Method for the manufacture of french doors made of plastic material with threshold

Abstract

The method for the manufacture of French doors made of plastic material with threshold, comprises the following phases: supplying at least two lateral profiled elements (1), one upper profiled element (2) and one threshold profiled element (3), made of plastic material, extending along respective longitudinal directions and each provided, at the relevant ends, with at least one pair of areas to be welded (4,5,6,7); positioning the profiled elements (1,2,3) with the areas to be welded (4,5,6,7) facing each other; heating the areas to be welded (4,5,6,7) until partial melting of the plastic material; joining the areas to be welded (4,5,6,7) to each other to obtain a perimeter frame (8) for a French door with threshold.

Description

[0001] METHOD FOR THE MANUFACTURE OF FRENCH DOORS MADE OF PLASTIC MATERIAL WITH THRESHOLD

[0002] Technical Field

[0003] The present invention relates to a method for the manufacture of French doors made of plastic material with threshold.

[0004] Background Art

[0005] In the window and door industry, French doors made of plastic material, usually PVC, are known to be provided with a threshold. In detail, the threshold is an element of the fixed frame, arranged at the base of the same, which is considerably thinner and smaller in size than the remaining perimeter profiled elements and makes, therefore, the French door more comfortable in use. In fact, the very thin thickness of the threshold allows easy crossing of the French door, avoiding excessive lifting of the feet from the ground. It follows that this solution is very appreciated by people with walking problems.

[0006] In addition to this, the threshold gives a valuable aesthetic appearance to the French door compared to solutions featuring instead a traditional profiled element at the base.

[0007] At the structural level, the remaining side and upper profiled elements are intended to abut against the frame of the movable leaf and therefore have lateral surfaces complementary to the latter so as to ensure optimal mechanical and thermal sealing.

[0008] The threshold, on the other hand, is made from a distinctly different profiled element with a substantially rectangular cross-section. The profiled element used for the threshold may also have a different coloring and finish.

[0009] The manufacturing methods known to date first comprise welding the two lateral profiled elements together with the upper profiled element. Then the threshold is attached to the base of the lateral profiled elements.

[0010] Generally, the threshold is made on site, depending on the actual distance between the lateral profiled elements, by cutting the corresponding precursor profiled element.

[0011] Following cutting, known methods involve the use of “L”-shaped fittings wherein one portion is fited and atached to the threshold and the other portion is fited and atached to the respective lateral profiled element. The atachment can be done, e.g., by means of screws or the like.

[0012] This method is, however, impractical because, first of all, it requires the use of an excessive number of components, and secondly, it requires that part of the frame being assembled at the factory and the remainder being assembled on site. In addition to this, the known methods involve long assembly times.

[0013] Still, through known manufacturing methods, a perimeter frame is obtained that does not ensure optimal thermal sealing at the joints between the threshold and the lateral profiled elements.

[0014] Description of the Invention

[0015] The main aim of the present invention is to devise a method for the manufacture of French doors made of plastic material with threshold which allows reducing the number of the components required.

[0016] Another object of the present invention is to devise a method for the manufacture of French doors made of plastic material with threshold which allows reducing the assembly timeline compared with known solutions.

[0017] Still one object of the present invention is to devise a method for the manufacture of French doors made of plastic material with threshold which allows ensuring optimal thermal sealing of the obtained frame.

[0018] Another object of the present invention is to devise a method for the manufacture of French doors made of plastic material with threshold which allows the aforementioned drawbacks of the prior art to be overcome within the framework of a simple, rational, easy and effective solution that may also be inexpensive. The aforementioned objects are achieved by this method for the manufacture of French doors made of plastic material with threshold having the characteristics of claim 1.

[0019] Brief Description of the Drawings

[0020] Other characteristics and advantages of the present invention will become more apparent from the description of a preferred, but not exclusive embodiment of a method for the manufacture of French doors made of plastic material with threshold, illustrated by way of an indicative, yet non-limiting example in the accompanying tables of drawings in which:

[0021] Figure 1 is a schematic representation of a welding machine for plastic profiled elements configured to implement the method according to the invention;

[0022] Figure 2 is a schematic representation of a welding machine for plastic profiled elements configured to implement the method, in accordance with an additional embodiment;

[0023] Figure 3 is a schematic representation of a placement phase of the method according to the invention;

[0024] Figure 4 is a schematic representation of a heating phase of the method according to the invention;

[0025] Figure 5 is a schematic representation of a joining phase of the method according to the invention.

[0026] Embodiments of the Invention

[0027] The method for the manufacture of French doors made of plastic material with threshold can be implemented by means of a machine 20 for welding profiled elements made of plastic material, which will be described in more detail later in this disclosure.

[0028] The method according to the invention first comprises a phase of supplying at least two lateral profiled elements 1, one upper profiled element 2 and one threshold profiled element 3, made of plastic material and extending along respective longitudinal directions.

[0029] Preferably, the profiled elements 1,2,3 are made of PVC.

[0030] It cannot, however, be ruled out that the profiled elements are made of a heat- sealable plastic material other than PVC and / or of a plastic material loaded with a reinforcing material, e.g., in the form of fibers such as glass fibers or the like. Likewise, embodiment solutions cannot be ruled out wherein the profiled elements are partly made of plastic material and partly of a different material, in a maimer similar to some known types of profiled elements that are provided e.g. with a canopy, an outer covering or an inner core made of metal, wood or the like. The profiled elements 1,2,3 can be obtained, e.g., by extruding the plastic material within an extrusion line, so that the longitudinal direction of the profiled elements 1,2,3 coincides with the direction of the plastic material leaving the extrusion line. The resulting precursor of indefinite length, once cooled down, is then cut into portions according to the desired length.

[0031] Each of the profiled elements 1,2, 3 is provided, at the relevant ends, with at least one pair of areas to be welded 4, 5, 6, 7.

[0032] In the context of this disclosure, the term “area to be welded” relates to a profiled element surface through which the profiled element itself is joined by welding to another profiled element, as will be described in detail later in this disclosure.

[0033] The method then comprises the following phases: positioning the profiled elements 1,2,3 with the areas to be welded 4, 5, 6, 7 facing each other; heating the areas to be welded 4, 5, 6, 7 until partial melting of the plastic material; joining the areas to be welded 4, 5, 6, 7 to each other to obtain a perimeter frame 8 for a French door with threshold.

[0034] In detail, the heating phase involves the softening of the plastic material and the joining phase is carried out by moving the profiled elements 1,2,3 close to each other. In this way, during the joining phase, the areas to be welded 4, 5, 6, 7 partly melted come into intimate contact with each other and, the plastic material, once cooled down, hardens again and keeps the profiled elements 1,2,3 joined together. Specifically, each lateral profiled element 1 is welded, at one end, to the upper profiled element 2 and, at the other end, to the threshold profiled element 3.

[0035] In actual facts, the profiled elements 1,2,3 defining the perimeter frame 8 of the French door are all joined together by welding.

[0036] This avoids the use of additional components and, in addition, gives the perimeter frame 8 an optimal thermal sealing as well as mechanical sealing.

[0037] Advantageously, each of the heating and joining phases is carried out substantially simultaneously on all the profiled elements 1,2,3. In other words, the threshold profiled element 3 is welded to the lateral profiled elements 1 simultaneously with the welding of the latter to the upper profiled element 2. This method thus makes it possible to obtain the perimeter frame 8 of French doors with threshold through an individual operation, thus allowing a reduction in production and assembly timeline and avoiding ancillary machining operations at the installation site.

[0038] As shown above, each of the profiled elements 1,2,3 is provided with a pair of areas to be welded 4, 5, 6, 7.

[0039] Advantageously, each of the lateral profiled elements 1 comprises an upper area to be welded 4 intended to be welded to the upper profiled element 2 and inclined by an angle of between 10° and 80° to the respective longitudinal direction.

[0040] Similarly, the upper profiled element 2 comprises a pair of extreme areas to be welded 6 inclined by an angle of between 10° and 80° to the respective longitudinal direction.

[0041] It should be specified that the upper profiled element 2 and the lateral profiled elements 1 are derived from an individual precursor that is cut according to predefined lengths and, therefore, have the same internal matrix. In this case, as known to the engineer in the field, their mutual welding is most effective when it also involves the internal matrices.

[0042] For this reason, the upper areas to be welded 4 and the extreme areas to be welded 6 are surfaces obtained by cutting the respective profiled elements along a transverse plane and inclined with respect to the longitudinal direction, resulting in turn inclined with respect to the latter.

[0043] Preferably, the upper areas to be welded 4 and the extreme areas to be welded 6 are inclined by an angle substantially equal to 45° to the longitudinal directions of the respective profiled elements.

[0044] The areas to be welded inclined at 45° allow for full overlap of the internal matrices and optimal mechanical sealing. The welding operation of the lateral profiled elements 1 to the upper profiled element 2 generates, therefore, the so- called “quarter-sawn” joints.

[0045] It is specified that the aforementioned angle is suitable for obtaining a frame of substantially rectangular shape, which is generally used in common window and door frames. It is easy to appreciate, however, that if the perimeter frame 8 is to have a different shape, the areas to be welded must also be inclined at different angles.

[0046] Usefully, each of the lateral profiled elements 1 also comprises a lower area to be welded 5 intended to be welded to the threshold profiled element 3, which is substantially orthogonal to the lying plane of the perimeter frame 8.

[0047] Similarly, the threshold profiled element 3 comprises a pair of ending areas to be welded 7 substantially orthogonal to the lying plane of the perimeter frame 8.

[0048] The threshold profiled element 3 is generally of a different conformation than the lateral profiled elements 1 and the upper profiled element 2. In this case, the threshold profiled element 3 has a substantially rectangular profile and a substantially planar development. In actual facts, the threshold profiled element 3 is significantly thinner than the lateral profiled elements 1 and the upper profiled element 2 which allows the French door to be more comfortable in use.

[0049] As a result, it is difficult for the threshold profiled element 3 to be welded to the lateral profiled elements 1 by means of quarter-sawn joints. In fact, the threshold profiled element 3 is derived from a different precursor from the lateral profiled elements 1 and, in addition to having different dimensions, it also has a different arrangement of the internal matrices, such that it does not allow for a quartersawn welding.

[0050] Therefore, preferably, the lateral profiled elements 1 and the threshold profiled element 3 are “square” welded that is, across a head surface of one of the two profiled elements and a lateral surface of the other of the two profiled elements. In accordance with the embodiment shown in the figures, in the perimeter frame 8, the threshold profiled element 3 is placed between the lateral profiled elements 1.

[0051] Conveniently, therefore, each of the lower areas to be welded 5 corresponds to an extreme portion of the lateral surface 9 of the lateral profiled element 1 and each of the ending areas to be welded 7 develop on a surface substantially orthogonal to the plane of development of the threshold profiled element 3.

[0052] In the context of this disclosure, the expression “lateral surface” means the surface of the lateral profiled element 1 which, in use, faces the inside of the perimeter frame 8, i.e., facing the other lateral profiled element 1. The lateral surfaces of the profiled elements are generally irregular and have protrusions and recesses intended to ensure optimal sealing of the finished window or door frame. The lower area to be welded 5 may, therefore, have an irregular shape, depending on the shape of the lateral profiled element 1.

[0053] In accordance with an alternative embodiment, in the perimeter frame 8, the threshold profiled element 3 is arranged inferiorly to the lateral profiled elements 1. In such a case, each of the ending areas to be welded 7 corresponds to an extreme portion of the upper surface of the threshold profiled element 3 and each of the lower areas to be welded 5 develops on a surface substantially orthogonal to the longitudinal direction of the relevant lateral profiled element 1.

[0054] Advantageously, prior to the phase of heating, the method comprises a phase of shaping the threshold profiled element 3 to obtain the ending areas to be welded 7 substantially complementary to the lateral surface 9.

[0055] In this way, following the phase of joining, the threshold profiled element 3 and the lateral profiled elements 1 are seamlessly joined together.

[0056] The ending area to be welded 7 undergoes, therefore, what is known as “head butting”, i.e., the shaping of the threshold profiled element 3 depending on the shape of the lateral profiled element 1. In contrast, the lateral profiled element 1 is simply cut at the end along a plane substantially orthogonal to the respective longitudinal direction.

[0057] Usefully, the phase of shaping comprises at least one step of detecting the profile of the lateral surface 9 and one step of milling the threshold profiled element 3 depending on such profiled element.

[0058] The step of detecting can be carried out electronically so as to obtain an electronic profile of the lateral surface 9 and the step of milling, in turn, can be carried out in an automated maimer starting from the electronic profile. In detail, the step of detecting can be carried out by means of a scanning tool and the step of milling can be carried out by means of a milling tool movable with respect to the threshold profiled element 3 according to a path worked out on the basis of the electronic profile. Usefully, the method comprises a phase of supplying a transverse profiled element 10 provided with respective transverse areas to be welded 11. In such a case, the phases of positioning, heating and joining are also carried out the with the transverse profiled element 10.

[0059] The method, in fact, also allows the manufacture of French doors provided with two or more different parts which are separated, precisely, by one or more transverse profiled elements 10. For example, the French door can be provided with an openable part, that is, provided with a movable leaf, and with a fixed part, that is, provided with either a transparent or non-transparent paneling or with two different openable parts.

[0060] The transverse profiled element 10 is substantially similar to the upper profiled element 2 and to the lateral profiled elements 1, i.e., also provided with irregular surfaces to abut against an openable leaf or paneling, but may be derived from a different precursor. In other words, the transverse profiled element 10 may have dimensions and internal matrices which are different from the lateral profiled elements 1 and to the upper profiled element 2.

[0061] The transverse profiled element 10 is intended to be welded to the lateral profiled elements 1.

[0062] In detail, each of the lateral profiled elements 1 comprises at least one intermediate area to be welded 12 corresponding to an intermediate portion of the lateral surface 9.

[0063] At the same time, similarly to the threshold profiled element 3, the transverse areas to be welded 11 are substantially complementary to the lateral surface 9. Conveniently, in fact, the phase of shaping is also carried out on the transverse profiled element 10.

[0064] Even in the case where there is a transverse profiled element 10, the phases of heating and joining are advantageously carried out substantially simultaneously on all the profiled elements 1,2,3,10.

[0065] Advantageously, the phases of positioning, heating and joining are carried out on board an individual machine 20 for welding the profiled elements made of plastic material. The machine 20 is provided with: at least two upper welding heads 21 configured to weld the upper profiled element 2 to the lateral profiled elements 1 and each provided with at least one heating plate 22 inclined by an angle of between 10° and 80° to the longitudinal direction of the lateral profiled elements 1; and at least two lower welding heads 23 configured to weld the threshold profiled element 3 to the lateral profiled elements 1 and each provided with at least one heating unit 24 arranged substantially parallel to the longitudinal direction of the lateral profiled elements 1.

[0066] In detail, the heating plate 22 is of the type of an electric resistance plate which is inclined so as to contact the upper areas to be welded 4 and the extreme areas to be welded 6 substantially at the same time. Preferably, the heating plate 22 is inclined by 45° with respect to the longitudinal direction of the lateral profiled elements 1.

[0067] The heating unit 24 is in turn of the type of an electric resistance body and faces the lateral surface 9.

[0068] In case it is also necessary to weld a transverse profiled element 10, the machine 20 usefully also comprises at least two transverse welding heads 25 configured to weld the transverse profiled element 10 to the lateral profiled elements 1, wherein each transverse welding head 25 is in turn provided with at least one heating unit 24 arranged substantially parallel to the longitudinal direction of the lateral profiled elements 1.

[0069] The heating unit 24 is suitably shaped so as to fit, on the one side, the lower area to be welded 5, and on the other side, the ending area to be welded 7 or the transverse area to be welded 11. In this regard, it is specified that, however, for simple representational convenience, the heating unit 24 is shown in the figures as a parallelepiped.

[0070] As previously mentioned, in fact, while the upper areas to be welded 4 and the extreme areas to be welded 6 lie on a substantially flat surface, the lower areas to be welded 5, the ending areas to be welded 7 and the transverse areas to be welded 11 run on a very uneven surface, provided with recesses and protrusions the depth of which varies depending on the type of the lateral profiled element 1.

[0071] As a result, the heating unit is generally provided with a large size and an irregular shape in order to be able to effectively contact either the lateral profiled element 1 or the threshold profiled element 3 or the transverse profiled element 10.

[0072] For example, this method can be implemented on board a welding machine for profiled elements made of plastic material similar to the one described in WO2022 / 113029A2, wherein the upper welding heads 21 correspond to the “main welding devices 3” and the lower welding heads 23 and, when present, the transverse welding heads 25, correspond to the “intermediate welding devices 7”. In WO2022 / 113029A2, in order to obviate the problem of the size of the heating unit, each of the main welding devices comprises a pair of heating plates arranged substantially parallel and spaced apart from each other, similarly to what is shown in the attached Figures 1-6. It cannot, however, be ruled out that each of the upper welding heads 21 of the machine 20 comprises an individual heating plate 22 of greater thickness.

[0073] In addition, in WO2022 / 113029A2, the machine involves that the joining phase is carried out by moving the lateral profiled elements 1 and the upper profiled element 2 towards the center of the machine itself, while keeping the threshold profiled element 3 and the transverse profiled element 10 stationary, when present, similarly to what is shown in the attached Figure 4.

[0074] It cannot, however, be ruled out that this method can be implemented on a machine of different type wherein the joining phase is carried out by moving only the lateral profiled elements 1 in mutual approach towards the center of the machine itself and keeping the upper profiled element 2, the threshold profiled element 3 and the transverse profiled element 10, when present, stationary.

[0075] It has in practice been ascertained that the described invention achieves the intended objects, and in particular, the fact is emphasized that the method according to the invention for the manufacture of French doors made of plastic material with a threshold allows for a reduction in the number of necessary components.

[0076] In addition, the present method for the manufacture of French doors made of plastic material with a threshold allows for shorter assembly times than known solutions.

[0077] Finally, the present method for the manufacture of French doors made of plastic material with a threshold allows for optimal thermal sealing of the frame obtained.

Claims

CLAIMS1) Method for the manufacture of French doors made of plastic material with threshold, characterized by the fact that it comprises the following phases: supplying at least two lateral profiled elements (1), one upper profiled element (2) and one threshold profiled element (3), made of plastic material, extending along respective longitudinal directions and each provided, at the relevant ends, with at least one pair of areas to be welded (4, 5, 6, 7); positioning said profiled elements (1,2,3) with said areas to be welded (4, 5, 6, 7) facing each other; heating said areas to be welded (4, 5, 6, 7) until partial melting of said plastic material; joining said areas to be welded (4, 5, 6, 7) to each other to obtain a perimeter frame (8) for a French door with threshold.2) Method according to claim 1, characterized by the fact that each of said heating and joining phases is carried out substantially simultaneously on all profiled elements (1,2,3).3) Method according to one or more of the preceding claims, characterized by the fact that each of said lateral profiled elements (1) comprises an upper area to be welded (4) intended to be welded to said upper profiled element (2) and inclined by an angle of between 10° and 80° to the respective longitudinal direction, and by the fact that said upper profiled element (2) comprises a pair of extreme areas to be welded (6) inclined by an angle of between 10° and 80° to the respective longitudinal direction.4) Method according to one or more of the preceding claims, characterized by the fact that said upper areas to be welded (4) and said extreme areas to be welded (6) are inclined by an angle substantially equal to 45° to the longitudinal directions of the respective profiled elements.5) Method according to one or more of the preceding claims, characterized by the fact that each of said lateral profiled elements (1) comprises a lower area to be welded (5) intended to be welded to said threshold profiled element (3), substantially orthogonal to the lying plane of said perimeter frame (8), and by thefact that said threshold profiled element (3) comprises a pair of ending areas to be welded (7) substantially orthogonal to said lying plane of said perimeter frame (8).6) Method according to one or more of the preceding claims, characterized by the fact that each of said lower areas to be welded (5) corresponds to an extreme portion of the lateral surface (9) of said lateral profiled element (1) and by the fact that each of said ending areas to be welded (7) develop on a surface substantially orthogonal to the plane of development of said threshold profiled element (3).7) Method according to one or more of the preceding claims, characterized by the fact that, prior to said phase of heating, it comprises a phase of shaping said threshold profiled element (3) to obtain said ending areas to be welded (7) substantially complementary to said lateral surface (9).8) Method according to one or more of the preceding claims, characterized by the fact that said phase of shaping comprises at least one step of detecting the profile of said lateral surface (9) and one step of milling said threshold profiled element (3) depending on said profile.9) Method according to one or more of the preceding claims, characterized by the fact that it comprises a phase of supplying a transverse profiled element (10) provided with respective transverse areas to be welded (11), each of said lateral profiled elements (1) comprising at least one intermediate area to be welded (12) corresponding to an intermediate portion of said lateral surface (9), and by the fact that said phases of positioning, heating and joining are also carried out with said transverse profiled element (10).10) Method according to one or more of the preceding claims, characterized by the fact that said phase of shaping is also carried out on said transverse profiled element (10).11) Method according to one or more of the preceding claims, characterized by the fact that said phases of positioning, heating and joining are carried out on board an individual machine (20) for welding profiled elements made of plastic material provided with:at least two upper welding heads (21) configured to weld said upper profiled element (2) to said lateral profiled elements (1) and each provided with at least one heating plate (22) inclined by an angle of between 10° and 80° to the longitudinal direction of said lateral profiled elements (1); - at least two lower welding heads (23) configured to weld said threshold profiled element (3) to said lateral profiled elements (1) and each provided with at least one heating unit (24) arranged substantially parallel to the longitudinal direction of said lateral profiled elements (1).

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