Door leaf comprising at least one stone cover plate preferably for an interior door, and method for producing the same

Abstract

The invention relates to a door leaf, preferably for an interior door, and to a method for producing the same. The aim of the invention is to provide a door leaf for a double-wing door or revolving door, which is relatively light-weight and stable and which can be opened using normal force. The outer layer should consist of a layer that is break-proof, scratch-resistant and not susceptible to shocks and should be securely linked with the subject layer without complications. The use of water should be possible during the production of the door without damaging the door leaf. According to the invention, cover plates are glued onto the entire surface of both sides of an inner layer that has a suitable size for a double-wing door or revolving door. At least one of the one-piece cover plates consists of natural stone or artificial stone. During production of the door leaf the inner layer is foamed from high-resistance plastic foam in a mold and is removed from the mold after setting and then glued together with the cover plates. The cover plates are cut down to minimum thicknesses and / or ground down (calibrated). Alternatively, the inner layer is foamed from high-resistance plastic foam in a mold. The cover plates are first inserted in the mold at a distance to each other and then foamed to the inner layer. After setting, the door leaf is removed from the mold and the cover plates are cut down to minimum thicknesses and / or ground down (calibrated).

Description

FIELD OF THE INVENTION [0001] The invention relates to a door leaf, preferably for an interior door, based on the overall concept of Patent claim 1, and a procedure for its manufacture. BACKGROUND OF THE INVENTION [0002] A folding door is known from DE prototype 84 30 609.2 U1 whose narrow door leaf segments are stiff against deformation, mounted in pivoting links with vertical pivot axes, and are folded individually upon one another in a zigzag pattern into at least one packet in their opened position. Each of the door leaf segments includes a block of closed-pore hard foam, preferably of polyurethane. On both sides of the block, cover plates of solid, monolithic plastic reinforced with mineral or fiberglass fibers are mounted flat or laminated with adhesive. [0003] This solution will publish only segmented door leafs without reference to applicability for double-wing or revolving door leafs. [0004] A house entry door is known from DE 197 01 185 A1 consisting of preferably four lay...

AI Technical Summary

Benefits of technology

"The invention is a lightweight, strong double-wing or revolving door leaf that can be opened using normal force. The outer layer of the leaf is made of a layer that is not susceptible to breakage, impact, or scratching, and is bound with low cost to the lower layer. The use of water can be possible during door manufacture without damage to the door leaf. The door leaf is made of an inner layer of hard foam, preferably polyurethane, with cover plates bonded flat on both sides of the inner layer. The cover plates can be made of natural or artificial stone, or other known materials. Fiberglass elements or plastic or melanin epoxy can be embedded in or attached to the foam to increase strength. The manufacturing process involves foaming the inner layer and bonding it with the cover plates. The cover plates are then cut and / or ground to minimum thicknesses. The resulting door leaf has a weight that allows easy operation."

Problems solved by technology

Connection of the anchor bushings with the outer layer requires a considerable minimum thickness of this outer layer so that the door is heavy, and thus difficult to operate.

Simultaneously, breakage hazard to the stone plates, which possess only low resistance to impact, is increased by the point attachments in the form of anchor bolts.

Further, because of the weight, an outer layer of natural stone with no seams is not practical.