7 89.9 44.2 508.9 t1 = 1 hour 34.1 89.9 44.6 510 t2 = 2 hours 34.4 90.1 44.9 510.5 t3 = 24 hours 36.1 90.1 46.45 516 Relative increment, from t0 to te 7.12% 0.22% 5.09% 1.40%

PL 229 642 B1

Visual assessment: samples after testing are distorted and have a clearly visible line separating a fragment of the sample submerged in water from the fragment above the water surface, and there is also a delamination of the veneer from the MDF material.

P r z k ł a d 5 (comparative)

The door frame sets were prepared according to test procedure I, in the following execution: construction material - profile cut from MDF board (basic version), Golden Oak TWIN veneer, polyurethane adhesive. The samples for measurement were prepared as in test procedure I, using the measurement mode as in test procedure I. The averaged measurement results (mean values from thirty measurements) are shown in Table 5.

T a b e l a 5. Test results for samples of the door frame set immersed in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 33.8 90 44.2 512.5 t1 = 1 hour 33.9 90 44.5 513.4 t2 = 2 hours 34.2 90.1 44.8 513.7 t3 = 24 hours 35.2 90.25 46.1 517.2 Relative increment, from t0 to te 4.14% 0.28% 4.30% 0.92%

Visual assessment: samples after testing are distorted and have a clearly visible line separating a fragment of the sample submerged in water from the fragment above the water surface, and there is also a delamination of the veneer from the MDF material.

P r z k ł a d 6 (comparative)

The door frame sets were prepared according to test procedure I, in the following execution: construction material - profile cut from moisture-resistant MDF board, Akacja CPL veneer, polyolefin glue. The samples for measurement were prepared as in test procedure I, using the measurement mode as in test procedure I. The averaged measurement results (mean values from thirty measurements) are shown in Table 6.

T a b e l a 6. Test results for samples of the door frame set immersed in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 33.5 89.55 44.25 522.5 t1 = 1 hour 33.7 89.6 44.4 523.3 t2 = 2 hours 33.9 89.8 44.6 523.6 ta = 24 h 35 89.8 45.8 529.7 Relative increment, from t0 to fe 4.48% 0.28% 3.50% 1.38%

Visual assessment: samples after testing have a visible line separating a fragment of the sample submerged in water from the fragment above the water surface, and there is also peeling of the veneer from the MDF material.

P r z k ł a d 7 (comparative)

The door frame sets were prepared according to test procedure I, in the following execution: construction material - profile cut from MDF board (in the basic version), veneer

Acacia CPL, polyolefin glue. The samples for measurements were prepared as in test procedure I, using the measurement mode as in test procedure I. The averaged measurement results (mean values from thirty measurements) are shown in Table 7.

PL 229 642 B1

T a b e l a 7. Test results for samples of the door frame immersed in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 33.45 89.4 44.25 512.2 t1 = 1 hour 33.85 89.5 44.5 513.9 t2 = 2 hours 34.3 89.6 44.9 514.8 ta = 24 h 36.4 89.6 46.6 525.3 Relative growth, from this to these 8.82% 0.22% 5.31% 2.56%

Visual assessment: samples after testing are distorted and have a clearly visible line separating a fragment of the sample submerged in water from the fragment above the water surface, and there is also a delamination of the veneer from the MDF material.

P r z k ł a d 8 (comparative)

The door frame sets were prepared according to test procedure I, in the following execution: construction material - profile cut from MDF board (basic version), Akacja CPL veneer, polyurethane adhesive. Measurement samples were prepared as in test procedure I, using the measurement mode as in test procedure I. The averaged measurement results (mean values from thirty measurements) are shown in Table 8.

T a b e l a 8. Test results for samples of the door frame set immersed in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. this 33.5 89.7 44.15 507.8 t1 = 1 hour 33.65 89.7 44.4 508.9 t2 = 2 hours 34 89.95 44.7 509.3 t3 = 24 hours 35.5 90 46.15 513 Relative growth, from this to these 5.97% 0.33% 4.53% 1.02%

Visual assessment: samples after testing are distorted and have a clearly visible line separating a fragment of the sample submerged in water from the fragment above the water surface, and there is also a delamination of the veneer from the MDF material.

P r z k ł a d 9 (comparative)

The door frame sets were prepared according to test procedure I, in the following execution: construction material - profile cut from moisture-resistant MDF board, Greco oak dark veneer, polyolefin glue. The samples for measurement were prepared as in test procedure I, using the measurement mode as in test procedure I. The averaged measurement results (mean values from thirty measurements) are shown in Table 9.

T a b e l a 9. Test results for samples of the door frame set immersed in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 33.3 89.3 44.3 500 t1 = 1 hour 33.55 89.3 44.5 500.7 t2 = 2 hours 33.7 89.4 44.7 501 t3 = 24 hours 34.75 89.4 46.1 506.8 Relative increment, fe to te 4.35% 0.11% 4.06% 1.36%

PL 229 642 B1

Visual assessment: samples after testing have a clearly visible line separating a fragment of the sample immersed in water from the fragment above the water surface, and there is also a detachment of the veneer from the MDF material.

P r z k ł a d 10 (comparative)

The door frame sets were prepared according to test procedure I, in the following execution: construction material - profile cut from moisture-resistant MDF board, Greco oak dark veneer, polyurethane adhesive. Measurement samples were prepared as in test procedure I, using the measurement mode as in test procedure I. The averaged measurement results (mean values from thirty measurements) are shown in Table 10.

T a b e l a 10. Test results of the samples of the immersed door frame set

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 33.3 89.2 44.15 521.3 t1 = 1 hour 33.5 89.3 44.35 522.1 t2 = 2 hours 33.7 89.4 44.5 522.5 t3 = 24 hours 34.6 89.5 44.6 528.9 Relative increment, fe to te 3.90% 0.34% 1.02% 1.46%

Visual assessment: samples after testing show damage, have a clearly visible line separating a fragment of the sample immersed in water from the fragment above the water surface, and there is also a detachment of the veneer from the MDF material.

P r z k ł a d 11 (comparative)

The door frame sets were prepared according to test procedure I, in the following execution: construction material - profile cut from MDF board (basic version), Greek walnut veneer, polyolefin glue. The samples for measurement were prepared as in test procedure I, using the measurement mode as in test procedure I. The averaged measurement results (mean values from thirty measurements) are shown in Table 11.

T a b e l a 11. Test results for samples of the door frame set immersed in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 33.3 89.3 44.1 509.8 t1 = 1 hour 33.45 89.45 44.3 510.8 t2 = 2 hours 34.05 89.5 44.6 511.1 t3 = 24 hours 36.15 89.6 46.35 515.8 Relative increment, from t0 to te 8.56% 0.34% 5.10% 1.18%

Visual assessment: samples after testing are distorted and have a clearly visible line separating a fragment of the sample submerged in water from the fragment above the water surface, and there is also a delamination of the veneer from the MDF material.

P r z k ł a d 12 (comparative)

The door frame sets were prepared using the method according to test procedure I, in the following execution: construction material - profile cut from MDF board (basic version), Greco oak dark veneer, polyurethane adhesive. Measurement samples were prepared as in test procedure I, using the measurement mode as in test procedure I. Averaged measurement results (mean values from thirty measurements are shown in Table 12.

PL 229 642 B1

T a b e l a 12. Test results for samples of the door frame set immersed in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 33.35 89.4 44.1 504.6 t1 = 1 hour 33.6 89.5 44.3 505.6 t2 = 2 hours 33.8 89.5 44.6 505.8 t3 = 24 hours 35.3 89.7 46.1 509.3 Relative increment, from t0 to t3 5.85% 0.34% 4.54% 0.93%

Visual assessment: samples after testing have a clearly visible line separating a fragment of the sample immersed in water from the fragment above the water surface, and there is also a detachment of the veneer from the MDF material.

The results from Examples 1-12 show that during a 24-hour exposure to water, the samples of the frame assembly absorb water in the range of 0.9-2.6% of the original weight, regardless of whether they are made of basic or moisture-resistant MDF. On the other hand, the samples of the door frame set made of MDF in the basic version show a clearly greater and more uneven level of swelling and greater damage than in the case of moisture-resistant MDF. In the case of samples of the door frame set, veneered with polyolefin glue, there are at least damage such as peeling of the veneer. Compared to comparative examples 3-12, the inventive examples, i.e. Examples 1 and 2, show an improved water resistance, where a combination of moisture-resistant MDF, a substantially non-absorbent veneer and a polyurethane adhesive are used.

P r x l a d 13

The door leaf panels were assembled according to test procedure II, in the following execution: edge according to Fig. 5, construction material - rails cut from moisture-resistant MDF board, filling - Homalight D board, sheathing - moisture-resistant HDF board, CPL White veneer, polyurethane adhesive. The samples for measurement were prepared as in test procedure II, using the measuring mode as in test procedure II. The averaged measurement results (average values from thirty measurements) for the slices cut out according to Fig. 5 are shown in Table 13.

T a b e l a 13. Test results for panel samples submerged in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 40.3 240.5 242 1152.4 t1 = 1 hour 40.4 240.5 242 1154.6 t2 = 2 hours 40.65 240.5 242 1156 ta = 24 h 41.35 241.5 243 1181.1 Relative increment, from t0 to t3 2.61% 0.41% 0.41% 2.49%

Visual assessment: samples after the tests retain their original performance characteristics and there is no visible line separating the fragment of the sample immersed in water from the fragment above the water surface; in a few cases, a slight detachment of the veneer from the MDF / HDF material was observed.

P r z k ł a d 14 (comparative)

The door leaf panels were assembled according to test procedure II, in the following execution: edge according to Fig. 5, construction material - rails cut from moisture-resistant MDF board, filling - Homalight D board, sheathing - moisture-resistant HDF board, CPL White veneer, polyolefin glue. The samples for measurement were prepared as in test procedure II, using the measuring mode as in test procedure II. The averaged measurement results (average values of thirty measurements) for the slices cut out according to Fig. 5 are shown in Table 14.

PL 229 642 B1

T a b e l a 14. Test results for panel samples submerged in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 40.25 240.5 242 1152.8 t1 = 1 hour 40.4 240.5 242 1154.5 t2 = 2 hours 40.75 240.5 242 1155.4 t3 = 24 hours 41.3 241.5 243 1177.5 Relative increment, from t0 to t3 2.61% 0.41% 0.41% 2.14%

Visual assessment: samples after testing have blisters, there is a detachment of the veneer from the substrate and a clearly visible line separating the part of the sample submerged in water from the part above the water surface.

P r z k ł a d 15 (comparative)

The door leaf panels were assembled according to test procedure II, in the following version: edge according to Fig. 4, construction material - rails cut from MDF board (basic version), sheathing - HDF board (basic version), filling - honeycomb, veneer CPL Acacia, polyolefin glue. The samples for measurement were prepared as in test procedure II, using the measuring mode as in test procedure II. The averaged measurement results (average values from thirty measurements) for the slices cut out according to Fig. 4 are shown in Table 15.

T a b e l a 15. Test results for panel samples submerged in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 40 240 240 770.6 t1 = 1 hour 40.5 240 240 774.6 t2 = 2 hours 40.55 240 241 775.7 t3 = 24 hours 41.6 241 245 789.6 Relative increment, from t0 to t3 4.00% 0.42% 2.08% 2.47%

Visual assessment: samples after testing show cracks and delamination of the MDF board, damage is visible at the edges where the veneer sheets meet.

P r z k ł a d 16 (comparative)

The door leaf panels were assembled according to test procedure II, in the following version: edge according to Fig. 5, construction material - rails cut from MDF board (basic version), sheathing - HDF board (basic version), filling - Homalight board, veneer greco oak dark, EVA glue. The samples for measurement were prepared as in test procedure II, using the measuring mode as in test procedure II. The averaged measurement results (average values from thirty measurements) for the slices cut out according to Fig. 5 are shown in Table 16.

T a b e l a 16. Test results for panel samples submerged in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 40.05 240 240 1232.3 t1 = 1 hour 40.5 240 240 1235.3 t2 = 2 hours 40.5 240 240.8 1236.2 t3 = 24 hours 41.4 241.8 242 1244.1 Relative increment, from t0 to t3 3.37% 0.75% 0.83% 0.96%

PL 229 642 B1

Visual assessment: samples after testing are distorted, there is delamination of the MDF board, veneer cracks are visible and the line separating the fragment of the sample immersed in water from the fragment above the water surface is clearly visible.

P r z k ł a d 17 (comparative)

The door leaf panels were assembled according to test procedure II, in the following version: edge according to Fig. 4, construction material - rails cut from MDF board (basic version), sheathing - HDF board (basic version), filling - Homalight board, veneer walnut, EVA glue. The samples for measurement were prepared as in test procedure II, using the measuring mode as in test procedure II. The averaged measurement results (average values from thirty measurements) for the sections cut out according to Fig. 4 are shown in Table 17.

T a b e l a 17. Test results for panel samples submerged in water

Value of the linear dimension [mm] Sample weight [g] Measurement mode AND B C. t0 40.1 240 240 1247.7 t1 = 1 hour 40.7 240 240 1250.7 t2 = 2 hours 40.8 240 241 1251.6 t3 = 24 hours 42.2 243 243 1263.3 Relative increment, from t0 to te 5.24% 1.25% 1.25% 1.25%

Visual assessment: samples after testing are distorted, there is delamination of the MDF board, veneer cracks are visible and the line separating the fragment of the sample immersed in water from the fragment above the water surface is clearly visible.

The results from Examples 13-17 show that during a 24-hour exposure to water, the samples of the door leaf panels absorb water in the range of 1-2.5% of the original weight, regardless of whether they are made of MDF and HDF in the basic or with Moisture-resistant MDF and HDF. On the other hand, the samples of panels made of MDF and HDF in the basic version show a clearly greater and more uneven level of swelling and greater damage than in the case of moisture-resistant MDF and HDF. In the case of panels veneered with EVA and polyolefin glue, there are at least damage such as peeling of the veneer. Compared to comparative examples 14-17, the example of the invention shows an improved water resistance, where a combination of moisture-resistant MDF, moisture-resistant HDF board, substantially non-absorbent veneer and polyurethane adhesive (Example 13) is used.

Claims (6)

A method of producing a door assembly, comprising a door leaf panel with a frame structure composed of stiles made of moisture-resistant MDF, covered on both sides with a moisture-resistant HDF board, having a structured light filling, and a frame set made of moisture-resistant MDF, in which the facing surfaces of the door assembly are then taped veneer with the use of hot-melt glue, characterized in that in the following stages: a) use a moisture-resistant MDF and a board made of moisture-resistant HDF, containing a melamine-urea-formaldehyde resin as an adhesive for wood fibers, and containing the addition of a wax emulsion, b) a raw door leaf panel (1) with a frame structure made of vertical and horizontal stiles made of moisture-resistant MDF, covered on both sides with a moisture-resistant HDF board with the use of dispersion adhesive, after placing a light structured filling in the space between the stiles in the form of an LDF board with a density not exceeding 300 kg / m ³ , c) raw elements of the door frame set (2), including two posts (2.1), a cross beam (2.2), are delivered, milled from moisture-resistant MDF, PL 229 642 B1 d) the above-mentioned panel (1) and the posts (2.1) and the beam (2.2) of the frame set (2) are glued independently with a veneer that is substantially water-impermeable with the use of a hot-melt, reactive polyurethane adhesive applied by means of a nozzle applying glue in the amount of 60-80 g / m ² , at a temperature of 110-130 ° C, and e) the glued panel (1) and the posts (2.1) and the beam (2.2) of the door frame assembly (2) are left to cross-link the polyurethane adhesive, producing a door assembly with increased water resistance, showing no deformation of the shape or substantially detachment of the veneer from the MDF material surface / HDF in conditions of high humidity, variable humidity and / or at least 24 hours of exposure to liquid water. 2. A method for manufacturing a door assembly according to claim 1. The method of claim 1, characterized in that the use of a moisture-resistant MDF board and a board of moisture-resistant HDF with a melamine urea-formaldehyde resin content of 14-24% and a wax emulsion of 1-3% are used. 3. A method for manufacturing a door assembly according to claim 1. A method as claimed in claim 1 or 2, characterized in that, after step e), a narrow plane (3) of the door leaf panel (1) is glued with at least one rim made of water-repellent veneer. 4. A method for manufacturing a door assembly as claimed in claim 1. A veneer according to claim 1, wherein the substantially water-impermeable veneer is a veneer having at least one backing layer made of organic plastic or a veneer having at least one backing layer made of cellulose material impregnated with synthetic organic resins. 5. A method for manufacturing a door assembly as claimed in claim 1. The method of claim 1, characterized in that in step d) the adhesive is applied at a temperature of 115-130 ° C. 6. A method for manufacturing a door assembly as claimed in claim 1. The process of claim 1, wherein in step b) a polyvinyl acetate-based dispersion adhesive is used.