WO1987005355A1

WO1987005355A1 - A method and an arrangement for the manufacture of doors

Info

Publication number: WO1987005355A1
Application number: PCT/SE1987/000093
Authority: WO
Inventors: Lars Alvergren; Tom Fredlund; Anders Westas
Original assignee: Pur-Gruppen I Partille Ab
Priority date: 1986-02-28
Filing date: 1987-02-25
Publication date: 1987-09-11
Also published as: DK165424C; DK165424B; AU7082387A; DK553687A; SE8600895L; SE8600895D0; DK553687D0; SE455872B

Abstract

A method for the manufacture of doors (1) and other building elements which extend in the form of a sheet and which are formed from a rectangular frame (2), preferably made of a wooden material and exhibiting an internal cavity (4), which frame is intended to be filled with cast plastic material (3) and to be covered with side trims (5, 6) in the form of sheets. The invention permits, amongst other things, the systematic manufacture of doors which exhibit internal insulation made of a cast plastic material and which are imparted with good strength characteristics and temperature characteristics. A mounting sheet (7, 8) in the form of a sheet provided with a number of holes (11) is placed between the frame (2) and said side trims (5, 6). Said cavity (4) in the frame is then filled with cast plastic material (3) of a liquid consistency so that the cast plastic material (3) penetrates through the holes (11) in the mounting sheet and adheres to parts (7A, 8A; 9, 10) situated along adjacent parts of the mounting sheet (7, 8) in question. The invention also relates to an arrangement for the execution of the method.

Description

A method and an arrangement for the manufacture of doors

The present invention relates to a method for the manufacture of doors and other building elements which extend in the form of a sheet and which are formed from a rectangular frame, preferably made of a wooden material and exhibiting an internal cavity, which frame is intended to be filled with a cast plastic material and to be covered with side trims in the form of sheets. The principal object of the present invention is, in the first place, to make available a method of the kind indicated above which permits, amongst other things, the manufacture of doors, etc., in a simple and systematic fashion and the achievement of the optimum characteristics in each of the materials from which the doors are manufactured. Said object is achieved by a method in accordance with the present invention which is characterized essentially in that a mounting sheet in the form of a sheet provided with a number of holes is placed between the frame and said side trim, and in that said hollow cavity in the frame is then filled with cast plastic material of a liquid consistency so that the cast plastic material penetrates through the holes in the mounting sheet and adheres to parts situated along adjacent parts of the mounting sheet in question.

The invention also relates to an arrangement which permits said method for the manufacture of doors, etc., to be performed in accordance with what is stated above, whereby the manufacture is permitted of doors, etc., in which the more desirable characteristics of various materials are combined in order to obtain a simple, strong and inexpensive door, preferably made of polyurethane and wood.

Said further object is achieved by means of an arrangement in accordance with the present invention which is characterized essentially in that the frame is so adapted as to support a mounting sheet provided with a number of holes and capable of being accommodated between the side trim and the frame.

The invention is described below as a preferred illustrative embodiment, in conjunction with which reference is made to the accompanying drawings, in which:

Fig. 1 shows a vertical view of a door manufactured in accordance with the present invention; 5 Fig. 2 shows a horizontal view of said door;

Fig. 3 shows a principle sketch of a part of a door in accordance with the present invention; and

Fig. 4 shows a principle sketch of a method in accordance with the present invention for the manufacture of a TO door.

A door 1 or some other building element, which extends in the form of a sheet and which is formed from a rectangular frame 2, which accommodates internal insulation 3 consisting of a plastics material inside an internal hollow cavity T5. 4, which is covered by side trims 5, 6 in the form of sheets, contains in accordance with the invention a mounting sheet 7, 8 in the form of a sheet provided with holes positioned between the frame 2 and the side trim 5, 6. The door frame 2, which consists of a wooden material, can exhibit around its periphery rebates or 2H other similar recesses 9, 10 on the side 2A of the frame which faces towards said space 4 as well as door frame lateral surfaces 2B, 2C situated at a certain distance from one another and facing away from one another. Said mounting sheets 7, 8, which are provided with a number of holes 11, can be accommodated by their 5 respective peripheral parts 7A, 8A in corresponding recesses 9, 10 of the kind in question, for example as shown in Fig. 2.

The mounting sheets 7, 8 consist preferably of a metallic material, such as aluminium or some other light metal, or of sheet steel, and can exhibit a number of previously perforated 0 holes 11 over most of their surface. The thickness T of the mounting sheets 7, 8 at least along their peripheral parts is appropriately less than the depth D of said recesses so as to permit them to fit flush therein.

The side trims 5, 6, which preferably also consist 5 of a wooden material, are intended to be capable of being attached to the frame 2 by means of a bonding agent 12, for example an adhesive, for which purpose the lateral surfaces 2B, 2C of the frame are coated with an adhesive, for example, before the side trims 5, 6 are pressed against the frame 2. The side trims 5, 6 are also so arranged as to be attached to the plastics material 3 via the plastics material 3A which emerges from the plastic— —accommodating cavity 4 between the mounting sheets 7, 8 through the holes in said mounting sheets 7, 8, whilst the mounting sheets 7, 8 adhere to the plastics material 3 over the rest of their surfaces 7A, 8A which face towards the cavity 4 and the frame 2, which plastics material is accommodated in the cavity 4 and in the recesses 9, 10.

The plastics material 3, with which it is proposed to fill the cavity 4, consists of a cast piastres material of a liquid consistency, preferably an expanded cast plastics material, preferably polyurethane of preferably average density.

Before casting said plastics material 3 to produce internal insulation inside the door 1, distance pieces 13, which preferably consist of pieces of a plastics material similar to the plastics material 3 with which it is proposed to fill the mould cavity 4, are preferably arranged between the two mounting sheets 7,8, so that these are maintained at the desired relative distance from one another during the plastic casting operation.

The plastic casting operation can take place in a previously disclosed manner, for example by the procedure outlined in SE, B, 8207223—2, by introducing the plastic casting material 3 in liquid form via a number of inlets 14 passing through the frame 2 and into the cavity 4, and by permitting any air or gas, etc., which is produced during casting or which is present in said cavity 4 beforehand, to be evacuated via a number of evacuation openings 15 similar to bore holes in the frame 2.

The manufacture of a door leaf 1, etc., in accordance with a method in accordance with the present invention takes place by a procedure which involves a frame 2, which exhibits recesses 9, 10 around its periphery in accordance with _what is stated above, and which can also exhibit a number of grooves 16 which a r^~ intended to absorb forces in the frame 2, being so arranged as to accommodate on either side mounting sheets 7, 8 with distance pieces 13 between same. One mounting sheet 8 is so arranged as to be supported by one 6 of the two trim sheets 5, 6, which is bonded securely to the frame 2 along the lateral edges 2B, 2C of the frame. The mounting sheets 7, 8 are positioned freely without being attached to the frame 2 and/or the trim sheets 5, 6. The cast plastic material 3 is then introduced in a liquid consistency via the inlet 14 through the frame 2, for example, preferably on one of the short sides of the frame. Once the cast plastic material 3, which preferably consists of polyurethane, has entirely filled the cavity 4 and has penetrated through the holes 11 in the mounting sheets 7, 8 and the recesses 9, 10, any surplus cast plastic material together with air and gas, etc., will flow out through the outlet holes 15, which are preferably situated on the opposite short side of the frame 2. Any cast plastic material which finds its way into the recesses 9, 10 will adhere to the outer parts 7A, 8A of the mounting sheets and to parts of the recesses 9, 10.

The entire door leaf 1 is appropriately accommodated lying essentially horizontally in a press 17, for example in the manner illustrated schematically in Fig. 4, and when the parts 17A, 17B of the press are forced together relative to one another to the desired degree, the cast plastic material 3 in the door leaf 1 will set so that a so—called skin is formed along its peripheral surface. Amongst other things, said skin prevents gases from the plastics material from escaping into the surroundings when the door 1 is in use, and the gases will be effectively contained inside the plastics material. The plastics material 3A penetrates through the holes 11 in the mounting sheets 7, 8 and effectively adheres securely to the internal surface 5A, 6A of each trim sheet and flows into the recesses 9, 10 and adheres securely to the frame 2 in said area and on its side 2A and in the groove 16. The distance pieces 13 are also embedded in and held together by means of the plastics material 3. Following the casting process, which preferably takes place at a given temperature, for example approximately 30-35°C, and the removal of the door leaf 1 from the press 17, a door leaf 1 or some other appropriate building element will have been produced which is easy to handle and which exhibits outstanding characteristics with regard both to its strength and to its thermal insulation capacity. In those cases in which the mounting sheets 7, 8 consist of metal, the resulting door 1 will exhibit excellent fire protection characteristics in addition to its excellent strength characteristics, for example against break—ins, etc. The mounting sheets 7, 8 are held by the plastics material 3 in such a way that they a re permitted to move for a certain distance, whereby any differences in temperature which influence the door on its outside and its inside 1A, 1B can be absorbed by said mounting sheets 7, 8 thanks to their ability to move inside the door 1 relative to the associated side, trim 5, 6.

Once it has hardened, the door 1 can be finished, if this has not. already been done, for example by milling the frame 2 to its final form and by cutting any rebates for hinges and locks, etc., in the door, whereupon the door can be surface—treated.

If it is wished for the door leaf 1 to be provided with windows 18, this is easily carried out on a door leaf 1 manufactured in accordance with the invention. All that is necessary is simply to saw out the desired window opening 19 in the door leaf 1, cutting through both the "side trims 5, 6, the mounting sheets 7, 8 and the plastic insulation 3. One of the window frames 20, which consists of profile sections, is placed in said opening 19, and the intended windows 21, 22, which are introduced into the frame 20, are secured by means of, for example, internal securing profiles 23. The mounting sheets 7, 8, which are attached to the side trim sheets 5, 6 via the plastic 3, which passes through the large number of holes 11 arranged in the mounting sheets 7, 8, permit said hole to be sawn at any desired point on the surface of the door 1 without any separation being observed between the insulation 3 and the side trim 5, 6 after sawing the hole. The invention is not restricted to the illustrative embodiment described above, but may be modified within the scope of the Patent Claims without as a result departing from the idea of invention.

Claims

P a t e n t C l a i m s

1. A method for the manufacture of doors (1) and other building elements which extend in the form of a sheet and which are formed from a rectangular frame (2), preferably made of a wooden material and exhibiting an internal cavity (4), which frame is intended to be filled with a cast plastic material (3) and to be covered with side trims (5, 6) in the form of sheets, c h a r¬ a c t e r i z e d in that a mounting sheet (7, 8) in the form of a sheet provided with a number of holes (11) is placed between the frame (2) and said side trim (5, 6), and in that said hollow cavity (4) in the frame is then filled with cast plastic material (3) of a liquid consistency so that the cast plastic material (3) penetrates through the holes (11) in the mounting sheet and adheres to parts (7A, 8A; 9, 10) situated along adjacent parts of the mounting sheet (7, 8) in question.

2. A method in accordance with Patent Claim 1, c h a r¬ a c t e r i z e d in that a mounting sheet (7, 8) is positioned on the side parts (2B, 2C) which face away from one another so that these are permitted to move relative to the associated side trim (5, 6), preferably accommodated in recesses (9, 10) extending around the periphery of the frame.

3. A method in accordance with Patent Claim 2, c h a r¬ a c t e r i z e d in that the mounting sheets (7, 8) which are positioned consist of a metallic material, preferably aluminium or sheet steel.

4. A method in accordance with either of the preceding Patent Claims 2—3, c h a r a c t e r i z e d in that distance pieces (13) are positioned between the two mounting sheets (7, 8), which distance pieces preferably consist of a similar material to the aforementioned cast plastic material (3).

5. A method in accordance with any of the preceding Patent Claims, c h a r a c t e r i z e d in that the frame (2) is bonded to each side trim (5, 6) by means of a bonding agent (12), such as an adhesive.

6. A method in accordance with any of the preceding Patent Claims, c h a ra c te r i zed in that said side trims (5, 6) are pressed in conjunction with the casting operation in a direction towards one another, preferably with heating of the area of casting.

7. An arrangement for the manufacture of doors

(1) and other building elements which extend in the form of a sheet and which are formed from a rectangular frame (2), preferably made of a wooden material and exhibiting an internal cavity (4), which frame is intended to be filled with a cast plastic material (3) and to be covered with side trims (5, 6) in the form of sheets in accordance with any of the preceding Patent Claims, cha r ac t e r i ze d in that the frame (2) is so adapted as to support a mounting sheet (7, 8) provided with a number of holes (11) and capable of being accommodated between the side trim (5, 6) and the frame (2).

8. An arrangement in accordance with Patent Claim 7, c h a r a c t e r i zed in that the side parts (28, 2C) of the frame

(2) which face away from one another exhibit recesses (9, 10) so adapted as to accommodate the peripheral part (7A, 8A) of a mounting sheet of the kind in question.

9. An arrangement in accordance with either of the Patent Claims 7—8, c h a r a c t e r i z ed in that said mounting sheets (7, 8) consist of a metallic material, preferably in the form of perforated sheets of aluminium or sheet steel.

10. An arrangement in accordance with any of the Patent

Claims 7—9, c h a ra c t e r i zed in that at least the frame (2) consists of a wooden material, and in that preferably also the side trims (5, 6) consist of a wooden material.