Door leaf, door and method for manufacturing the door leaf

Description

[0001] The present invention relates to a door leaf according to the preamble of claim 1, as well as a door and a method for producing the door leaf.

[0002] State-of-the-art door leaves are often additionally glued. This applies, among other things, to the attachment of the door panels to a frame. The disadvantage of this is that the curing time of the adhesive often takes up a significant portion of the production time. In many designs, the bonding must also be performed in a horizontal position, which can potentially disrupt the production process. Therefore, purely mechanical solutions for the connection between the door leaf and frame are preferable.

[0003] A generic door leaf is described in EP 3 269 915 A1. L-shaped frame members, also referred to as sash frame profiles in the aforementioned document, are first assembled to form a frame. The panel-shaped door panel is then inserted into the frame and screwed through a shell of the door panel parallel to the surface normal of the panel plane of the door panel. Finally, one of the shells of the door panel is covered by the frame member.

[0004] With this design, the primary concern was to eliminate the need to glue the frame members to the panel. The panels can therefore be processed immediately. A lengthy curing time, as is required for glued panels, is not required. This is made possible by the aforementioned special assembly sequence and panel screwing.

[0005] The manufacturing method described in EP 3 269 915 A1 is suitable for a single-sided sash-covering construction, but not for a double-sided sash-covering construction, in which the sash frame profile or frame stile is covered by the door panel on both sides. Screwing to the inner shell is unacceptable for aesthetic reasons.

[0006] DE 10 2004 057 162 also represents the state of the art for a variant with a double-sided sash cover. Here, the individual frame members are inserted into the finished panel and only then joined to form a frame. The advantage is that the panel can be manufactured by a panel manufacturer, for example, while the door manufacturer subsequently manufactures the frames around the panel and installs the fittings.

[0007] A disadvantage of this design is that the shells, referred to in the publication as paneling, are manufactured undersized, meaning they have a particularly thick panel, which makes inserting the frame beams very difficult due to the clamping pressure. Furthermore, the shells must be glued to the beams, which, as described above, should be avoided. This is particularly time-consuming, and the long curing time for the adhesive bond interrupts the assembly process. The door panels, which must be stored temporarily, take up considerable space, as they must cure lying down.

[0008] Further relevant prior art is known from DE 202 04 177 U1, AT 399 019 B and BE 903 601 A.

[0009] It is therefore the object of the present invention to improve the aforementioned constructive solutions and in particular to provide a door leaf and a method for its production in which a two-sided leaf-covering construction can be realized without the use of adhesive.

[0010] The present invention solves this problem by a door leaf having the features of claim 1 and by a method for its production having the features of claim 12. Furthermore, the invention relates to a door having the features of claim 11.

[0011] A door leaf according to the invention comprises a frame with at least one frame beam and a plate-shaped door panel.

[0012] The door panel comprises at least an inner shell, an outer shell, and an insulating layer arranged between them. Additional intermediate shells, insulating layers, expansion compensating layers, inserts for anchoring mechanical fasteners, and the like can also be optionally provided.

[0013] The door panel also has a recess on the edge, which is arranged between the inner shell and the outer shell, wherein the frame member is at least partially arranged in the recess.

[0014] In comparison to the glued door variants in which there is a material bond between the frame and the door panel, the frame beam of the present invention is mechanically fixed in the recess and force-fitted to the door panel.

[0015] In this door leaf construction, the door panel can cover both sides of the frame beams.

[0016] The panel can be completely manufactured first. The panel is attached to the frame purely mechanically, i.e., without adhesives. This results in assembly and cost advantages.

[0017] The recess is groove-shaped so that a flat connection is created between the frame beam and the door panel.

[0018] The frame beam is inserted into the groove-shaped recess in a direction parallel to the plate plane of the plate-shaped door panel, so that the frame beam can be covered by the door panel on both sides.

[0019] The door leaf has an insert, for example a solid or hollow profile, for anchoring the connecting element, wherein the insert is arranged in the groove-shaped recess.

[0020] In the hollow profile design, the insert has a first groove or a first channel, particularly in a region of the insert opposite the base, as a screw groove or a screw channel. The groove or channel has a longitudinal axis for engagement by a first mechanical connecting element, particularly a screw. The thread of the screw engages the wall of the groove or channel.

[0021] Advantageous embodiments of the invention are the subject of the dependent claims. The frame beam can advantageously be connected to the door panel without adhesive and preferably detachably.

[0022] The frame beam is secured in the recess by at least one first mechanical connecting element. This is particularly advantageous for reliably securing the frame to the door panel without causing any unintentional displacement of the door panel within the frame. A suitable mechanical connecting element can be a screw, pin, bolt, and / or rivet.

[0023] The connecting element can be arranged in a direction parallel to the plate plane of the plate-shaped door panel in the door leaf, so that no screw heads or the like protrude along the visible sides of the door panel.

[0024] In the design as a solid profile, it can, for example, be a solid wooden profile or a solid foam profile.

[0025] The insert can also be arranged only at a few selected positions in the recess or extend along the entire groove-shaped recess.

[0026] The arrangement of the connecting element in the insert part can have a greater pull-out value than an arrangement of the connecting element in the insulating material of the insulating layer, wherein the insert part is not to be assigned to the insulating material of the insulating layer within the scope of the present invention, even if it can itself have insulating properties.

[0027] The aforementioned pull-out value of the insert can be at least 20%, preferably at least 50% higher than when the connecting element is arranged in the insulating material of the insulating layer.

[0028] The insulation material of the insulation layer and / or the insert can advantageously be made of rigid PU foam. This material is particularly suitable for anchoring connecting elements.

[0029] The insulation material can also be made of PU foam or polystyrene foam. This material usually has good insulation values, but due to its low hardness, it is unsuitable for anchoring connecting elements.

[0030] The frame beam can advantageously be made of composite material, in particular metal and plastic profiles.

[0031] The groove-shaped recess can advantageously have a groove base and two side surfaces that extend obliquely, in particular perpendicularly, to the groove base, and wherein the frame member is L-shaped. The frame member can have a web on a first leg of the L-shaped frame member with at least one web end for bearing against a first of the two side walls of the groove-shaped recess. The frame member can also have a bearing surface on a second leg of the L-shaped frame member for bearing against the second of the two side walls of the groove-shaped recess.

[0032] The contact between the side walls is achieved with a clearance. This clearance can preferably be 0.2 to 2 mm. Thus, the frame member can contact one side wall on one side, with the clearance only being present towards the second side wall, or the frame member can have a clearance towards each of the two side walls. The term "contact" in this case, according to the definition of the present invention, can encompass a slight spacing, which is expressed by the clearance.

[0033] The groove base can advantageously be stepped, with two base surfaces running essentially parallel to one another. The groove-shaped recess can preferably be formed as a first groove-shaped recess. One of the base surfaces can be formed as a groove base of a second recess, which is part of the first groove-shaped recess, with the insert being arranged within the second recess. The second recess is part of the first groove-shaped recess. This advantageously allows the statically supporting part of the frame member to be arranged on one side of the recess, which forms the inside of the door and accommodates fittings such as door hinges and locks.

[0034] The side walls of the recess can be formed by the inner shell and the outer shell, with the frame member being spaced apart from the inner or outer shell at least on one side. This provides sufficient clearance to counteract expansion of the filling materials, particularly the outer and inner shells, which can occur, for example, due to solar radiation, and facilitates the insertion and installation of the frame member into the recess.

[0035] The door leaf can advantageously have a cover profile for at least partially covering the mechanical connecting element, which cover profile can be attached to the frame member and / or to the outer or inner shell. This also creates a tactile and visually appealing surface on the edge, and the connecting element is better protected against environmental influences.

[0036] The door leaf can advantageously have at least one sealing element, in particular a sealing profile and / or a sealing stop, which can be fixed to the frame member and which, together with the frame member, forms a flat rebate at least in some areas.

[0037] The inner and / or outer shell can extend beyond the frame beam or be flush with it. This allows the respective shell to conceal the frame beam in the viewing direction, relative to a surface normal to the panel plane of the door panel.

[0038] In a second embodiment of the invention, the insert can be designed as a hollow profile comprising at least one hollow chamber. The hollow profile can preferably be designed as a metal hollow profile and particularly preferably as an aluminum hollow profile.

[0039] Preferably, the insert part can have a first wall which runs parallel to the inner shell and an opposite second wall which partially rests against the inner shell, wherein at least a receiving area for introducing adhesive is arranged between the wall and the inner shell.

[0040] The insert can preferably be glued in the area between the second wall and the inner shell.

[0041] The insert may have a continuous bottom in contact with at least one of the bottom surfaces of the recess.

[0042] The insert may have a second groove or a second channel, in particular a screw groove or a screw channel, with a longitudinal axis for engagement by a second mechanical connecting element, in particular for a screw. The second connecting element may connect a further insert to the aforementioned insert, so that a corner connection of a frame composed of multiple inserts can be formed.

[0043] The first mechanical connecting element can be provided for mechanically fixing the frame member in the recess and the second mechanical connecting element can be provided for fixing the insert part with another insert part to form a frame comprising a plurality of insert parts, in particular in a corner connection area of ​​this frame.

[0044] The longitudinal axis of the first groove or the first channel for engagement of a mechanical connecting means may be arranged perpendicular to the longitudinal axis of the second groove or the second channel for engagement of a mechanical connecting means.

[0045] The insert part can have a receptacle for a screw head, in particular a countersunk screw head, adjacent to the first groove or the first channel for engagement of the first connecting means.

[0046] Furthermore, the invention provides a door comprising a frame and a door leaf according to the invention connected to the frame.

[0047] A method for producing a door leaf according to the invention is characterized by the following steps: a. Providing the frame members and the door panel; b. Joining, in particular inserting, the frame members into the door panel; and c. Connecting the frame members to form a frame d. Connecting the frame members to the door panel, in particular by means of at least one mechanical connecting means.

[0048] The aforementioned process enables the adhesive-free production of a door leaf. The assembly in step b is performed without fixation as a kind of pre-positioning, allowing for subsequent re-centering of the door panel after the frame is provided. The actual connection between the door panel and the frame takes place in step d).

[0049] Advantageous embodiments of the method are the subject of the subclaims.

[0050] Preferably, the mechanical fastener can be anchored in the door panel without penetrating the inner and / or outer shell. This avoids recutting in the event of accidental mispositioning, for example, and reduces the scrap rate during production. Furthermore, such positioning of the fasteners is undesirable for the customer. Furthermore, the expansion of the shells is not hindered or restricted.

[0051] In a further optional step, the connecting elements for connecting the frame beams to the door panel can be concealed using one or more cover profiles.

[0052] In addition, in an additional step, a flat fold can be formed by applying sealants to the frame beam.

[0053] The respective frame member can advantageously be inserted in step b) into a respective recess in the door panel in a direction parallel to the panel plane of the panel-shaped door panel.

[0054] In step d), the connecting element can advantageously be inserted and fixed in the door leaf in a direction parallel to the plate plane of the plate-shaped door panel.

[0055] The invention will be explained in more detail below using an exemplary embodiment and the accompanying figures. They show: Fig. 1 Section through the edge area of ​​a filling of the door leaf according to the invention; Fig. 2 Section through a frame beam of the door leaf according to the invention; Fig. 3 Section of a mounting arrangement comprising the frame beam of the Fig. 2 and the filling of the Fig. 1 ; Fig. 4Section of the mounting arrangement of the Fig. 3 wherein the frame beam and the filling are fixed together; Fig. 5 Section of the mounting arrangement with further supplementary profiles of the door leaf; Fig. 6 Section of a door cutout, a section of the door leaf and a section of a frame; Fig. 7 Section of a door cutout, a section of a second embodiment of a door leaf according to the invention and a section of a frame; Fig. 8 Detail view through a variant of the Fig. 7 inserted frame beam with an insert; Fig. 9Detail view of the insert of the Fig. 8 ; and Fig. 10 schematic representation of a corner connection area of ​​two inserts according to the Fig. 9 a door leaf according to the invention.

[0056] Fig. 1 shows a section through the edge region of a prefabricated door panel 1, which is designed as a multi-layer panel. The door panel 1 comprises at least one inner shell 2, at least one outer shell 3, and at least one insulating layer 4. It can preferably be designed as a sandwich panel and / or sandwich plate.

[0057] The terms "inside" and "outside" refer, for example, to an interior of a building, which the door panel 1 (a door fitted with the door panel) separates from the surroundings or an outside area. Here, the inner shell 2 is the shell of the door panel 1, which is oriented in the direction of positive y-coordinates with respect to the coordinate system in Fig. 1 Accordingly, the outer shell 3 is the shell of the door panel 1, which is arranged in the direction of negative y-coordinates with respect to the coordinate system in Fig. 1 is arranged.

[0058] The door panel 1 has a stepped edge region 6. The stepped edge region 6 is preferably located on at least three sides relative to the panel plane of the door panel 1. On a fourth side (bottom horizontally for the installed door), the frame region 6 can be designed differently, for example, if a so-called base profile is used for the door leaf. In this case, the edge region roughly corresponds to the contour of the base profile.

[0059] The stepped edge region 6 of the door panel 1 has a first edge-side groove-shaped recess 31, which preferably extends along the entire length of a side region of the door panel 1. The recess 31 is delimited by the inner shell and the outer shell 2, 3 and by a groove bottom 32, which is formed by the insulating material of the insulating layer 4.

[0060] The groove bottom 32 is stepped with a first bottom surface 33 and a second bottom surface 34, which is arranged offset deeper in the insulation layer 4 compared to the first bottom surface 33, so that a second U-shaped recess 35 is arranged within the first groove-shaped recess 31, which is delimited on at least two sides by the insulation material of the insulation layer 4 and on a third side by the inner shell 2.

[0061] The inner shell 2 and the outer shell 3 can preferably consist of metallic plates, preferably aluminum. Other materials, such as plastic, wood, composite materials, e.g., made of metal and plastic, and the like, can also be used within the scope of the present invention. The size of the inner shell 2 can vary from the size of the outer shell 3. This can affect both the size of the plate surface and / or the plate thickness. Preferably, however, the plate thickness of the inner and outer shells 2 and 3 can also be the same.

[0062] Between shells 2 and 3, there is at least the aforementioned insulation layer 4, which is bonded to the inner and outer shells. This insulation layer 4 has a high thermal insulation value. This can preferably be between 0.022 and 0.078 W / (m*K).

[0063] The insulation layer can also be designed to be flexible to compensate for thermal expansion of the shells. The preferred elongation at break is greater than 150% according to DIN 53571, as of April 2018.

[0064] To anchor the filling with a screw connection, this can have high pull-out values ​​of at least 400 N, preferably from 900 to 1300 N. The pull-out values ​​refer to the material of the filling in combination with a connecting element, which is a sheet metal, wood, or assembly screw with a diameter of 3.9 to 7.5 mm.

[0065] This does not exclude the alternative use of other connecting elements, but serves as a reference value to describe the material properties of the insulation material and / or the material of the insert.

[0066] The insulation layer can thus be formed as a single piece from a heat-insulating material. In this case, the insulation layer can be designed, for example, as a dimensionally stable, heat-insulating plastic sheet, in particular as a plastic foam sheet, which provides sufficient resistance to anchor a mechanical fastener, in particular a screw or rivet.

[0067] If these properties cannot be sufficiently provided with one material, the insulation layer 4 can also be composed of several materials with the required properties.

[0068] A foam, such as PU foam or polystyrene foam, which is typically characterized by high thermal insulation, can preferably be used as the insulating material. This can also preferably be combined with one or more fastening segments, in particular with one or more inserts and / or insert profiles 5, for anchoring a mechanical fastener, in particular for a screw connection.

[0069] The fastening segment, in particular the insert(s) or

[0070] Insert profiles 5 thus form a fastening area, in particular a screw connection area 26. Suitable materials for the inserts and / or insert profiles include hard plastics and / or plastics with high pull-out values, in particular PVC, rigid polyurethane foam, fiber-reinforced plastic, in particular carbon fiber-reinforced plastic, as well as wood and / or metal. The inserts and / or profiles can also be equipped with hollow chambers and / or screw channels.

[0071] In addition, at least one flexible layer arranged over the entire surface or partially, e.g. made of elastic plastic, such as cellular rubber or a closed-cell foam elastomer, can be provided to compensate for expansion (dilation) and / or curvature. This layer can preferably be arranged between the insulating layer 4 on the outer shell 3. The aforementioned expansions can arise due to temperature differences on both sides of the door leaf and the associated greatly differing thermal expansions of the two shells 2 and 3. Due to its properties, the flexible layer compensates for the thermal expansion of the outer shell 3 on the outside of the door leaf. For a detailed description of the properties and function of the aforementioned layer, which is often also described as a compensating layer, reference is made at this point to DE 203 14 017 U1.

[0072] The individual layers / parts of the door panel are glued together and preferably completely prefabricated.

[0073] In Fig. 2 A frame beam 7 is provided. This comprises a metallic profile 8, in particular an aluminum profile, and a second plastic profile 13. Both profiles are connected to each other as a composite profile in a shear-resistant manner.

[0074] However, a push-free connection is also possible.

[0075] The first profile 8 has at least one, preferably two, hollow chambers 9. Furthermore, a functional groove 10 for concealed accommodation of connecting elements can preferably be provided on the first profile 8.

[0076] Advantageously, the first profile 8 has a mounting bar 11 at the transition to the second profile 13 for mounting one or more fittings, such as locks and / or hinges. The mounting bar 11 offers increased pull-out values ​​for screw connections and is located in the middle area of ​​the door panel 1, i.e., at approximately 35 to 65% of the panel thickness of the door panel 1.

[0077] The second profile 13, in its preferred embodiment, serves as a plastic profile, thermal insulation, and as a spacer for the outer shell 3. The second profile 13 can be connected to the first profile 8 via the fastening web 12 by means of a pressing process, both force-fitting and form-fitting. The second profile 13 can have several hollow chambers. Edge-side webs 14 of the second profile for contact with the outer shell 3 of the door panel 1 ensure a small contact surface to improve thermal insulation. The frame beam 7 can advantageously be provided completely pre-assembled, like the door panel 1, and in the preferred variant of the Fig. 2-6 L-shaped.

[0078] Figur 3 shows a section of a mounting arrangement 25 comprising the door panel 1 of the Fig. 1 and the frame beam 7 of the Fig. 2 .

[0079] The frame member 7 is at least partially inserted into the door panel 1, so that it is partially arranged at least in the first groove-shaped recess 31 and partially fills it. Thus, the frame member 7 is in Fig. 3 at least partially between the inner shell 2 and the outer shell 3.

[0080] Preferably, the frame member 7 is concealed by the inner shell 2 and / or by the outer shell 3 in a front view of the door panel 1, so that a visually particularly high-quality and advantageous impression of the mounting arrangement is created for the observer.

[0081] According to an embodiment variant of an assembly method also according to the invention, individual frame members 7 of a door leaf 1 can be brought into the frame areas 6 of the door panel 1 and inserted.

[0082] A frame member 7 preferably has a lower height, preferably less than 2 mm. This height is defined by the distance from a web 14 for contact with the outer shell 3 to a contact surface 15 of the frame member 7 on the inner shell 2. The aforementioned height is at least 0.2 mm less than the distance between the inner shell 2 and the outer shell 3 of the door panel 1. The play between the components, i.e., the frame member and the door panel, simplifies the insertion of the frame member or frame members 7 into the door panel 1.

[0083] Optionally, connecting elements (not shown) can be previously installed in hollow chambers 9 and / or grooves 10 of the frame members 7. These are preferably so-called corner connectors for mitered frame profiles. These are inserted into the hollow chambers 9. Alternatively, so-called T-connectors for butt-cut profiles can also be used. The structural solution of the present invention thus enables the cutting and assembly of differently cut frame profiles.

[0084] Then, several of the frame members 7 are connected to form a frame. The corner and / or T-connectors are nailed or screwed according to the state of the art to create a stable frame. However, the frame members 7 can also be simply connected to one another mechanically, in particular by screwing, riveting, and / or welding.

[0085] The frame can thus be pre-assembled in the door panel 1 by means of the frame beams 7 and is then pre-fixed to the door panel in a form-fitting manner.

[0086] The frame is then preferably fastened to the door panel 1 with at least one mechanical connecting element 16, in particular with one or more screws.

[0087] The frame can be advantageously aligned with the panel by hand and / or with the help of the screws 16, depending on how the screws 16 are tightened. The screw connection area 26 provides a secure hold for the mechanical connecting elements 16, in particular the screws. The screw shaft 18 penetrates the hollow chamber 9 of the frame member 7, and the screw head 17 is arranged or countersunk in a groove 10. This has the advantage that the screw is no longer visible after the installation of a cover profile 19, thereby improving the appearance of the door leaf edge.

[0088] In order to achieve the appearance and easy accessibility of the connecting element or elements 16, it is also particularly advantageous if the insertion of the connecting element takes place from a direction parallel to a plate plane A of the plate-shaped door panel 1.

[0089] The same applies to the insertion or insertion direction of the frame beam 7 into the door panel 1.

[0090] The frame beam 7 is in Fig. 4 , 5 and 6connected to the door panel 1 by means of a connecting element 16. However, other mechanical connections are also conceivable within the scope of the present invention, e.g., clamping the frame member 7 between the shells 2 and 3 or another anchoring option. For this purpose, spring legs can be arranged, for example, in the region of the contact surface 15, which resiliently bear against the inner shell 2. The connection between the frame member 7 and the door panel 1 is preferably detachable, particularly preferably without a material bond, in particular without adhesive.

[0091] Further optional advantageous elements, which are arranged on the frame member 7 and / or on the door panel 1, are shown in Fig. 5 and 6 shown.

[0092] The door leaf 23 according to the invention comprises at least the door panel 1 and at least one frame member 7, but in particular a frame comprising several frame members 7.

[0093] A front door comprises, in addition to the door leaf 23 according to the invention, also a frame 24, which Fig. 6 is indicated.

[0094] To seal the door leaf 23 to the frame 24, seals 20 and seal stops 21 are inserted into the mounting assembly 25, particularly in the edge area 6. These seals are designed such that, in interaction with the frame member 7 and the optional cover profile 19, a flat rebate 22 is created, which extends over at least 50%, preferably over at least 70%, of the edge area of ​​the plate-shaped mounting assembly 25 with the frame member 7 and the door panel 1. This rebate 22 improves the appearance and facilitates cleaning of this area. The feel is also improved.

[0095] Figur 6 shows the door leaf 23 according to the invention with the corresponding frame 24, shown here in the form of a frame profile to which the door leaf is attached, preferably hinged. Additional fittings such as hinges, locks, strike plates, handles, levers, and / or door closers are not shown, but can optionally be provided in a conventional manner.

[0096] The frame and the frame itself can be manufactured partially or entirely from extruded aluminum profiles. Alternatively, they can be manufactured from a different material, such as steel, and / or using a different manufacturing process. Optional insulating bars for the frame or frame beam can be made from a plastic material, such as polyamide (PA66, PA6, PPA), polyester (PET, PBT), polyolefin (PP), or even polyvinyl chloride (PVC), thus ensuring extensive thermal separation between individual profiles.

[0097] Mechanical fasteners include, among others, screws, nuts including clamped washers, pins, bolts, rivets and / or retaining rings.

[0098] Fig. 7 shows a section of a second embodiment of a door leaf 201 according to the invention and a section of a frame 202.

[0099] The door leaf 201 has a frame beam 117, which is analogous to the frame beam 7 of the variant of the Fig. 1-6 is trained.

[0100] Furthermore, the door leaf 201 has the same Fig. 1-6 a groove. Within the groove there is another variant of an insert 101.

[0101] Fig. 8 shows a connection of the frame member 117 with the insert 101 and Fig. 9 shows the insert again in detail.

[0102] The insert is formed as a hollow profile and comprises a hollow chamber 105. The insert 101 has a first wall 102, which runs parallel to the inner shell 2 of the door panel and is directed on its outer side toward the filling material of the door panel. A second wall 103 is arranged opposite this wall 102, which partially, particularly in its end regions, abuts the inner shell 2.

[0103] At least one receiving area 104 for introducing adhesive is then arranged between the wall 103 and the inner shell 2. The receiving area can also be subdivided so that multiple receiving areas can be arranged.

[0104] The insert 101 also has a continuous bottom 106 which delimits the cavity 105 and which is in contact with the bottom surface 34 of the recess 31.

[0105] The insert 101, particularly in a region of the insert 101 opposite the base 106, has a screw groove 107 with a longitudinal axis AL1 for engagement by a screw. Of course, a screw channel can also be provided instead of a groove. Other mechanical connecting elements are also conceivable.

[0106] The longitudinal axis AL1 of the first screw groove 107 is perpendicular to the longitudinal axis AL2 of the second screw channel 108.

[0107] The insert part 101 has a receptacle 109 for a screw head, in particular a countersunk screw head, adjacent to the first groove or the first channel for engagement of the first connecting means.

[0108] The insert also has a second screw groove or a second screw channel 108 with a longitudinal axis AL2, wherein the screw channel is provided for engagement of a second screw 116.

[0109] The first screw 16 serves analogously to Fig. 1-6 for mechanically securing the frame beam in the recess 31. The second screw 116 enables the fixation of the insert with a second insert, whereby a plurality of inserts form a frame. This is particularly useful in Fig. 10 shown. Here, a first and a second insert 101, 101' are shown. The inner shell 2 of the door panel is only indicated. The frame beam 117 is in Fig. 10 not shown, however, can be analogous to Fig. 7 placed on the respective insert 101 or 101' and connected by the screw 16. The insert 101' has an analogous structure to the insert 101, so that the same reference numerals are used for the further explanation.

[0110] In the case of screw 116, it is inserted parallel to the screw channel 107 of the insert 101'. It penetrates the surface of the receptacle 109, the screw channel 108, and the bottom 106 of the insert 101' and then screws into the screw channel 108 of the insert 101. The receptacle 109 can also be partially open to facilitate insertion of the screw 116 into the insert 101'.

[0111] By securing the inserts 101 and 101' with screw 116, a stable corner connection is created, allowing a frame to be formed from multiple inserts. It works both in a butt-jointed corner connection of the inserts 101 and 101' and in a ridged corner connection.

[0112] The longitudinal axis of the screw 116 preferably lies on the longitudinal axis AL2 of the screw channel 108 of the insert 101. The screw head of the screw 116 then lies in the receptacle 109, so that the frame member 117 lies flush on the insert 101 (as in Fig 7 shown) can be attached. Bezugszeichenliste

[0113] 1 Door panel 2 Inner shell 3 Outer shell 4 Insulating layer 5 Insert 6 Frame area 7 Frame beam 8 Profile 9 Hollow chamber 10 Groove 11 Web 12 Web 13 Profile 14 Contact web 15 Contact surface 16 Connecting element 17 Screw head 18 Screw shaft 19 Cover profile 20 Seal 21 Seal stop 22 Rebate or rebate surface 23 Door leaf 24 Frame 25 Mounting arrangement 26 Screw fastening area 31 Recess 32 Groove base 33 Floor surface 34 Floor surface 35 Recess 101Insert 102First wall 103Second wall 104Receiving area 105Cavity 106Floor 107Screw groove 108Screw channel 109Receiver 116Second screw 117Frame beam 201Door leaf 202Frame 101'Insert AL1Longitudinal axis screw groove AL2Longitudinal axis screw channel tSurface normal APlate plane

Claims

1. Door leaf (23) having a frame comprising at least one frame spar (7), which comprises a first metallic profile (8) and a second profile (13) as a plastic profile, wherein the first profile (8) has at least one hollow chamber (9), wherein the door leaf (23) has a plate-shaped door panel (1), which door panel (1) comprises at least an inner shell (2), an outer shell (3) and an insulating layer (4) arranged therebetween, wherein the second profile (13) in its design as a plastic profile serves as a thermal insulator and as a spacer for the outer shell (3); wherein the door panel (1) comprises a peripheral recess (31) which is arranged between the inner shell (2) and the outer shell (3), wherein the frame spar (7) is arranged at least partially in the recess (31), wherein the frame spar (7) is mechanically fixed in the recess (31) and is non-positively connected to the door panel (1); characterized in that the frame spar (7) is inserted in a direction parallel to the plate plane (A) of the plate-shaped door panel (1) in the recess (31) which is designed groove-shaped, wherein the frame spar (7) is fixed in the recess (31) by means of at least one first mechanical connecting element (16), wherein an insert part (5, 101) for anchoring the first mechanical connecting element (16) is arranged in the groove-shaped recess, wherein the insert part (101) is formed as a hollow profile comprising at least one hollow chamber (105), wherein the insert part (101) has a first groove or a first channel, as a screw groove (107) or as a screw channel, having a longitudinal axis (AL1) for engagement for the first mechanical connecting element (16), or wherein the insert part (5) is formed as a solid profile.

2. Door leaf according to claim 1, characterized in that the first mechanical connecting element (16) is designed as a screw.

3. Door leaf according to one of the preceding claims 1 or 2, characterized in that the groove-shaped recess (31) has a groove bottom (32) and two side surfaces which extend obliquely, in particular perpendicular to the groove base (32), wherein the groove base (32) is preferably of stepped design with two base surfaces (33, 34) extending essentially parallel to one another.

4. Door leaf according to one of the preceding claims, characterized in that the door leaf (23) has a covering profile (19) for covering the first mechanical connecting element (16) at least in some regions, which covering profile (19) can be fixed to the frame spar (7).

5. Door leaf according to one of the preceding claims, characterized in that the door leaf (23) has at least one sealing element, in particular a sealing profile (20) and / or a sealing stop (21), which can be fixed to the frame spar (7) and which, together with the frame spar (7), forms a flat rebate (22) at least in some regions.

6. Door leaf according to one of the preceding claims, characterized in that the inner and / or outer shell (2, 3) extends beyond the frame spar (7) or is flush therewith in such a way that it covers the frame spar (7) in the viewing direction, with respect to a surface normal (t) of the plate plane (A) of the door panel (1).

7. Door leaf according to one of the preceding claims, characterized in that the insert part (101) preferably has a first wall (102) which extends parallel to the inner shell (2) and an opposite second wall (103) which rests in certain regions against the inner shell (2), wherein at least one receiving region (104) for the introduction of adhesive is likewise preferably arranged between the wall (103) and the inner shell (2).

8. Door leaf according to claim 1, characterized in that the insert part (101) has a second groove or a second channel, in particular a screw groove (107) or a screw channel (108), having a longitudinal axis (AL2) for engagement for a second mechanical connecting element (116), in particular for a screw.

9. Door leaf according to claim 1 or 8, characterized in that the longitudinal axis (AL1) of the first groove or of the first channel for the engagement of the first mechanical connecting element (16) of a first insert part (101) is arranged perpendicular to the longitudinal axis (AL2) of the second groove or of the second channel (108) for the engagement of the second mechanical connecting element (116) for connection to a second insert part (101').

10. Door leaf according to one of the preceding claims 1, 8 or 9, characterized in that the insert part (101) has, adjacent to the first groove or to the first channel for the engagement of the first connecting element (16), a receiver for a screw head, in particular a countersunk screw head, of the second connecting element (116).

11. Door, in particular a front door, comprising a frame (24) and a door leaf (23) connected to the frame (24), according to one of the preceding claims.

12. Method for producing a door leaf (23) according to one of the preceding claims, characterized by the following steps of a. providing the frame spars (7) and the door panel (1); b. joining, in particular inserting, the frame spars (7) into the door panel (1); and c. connecting the frame spars (7) to form a frame; and d. mechanically connecting the frame spars (7) to the door panel, in particular by means of at least one first mechanical connecting element (16).

13. Method according to claim 12, characterized in that before the assembly according to step b), inserts are inserted into the door panel, which are connected to one another, in particular by means of second connecting elements (116), to form a frame.

14. Method according to claim 12 or 13, characterized in that the first mechanical connecting means (16) is anchored in the door panel (23) without passing through the inner and / or outer shell (2, 3).

15. Method according to one of the preceding claims 12 to 14, characterized in that in an additional step, a flat rebate (22) is formed by fixing sealing means (20, 21) to the frame spar (7).

16. Method according to one of the preceding claims 12 to 15, characterized in that in step b), a respective frame spar (7) is inserted into a respective recess in the door panel (1) in a direction parallel to the plate plane of the plate-shaped door panel (1) in the recess (31) and wherein, preferably, the mechanical connecting element (16) is introduced and fixed in step d) in the door leaf (23) in a direction parallel to the plate plane of the plate-shaped door panel (1).