Methof for manufacturing a buidling door leaf, and a buidling door leaf

Abstract

The invention relates to a method for manufacturing a building door leaf (12), in particular a front door leaf, wherein a door leaf cavity (50) is formed which is bounded by side edges (44) forming narrow end faces (35) and panel elements (42) forming wide sides (34, 40) of the door leaf, wherein at least one projection (58) extending along the side edges (44) and projecting into the door leaf cavity (50) is arranged in the door leaf cavity (50) on at least one of the side edges (44), which has side surfaces (59) facing the panel elements (42), at least one of which extends obliquely towards the associated panel element (42) such that the door leaf cavity (50) tapers from the inside out towards the side edge (44) and wherein the door leaf cavity (50) is filled with foam.The invention further relates to a door leaf frame profile (48) for use in the method and to a door leaf (12) that is obtainable by such a method.

Description

[0001] The invention relates to a method for manufacturing a building door leaf, in particular a front door leaf, wherein a door leaf cavity is formed and this door leaf cavity is filled with foam. The invention further relates to a building door leaf.

[0002] From EP 2 116 449 A1, a panel for the box body of a truck, trailer and / or semi-trailer and a method for its manufacture are known. A box body for a semi-trailer is also described, in which the panel is used as a roof panel, a side wall panel, or a floor panel. The box body also has a rear wall formed by two doors, the construction of which is neither described nor shown in detail.

[0003] From US patent 3,750,333 A, a building door leaf and a method for its manufacture are known. In this method, edges of panel elements forming the broad sides of the door leaf are bent obliquely inwards to form a snap-fit ​​connection with a frame profile. The resulting cavity is filled with polyurethane foam. Thus, a method for manufacturing a building door leaf is disclosed, comprising forming a door leaf cavity bounded by side edges forming the narrow ends and panel elements forming the broad sides of the door leaf, with the broad sides of the door leaf being formed by means of the panel elements. At least one projection extending into the door leaf cavity is formed within the cavity, having side surfaces, at least one of which extends obliquely such that the door leaf cavity tapers from the inside out towards the side edge; and filling the door leaf cavity with foam.

[0004] GB 2 261 460 A1 discloses a door construction with several wooden frame elements held together by metal sheets. The broad surfaces of the wooden frame elements can be angled, and a foam material can be provided between these broad surfaces and the metal sheets for bonding them together.

[0005] Building doors, especially front doors, have a variety of functions they must fulfill. These include technical functions such as providing good thermal insulation or burglar resistance, as well as contributing to the visual appearance of the building to which they are installed.

[0006] Special standards have been established for the technical functions, specifying requirements for, for example, the thermal insulation properties or the burglar resistance properties of front doors.

[0007] However, the design aspect is particularly important for the customer, as a front door is the calling card of a building. The front door is almost always the most attractive door on a building, unlike purely functional doors such as fire doors in the boiler room or similar.

[0008] In order to provide a wide variety of front door designs, front doors are often manufactured in such a way that a frame is provided and a door panel is attached to or within it, which determines the design, as described, for example, in EP 1 568 842 B1 or EP 1 780 368 A2.

[0009] Effective thermal insulation, in accordance with the prescribed standards, is provided by the sandwich panel itself when it rests on the frame. However, front doors manufactured in this way have the disadvantage of being very thick and therefore appearing bulky. This can negatively influence the customer's purchasing decision.

[0010] Front doors where the sandwich panel is inserted into the frame are comparatively complex to manufacture and also require thermal break elements within the frame. This makes them expensive to produce.

[0011] One manufacturing method that results in a lightweight and well-insulated door would involve filling the door frame with insulating foam. However, the disadvantage here is that the pressure applied during the foaming process can create unsightly dents and bulges in the door leaf. This is undesirable for front doors, and customers are less willing to overlook such imperfections than, for example, in hidden basement doors. Therefore, if this method is used, the door leaf would have to be weighted down before the foaming process and compressed while the foam hardens to achieve a flat door leaf. This would be very labor-intensive.

[0012] During the curing process, the insulating material also shrinks, creating a gap around the perimeter between it and the elements forming the door leaf. This further complicates the process of producing door leaves with perfectly flat, even broadsides. Especially with front doors, for example those with glossy surfaces, even the slightest unevenness would be easily noticed and perceived as a defect.

[0013] The object of the invention is to propose a method for manufacturing a building door leaf that is less costly to implement and results in a better, in particular visually superior, door leaf.

[0014] This problem is solved by a method according to claim 1.

[0015] A building door leaf obtainable by such a method is the subject of claim 12.

[0016] Advantageous embodiments of the invention are the subject of the dependent claims.

[0017] A method for manufacturing a building door leaf, in particular a front door leaf, comprises in particular the following steps: a) Forming a door leaf cavity, which is bounded by side edges forming narrow end faces and panel elements forming wide sides of the door leaf, wherein at least one projection extending along the side edge and projecting into the cavity is formed in the door leaf cavity on at least one of the side edges, which has side surfaces facing the panel elements, at least one of which extends obliquely towards the associated panel element in such a way that the door leaf cavity tapers from the inside out towards the side edge; and b) Filling the door leaf cavity with insulating material.

[0018] It is intended that step a) comprises the following steps: a1) Forming the broad sides of the door leaf using the panel elements; a2) Forming the side edges by providing a door leaf frame with at least one frame profile provided with the projection on the inner perimeter side; and a3) Joining the door leaf frame with the panel elements.

[0019] In this process, a cavity for the door leaf is created in the usual way and then filled with expanding foam. Side edges and panel elements are joined together. A projection on the door leaf frame extends inwards into the cavity, which is typically rectangular in commercially available door leaves. This makes the cavity narrower towards the side edges.

[0020] This training has the following positive effects: Due to the narrowing of the door leaf cavity towards the side edges, less space is available for the insulating material during the foaming process. This results in less pressure being exerted against the panel elements forming the wide sides of the door leaf in this tapered area. Consequently, improved flatness of the door leaf can be achieved even without or with only minimal weighting of the panel elements. Depending on the design, it is even possible to forgo weighting entirely and still obtain a flat door leaf. This significantly simplifies the process. As the insulating material hardens, the protruding projection into the cavity causes shrinkage that is no longer abrupt and localized, but rather homogeneous and gradual, extending towards the center of the door leaf cavity. This results in more controlled shrinkage and an overall improved door leaf.

[0021] Preferably, the projection is formed with a wedge-shaped cross-section. The wedge shape (e.g., with a pointed or blunt end) is the preferred form for achieving the aforementioned advantages, as it advantageously allows for a symmetrical tapering of the door leaf cavity towards the side edges and, due to its special shape, advantageously directs the shrinkage further into the interior of the door leaf cavity than other geometric shapes.

[0022] Particularly advantageous in step a) is that each of the side edges is provided with the projection along its entire inner circumference that defines the door leaf cavity. If this projection is advantageously wedge-shaped, the door leaf cavity tapers on four sides, preferably symmetrically towards the side edges, and the positive effects can preferably act on both narrow sides of the door leaf.

[0023] According to the invention, in step a2) the frame profile is assembled from a door leaf frame profile bar and a wedge profile. This allows additional work to be preferably carried out on the door leaf frame profile bar, such as the insertion of wiring for, for example, a power supply for electronic components on the door leaf, and then the wedge profile can be attached, preferably as a closure.

[0024] Preferably, the frame profile is provided with a panel receptacle on the broad sides that are to be arranged parallel to the wide side of the door leaf. This particularly simplifies the fastening of the panel elements to form the door leaf.

[0025] Preferably, the frame profile is provided with a beveled surface at the corners between the broad side and the inner circumferential side. This beveled surface can then advantageously form the projection.

[0026] Preferably, ventilation openings are provided on the sloping surface, and a cavity is preferably formed in the frame profile so that, particularly preferably, ventilation can occur during the foaming process through the ventilation openings and the cavity. Advantageously, no additional ventilation openings, for example in the insulation material, need to be provided.

[0027] The wedge profile, with its inclined surfaces on both sides, is preferably attached flush to the door leaf frame profile. In a particularly preferred embodiment, the inclined surfaces of the wedge profile are aligned flush with the inclined surfaces of the frame profile, thus advantageously creating a seamless transition between the individual parts of the frame profile.

[0028] In an advantageous embodiment, the wedge profile and the door leaf frame profile bar are positively locked together by means of a self-centering projection-recess design. This makes joining the two elements particularly easy, as the self-centering feature preferably eliminates the need for readjustment of the joined elements.

[0029] Frame profiles are preferably made of fiber-reinforced plastic. Compared to the commonly used aluminum profiles, plastic has the advantage of being a poor thermal conductor. Therefore, the use of plastic frame profiles contributes to poor heat transfer between the panel elements and thus to good thermal insulation. Fiber-reinforced plastic is a material consisting of reinforcing fibers and a plastic matrix. The fibers can be, for example, glass fibers or carbon fibers, but other fiber types are also known. The reinforcing fibers are characterized by their high specific strength and stiffness, which, together with the surrounding plastic matrix, can be tailored to the desired parameters in terms of their mechanical and thermal properties.Fiber-reinforced plastic materials exhibit very high strength and can be particularly well adapted to specific requirements. The sheet elements are advantageously made of metal.

[0030] The wedge profile is preferably formed from polyurethane. Since the door leaf cavity is often preferably filled with polyurethane foam insulation, a particularly advantageous interaction between the wedge profile and the insulation material can be achieved, contributing to improved door leaf stability.

[0031] A door leaf, in particular a front door leaf, with the features of the dependent claim is preferably obtainable by the method described above. An embodiment of the invention is explained in more detail below with reference to the accompanying drawing. This drawing shows: Fig. 1 shows a horizontal section through a part of a door with a building door leaf and a door frame.

[0032] Fig. 1 shows a horizontal section through a part of a building door 10 in the form of an exterior door, in particular a front door, with a building door leaf 12, in particular a front door leaf, and a door frame 14.

[0033] The door frame 14 has a first and a second door frame profile 16, 18, which are connected to each other via webs 20 made of heat-insulating material.

[0034] The first door frame profile 16 is designed as a stop area 22 for a rebate area 24 of the building door leaf 12. Furthermore, the first door frame profile 16 has a counter bearing 26 for a catch 28 arranged in the building door leaf 12.

[0035] The second door frame profile 18 has a retaining device 30 for a seal 32, against which, when the door is closed, a first door leaf broad side 34 of the building door leaf 12 abuts.

[0036] The web 20 directed towards the building door leaf 12 has a further stop area 22 for a narrow end face 35 of the building door leaf 12.

[0037] Due to the special design of the door frame 14, the building door leaf 12 abuts the door frame 14 at three points. The arrangement of 22 seals 32 at these abutment points provides particularly good thermal separation between a warm inner side 36 and a colder outer side 38 of the building door 10. Furthermore, even relatively thick door leaves with high thermal insulation can be inserted very tightly into the frame with narrow gaps, without any jamming occurring during opening and closing.

[0038] The structure of the building door leaf 12 is in Fig. 1 The image is shown only in the area of ​​one narrow end face 35. The opposite narrow end face 35 with the door frame 14 is essentially mirror-symmetrical to this.

[0039] The building door leaf 12 has the first door leaf broad side 34 and a second door leaf broad side 40, both of which are provided by metal plate elements 42.

[0040] Furthermore, the building door leaf 12 has a side edge 44 forming the narrow end face 35, which is formed by a frame profile 48 made of fiber-reinforced plastic 49 of a door leaf frame 46.

[0041] The door leaf broad sides 34, 40 and the side edges 44 together form a door leaf cavity 50. The door leaf cavity 50 is filled with a polyurethane-based insulating material 52.

[0042] The frame profile 48 is composed of a door leaf frame profile bar 54 and a wedge profile 56, which together form a projection 58 that extends into the door leaf cavity 50 by means of side surfaces 59 of the projection 58 extending obliquely into the door leaf cavity 50.

[0043] Due to the projection of the protrusion 58, tapered areas 60 are formed in the door leaf cavity 50, in which the door leaf cavity 50 tapers from the inside out. When the insulating material 52 is foamed into these tapered areas 60, less insulating material 52 reaches them than the untapered area of ​​the door leaf cavity 50, so that a lower pressure is exerted by the insulating material 52 on the panel elements 42 in the tapered areas 60.

[0044] The wedge profile 56 is arranged on the inner circumferential side 57 of the door leaf frame profile bar 54.

[0045] The door leaf frame profile bar 54 has plate receptacles 62 on its broad sides 61, to which the plate elements 42 are attached, and sloping surfaces 64 on corner areas 63 between the broad sides 61 and the inner circumferential side 57, on which the wedge profile 56 with its sloping surfaces 66 is flush.

[0046] The wedge profile 56 has a projection 68 that engages in a recess 70 in the door leaf frame profile bar 54, thus centering the wedge profile 56. This projection-recess design 72 ensures that the wedge profile 56 and the door leaf frame profile bar 54 are positively locked together.

[0047] The wedge profile 56, together with the inclined surfaces 64, forms a cavity 74 through which cables 76 for electronic devices (not shown) of the building door leaf 12 are routed. The inclined surfaces 64 have ventilation openings 78 through which gases produced during the curing of the insulating material 52 can escape.

[0048] The door leaf frame profile bar 54 is made of fiber-reinforced plastic 49, and both the wedge profile 56 and the insulating material 52 are based on polyurethane 82. Thus, only door leaf elements made of poorly thermally conductive materials are located between the metal panel elements 42, so that good thermal insulation can be achieved through the poor heat transfer from the inside 36 to the outside 38 of the building door 10.

[0049] For this purpose, the door leaf frame profile bar 54 is additionally provided on its side facing the door frame 14 with retaining devices 30 for receiving seals 32. Furthermore, the door leaf frame profile bar 54 has a catch receptacle 84 for receiving the catch 28 and a handle receptacle 86 for attaching a door handle 88 or a rosette 90.

[0050] The special design of the frame profile 58, in particular the wedge profile 56 based on polyurethane 82, in conjunction with the inclined surfaces 64 of the door leaf frame profile bar 54, which are formed in line with the inclined surfaces 66 of the wedge profile 56, advantageously results in a flatter surface on the panel elements 42 when foamed with the insulating material 52. Additionally, the transition from the frame profile 48 to the insulating material 52 is no longer abrupt, but smooth and homogeneous. As a result, the shrinkage in the polyurethane 82, which is unavoidable, is no longer localized to a single point. Due to the in Fig. 1The geometry of the frame profile 48 shown reduces shrinkage. Changes to the door leaf 12 during the foaming or curing of the insulating material 52 are now almost imperceptible to the human eye, because the shrinkage is directed towards the center of the door leaf 12 by the special design of the frame profile 48.

[0051] Ventilation openings 78 can be positioned mechanically in the inclined surfaces 64. This eliminates the need for work on the insulation core. Additionally, the inclined surfaces 64 and the resulting cavity 74 offer the advantage that cables 76 for supplying power to any electronic components can be inserted into the frame profile 48 without the need for additional parts or other measures. Reference symbol list:

[0052] 10 Building door 12 Building door leaf 14 Door frame 16 First door frame profile 18 Second door frame profile 20 Web 22 Stop area 24 Rebate area 26 Counter bearing 28 Catch 30 Holding device 32 Seal 34 First door leaf wide side 35 Narrow end side 36 Inside side 38 Outside side 40 Second door leaf wide side 42 Panel elements 44 Side edge 46 Door leaf frame 48 Frame profile 49 Fiber-reinforced plastic 50 Door leaf cavity 52 Insulation material 54 Door leaf frame profile bar 56 Wedge profile 57 Inner perimeter side 58 Projection 59 Side surface 60 Tapered area 61 Wide side 62 Panel receptacle 63 Corner area 64 Slanted surface (Door leaf frame profile bar) 66 Slanted surface (wedge profile) 68 Projection 70 Recess 72 Projection-recess formation 74 Cavity 76 Cable 78 Ventilation opening 82 Polyurethane 84 Catch receptacle 86 Handle receptacle 88 Door handle 90 Rosette

Claims

1. Method for manufacturing a building-door door leaf (12), in particular a front door leaf, having two door-leaf broadsides (34, 40) and side edges (44) forming narrow front sides (35), the method comprising the following steps: a1) forming the door-leaf broadsides (34, 40) using plate elements (42); a2) forming the side edges (44) by providing a door leaf frame (46) having at least one frame profile (48) provided on the inner circumferential side (57) with a projection formation (58); and a3) joining the door leaf frame (46) to the plate elements (42) under creation of a door leaf cavity (50) bounded by the side edges (44) forming the narrow end faces (35) and by the plate elements (42) forming the door leaf broadsides (34, 40), wherein in the door leaf cavity (50), at least on one of the side edges (44), there is formed said at least one projection formation (58) which extends along the side edge (44) and projects into the door leaf cavity (50) and which has side surfaces (59) facing the plate elements (42), at least one of which extends obliquely toward the corresponding plate element (42) in such a way that the door leaf cavity (50) tapers toward the side edge (44) when viewed from the inside to the outside; and b) foaming the door leaf cavity (50) using an insulating material (52), characterized in that in step a2), the door leaf frame is provided in such a way that the frame profile (48) is composed of a door leaf frame profile bar (54) and a wedge profile (56).

2. Method according to claim 1, characterized in that in step 2a), the door leaf frame (46) is provided in such a way that the protrusion formation (58) is formed with a wedge-shaped cross section.

3. Method according to any of the preceding claims, characterized in that in step 2a), the door leaf frame (46) is provided such that each that each side edge (44) is provided with the projection formation (58) on its entire inner circumferential side (57) bordering the door leaf cavity (50).

4. Method according to any of the preceding claims, characterized in that the door leaf frame (46) is provided in such a way that the wedge profile (56) with inclined surfaces (66) on both sides is aligned flush with the door leaf frame profile bar (54).

5. Method according to any of the preceding claims, characterized in that the door leaf frame (46) is provided in such a way that the wedge profile (56) and the door leaf frame profile bar (54) are fixed together in a form-fitting manner by means of a self-centering projection-recess formation (72).

6. Method according to any of the preceding claims, characterized in that the door leaf frame (46) is provided in such a way that the wedge profile (56) is formed on the basis of polyurethane (82).

7. Method according to any of the preceding claims, characterized in that the door leaf frame (46) is provided in such a way that the frame profile (48) is arranged at the broadsides (61) to be arranged parallel to the door leaf broadside (34, 40) with a panel receptacle (62) and at the corner areas (63) between the broadside (61) and the inner peripheral side (57) with an inclined surface (64).

8. Method according to claim 7, characterized in that the door leaf frame (46) is provided in such a way that vent holes (78) are provided on the inclined surface (64) and that, during foaming, air is vented through the vent holes (78) and a cavity (74) formed in the frame profile (48).

9. Method according to any of the preceding claims, characterized in that the door leaf frame (46) is provided in such a way that the frame profiles (48) are made of fiber-reinforced plastic (49).

10. Method according to any of the preceding claims, characterized in that in step a1), the door leaf broadsides (34, 40) are formed by means of metal plate element(s) (42).

11. Method according to any of the preceding claims, characterized in that in step b), the door leaf cavity (50) is foamed with an insulating material (52) with polyurethane foam.

12. Building-door door leaf, in particular a front door leaf, comprising two door-leaf broadsides (34, 40) and side edges (44) forming narrow front sides (35), wherein the door leaf broadsides (34, 40) are formed by means of plate elements (42); wherein the side edges (44) are formed by a door leaf frame (46) with at least one frame profile (48) provided with a projection (58) on the inner peripheral side (57); and wherein the door leaf frame (46) is joined to the panel elements (42) to form a door leaf cavity (50) bounded by the side edges (44) forming the narrow end faces (35) and the door leaf side faces (34, 40) forming the door leaf, wherein the door cavity (50) has, on at least one of the side edges (44), at least one projection (58) extending along the side edge (44) and projecting into the door leaf cavity (50) (58) extending along the side edge (44) and protruding into the door leaf cavity (50), which has side surfaces (59) facing the plate elements (42), at least one of which extends obliquely to the associated plate element (42) in such a way that the door leaf cavity (50) tapers towards the side edge (44) when viewed from the inside to the outside; and wherein the door leaf cavity (50) is filled with an insulating material (52), characterized in that the frame profile (48) is composed of a door leaf frame profile bar (54) and a wedge profile (56).

13. Door leaf according to claim 12, characterized in that the door leaf frame profile bar (54) is arranged at the broadsides (61) to be arranged parallel to the broadside of the door leaf (34, 40) with a plate receptacle (62) and at the corner areas (63) between the broadside (61) and the inner peripheral side (57) with an inclined surface (64).

14. Door leaf according to any of claims 12 or 13, characterized in that the wedge profile (56) with inclined surfaces (66) on both sides is attached flush to the door leaf frame profile bar (54).

15. Door leaf according to any of claims 12 to 14, characterized in that the wedge profile (56) and the door leaf frame profile bar (54) are fixed to each other in a form-fitting manner by means of a self-centering projection-recess formation (72).

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