Door leaf and door comprising same
A mechanical connection via a connecting profile and fastening elements addresses the issue of temperature-induced deformation in door leaves, ensuring stability and durability by allowing flexibility and sealing the gap between the cover plate and sash frame.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- REHAU IND SE & CO KG
- Filing Date
- 2025-12-18
- Publication Date
- 2026-06-25
AI Technical Summary
Existing door leaves with rigid connections between the weather-facing cover plate and the sash frame are prone to deformation due to temperature fluctuations, leading to structural instability.
A mechanical connection is established between the weather-facing cover plate and the sash frame via a connecting profile, which is fastened to the sash frame using fastening elements, allowing for flexibility and preventing unwanted deformation under temperature changes.
The mechanical connection provides stability and flexibility, reducing deformation of the infill element and enhancing the durability of the door leaf by preventing water and dirt ingress.
Smart Images
Figure EP2025088101_25062026_PF_FP_ABST
Abstract
Description
[0001] REHAU Industries SE & Co. KG Rehau, December 20, 2024
[0002] International symbol: 24,083 / 1 hg
[0003] Door leaf as well as this comprehensive door
[0004] The present invention relates to a door leaf comprising a sash frame formed from several sections of a sash profile, wherein the sash frame includes a weather-facing exterior wall and an interior-facing exterior wall; and a filling element received in the sash frame, wherein the filling element comprises a weather-facing cover plate, at least one intermediate layer, and an interior-facing cover plate, the weather-facing cover plate of the filling element at least partially covering the weather-facing exterior wall of the sash frame. Furthermore, the present invention relates to a door, in particular an entrance door, comprising a door frame and a door leaf rotatably mounted on the door frame.
[0005] Such door leaves are referred to as leaves with a leaf-covering infill and are widely known in the art. For example, EP 2 034 119 A2 describes such a door leaf in which the overhang of the weather-facing cover plate of the infill element is bonded to the weather-facing outer wall of the leaf frame. A disadvantage of the door leaf described in EP 2 034 119 A2 is that the bonding alone creates a rigid connection between the weather-facing cover plate of the infill element and the leaf frame. This rigid connection can lead to deformation of the surface element, particularly during temperature fluctuations.
[0006] Against this background, the object of the present invention is to provide a door leaf that at least partially overcomes the disadvantages of the prior art. In particular, the door leaf according to the invention should be less susceptible to temperature-induced deformations of the surface element. Furthermore, the object of the present invention is to provide a door that includes such a leaf.
[0007] According to the present invention, these and other problems are solved by a door leaf with the features of claim 1 or by a door with the features of claim 12. Preferred embodiments of the door leaf according to the invention are described in the dependent claims.
[0008] According to the present invention, it was recognized that to avoid the rigid connection between the weather-side cover plate of the filling element and the REHAU Industries SE & Co. KG Rehau, 20.12.2024
[0009] International symbol: 24,083 / 1 hg
[0010] The sash frame also requires mechanical components for this connection, and a purely adhesive connection is not intended for this purpose. According to the invention, this is achieved by connecting the weather-facing cover plate of the infill element to the sash frame via a connecting profile. This profile is connected to the sash frame via a fastening element fixed to the sash frame, for example, by rustproofing or bonding. This mechanical connection allows for a certain degree of flexibility, thus preventing unwanted deformation of the infill element, particularly under temperature fluctuations. Additionally, the weather-facing cover plate can also be bonded to the weather-facing outer wall of the sash frame in the overlapping area.
[0011] Accordingly, the present invention comprises a door leaf comprising (a) a wing frame formed from several sections of a wing profile, wherein the wing frame includes a weather-facing outer wall and a room-facing outer wall; and (b) a filling element received in the wing frame, wherein the filling element comprises a weather-facing cover plate, at least one intermediate layer and a room-facing cover plate; wherein the weather-facing cover plate of the filling element at least partially covers the weather-facing outer wall of the wing frame, wherein the door leaf is characterized according to the invention in that it further comprises (c) a connecting profile connected to the weather-facing cover plate of the filling element, and at least one fastening element connected to the connecting profile and attached to the wing frame.Furthermore, the present invention lies in the provision of a door, in particular a front door, comprising a door frame and a door leaf rotatably mounted on the door frame according to the invention.
[0012] With regard to the door leaf according to the invention, it is preferred if the leaf frame has a stepped design on its weather-facing outer wall, wherein the connecting profile is supported at least partially, preferably over its entire length, on the step of the weather-facing outer wall of the leaf frame. Such a stepped geometry of the weather-facing outer wall of the leaf frame contributes to the overall stability of the connection of the interior cover plate.
[0013] Additionally or alternatively, it can also be helpful if the connecting profile includes a receiving channel, preferably with at least a partially rough inner surface. Such a receiving channel is suitable for attaching other components, for example the fastener, to the connecting profile. REHAU Industries SE & Co. KG, Rehau, December 20, 2024
[0014] Int. Ref: 24.083 / 1 hg by screwing. It may be preferred if the fastening element has a plug-in element that engages in the receiving channel of the connecting profile. Such a plug-in element can be easily inserted into the receiving channel and, in preferred embodiments, can be held therein due to the at least partially rough inner surface of the receiving channel. This allows for quick pre-fixing of the connection. Additionally or alternatively, it may be preferred if at least one fastening screw engages in the receiving channel of the connecting profile. The screwing serves for the final fastening of the fastening element to the connecting profile. It is understood that several such fastening elements engage in the connecting profile along the length of the profile section of the sash frame. Accordingly, several fastening screws can be used for their fastening.
[0015] It can also be beneficial if the connecting profile has a support spring that rests against the sash frame. This also contributes to the flexible connection of the infill element to the sash frame. The support spring is preferably formed integrally with the connecting profile.
[0016] In advantageous embodiments of the window sash according to the invention, it further comprises at least one fastening clip which engages in the receiving channel of the connecting profile. The fastening clip serves to pre-fix the infill element to the frame and thus facilitates the installation of the door sash according to the invention. It is particularly advantageous if the at least one fastening clip engages in an undercut in the connecting profile.
[0017] It may also be preferred if the fastening element is attached to the sash frame by at least one fastener, which preferably engages in a fastening channel of the sash profile. This allows for easy attachment to the sash frame without the need to screw into a steel reinforcement. The fastening element is preferably designed as a fastening screw.
[0018] It can also be advantageous if the connecting profile includes an engagement element on its side facing at least one intermediate layer of the infill element, which engages in a corresponding recess in the at least one intermediate layer. This provides an additional mechanical connection between the connecting profile and the infill element via the intermediate layer. REHAU Industries SE & Co. KG Rehau, December 20, 2024
[0019] International symbol: 24,083 / 1 hg
[0020] It can also be advantageous if the sash profile includes a preferably co-extruded sealing element on its weather-facing outer wall, which seals the gap between the weather-facing outer wall of the sash profile and the weather-facing cover plate of the infill element, at least partially. This prevents water or dirt from entering the gap between the weather-facing outer wall of the sash profile and the weather-facing cover plate of the infill element. This improves both the visual appearance of the door leaf according to the invention and the durability of any additional adhesive bond.
[0021] Preferably, the profiles for both the sash frame and the door frame are hollow chamber profiles comprising multiple hollow chambers, in particular plastic hollow chamber profiles comprising multiple hollow chambers or aluminum hollow chamber profiles comprising multiple hollow chambers, with plastic hollow chamber profiles being particularly preferred. This makes the design of the door according to the invention as a plastic door particularly preferred.
[0022] It can also be advantageous if the plastic of the sash profile and the profile of the door frame are thermoplastic. Such profiles can then be manufactured using a known extrusion process. Polyvinyl chloride (PVC), in particular rigid PVC (PVC-U) or post-chlorinated PVC, is preferred as the material for the hollow chamber profile according to the invention. The material can also be fiber-reinforced, in particular glass fiber-reinforced. Likewise, the connecting profile is preferably also designed as a plastic profile or as a metal profile. The fastening element is preferably an injection-molded component made of a thermoplastic or a die-casting alloy.
[0023] The features and effects described with regard to the door leaf according to the invention apply accordingly to the door according to the invention.
[0024] The door leaf and the door according to the invention, as well as individual parts thereof, can also be manufactured line by line or layer by layer using a line-by-line or layer-by-layer manufacturing process (e.g., 3D printing). REHAU Industries SE & Co. KG, Rehau, December 20, 2024
[0025] International symbol: 24,083 / 1 hg
[0026] However, the profiles of the door frame and the door leaf are preferably manufactured by extrusion or extrusion and cut to length into beams, which are mitered and welded or otherwise joined together.
[0027] The invention will now be explained in detail with reference to the embodiments illustrated in the figures. The present invention will be explained using a plastic door made of hollow plastic profiles as an example. However, it is understood that the present invention can also be applied analogously to other doors, for example, doors made of hollow aluminum profiles, wooden doors, composite doors, such as aluminum-wood composite doors, aluminum-plastic composite doors, and wood-plastic composite doors. The embodiments shown in the figures are therefore to be considered merely exemplary and are not intended to be limiting.
[0028] This shows
[0029] Fig. 1 shows a schematic representation of a door according to one embodiment of the present invention;
[0030] Fig. 2 shows a section of the door according to the invention shown in Fig. 1 in cross-section in the area of the lock case; and
[0031] Fig. 3 shows a cross-sectional view of a door leaf according to the invention in accordance with a further embodiment of the present invention.
[0032] Figure 1 shows a schematic representation of the basic structure of a door 1 according to an embodiment of the present invention. The door 1 according to the invention is designed as a plastic door. In the embodiment shown in Figure 1, the door 1 according to the invention comprises a door frame 2 and a door leaf 4 according to the invention, which is rotatably attached to the door frame 2 by means of three hinge elements 31, 32, 33. The door frame 2 is constructed from three profile sections 21, 22, 23 of a plastic profile, welded together at the corners, and a threshold 5, which is connected to the two adjacent plastic profile members 21, 23 by means of threshold supports.
[0033] The door leaf 4 comprises a wing frame 6 made of four plastic profile beams 61, 62, 63, 64 welded together at the corners, which have an identical cross-section and are not visible in the illustration according to Fig. 1, as they are supplied by REHAU Industries SE & Co. KG Rehau, 20.12.2024
[0034] International symbol: 24,083 / 1 hg
[0035] The sash frame 6 accommodates the infill element 7, in particular a door panel which may also include a glazing element, and which is completely covered in the area visible from the outside. A lock case 8 (Fig. 2) is incorporated into the plastic profile mullion 63, which can be identified in Fig. 1 by a keyhole 9 and can be operated with a door handle 10.
[0036] Figure 2 shows a cross-sectional view of such a door 1 according to the invention. The section around the lock case 10 is shown. The door leaf profile is made of a thermoplastic polymer material, preferably polyvinyl chloride (PVC), in particular rigid PVC (PVC-U) or glass fiber reinforced PVC, to which further additives, such as stabilizers, plasticizers, pigments, and the like, are added. It is constructed from a plurality of hollow chambers, each of which is surrounded by inner walls and partially also by outer walls of the door leaf profile. The door leaf profile has a weather-facing outer wall 631 and a room-facing outer wall 632. The hollow chamber arranged centrally in the door leaf profile is the main hollow chamber 633, into which a reinforcing element, preferably a steel reinforcement, is inserted and which is fastened to the door leaf frame 6 by means of fastening screws.In the illustrated embodiment, the lock case 8 is arranged between two legs of the reinforcement element. The weather-facing outer wall 631 is stepped. As a result, the sash frame 6 has a step 634. A support web 635, together with the upper web 636 and a retaining strip 637 engaged in a retaining strip groove, forms a rebate.
[0037] The infill element 7 is inserted into the rebate, so that the sash frame 6 surrounds the infill element 7 on its end face. The infill element 7 comprises a weather-facing cover plate 71, an insulating intermediate layer 72, and an interior-facing cover plate 73. The intermediate layer 72 and the interior-facing cover plate 73 are milled back to such an extent that the weather-facing cover plate 71 forms an overlap area, which covers the sash frame 6 up to just beyond the end of the weather-facing exterior wall 631. When the door 1 is closed, the sash frame is therefore not visible from the outside of the building. The gap between the weather-facing exterior wall 631 of the sash profile is closed by a sealing element 638 extruded onto the sash profile. This prevents the ingress of dirt or water.
[0038] A connecting profile 11 is arranged in the space between the intermediate layer 72 of the infill element 7 and the sash frame 6. The connecting profile 11 is manufactured by REHAU Industries SE & Co. KG, Rehau, on December 20, 2024.
[0039] Int. Ref: 24.083 / 1 hg. The illustrated embodiment is bonded to the weather-side cover plate 71, in particular by means of double-sided adhesive tape. The connecting profile 11 is designed as an extruded aluminum profile. It rests on the step 634 of the sash frame 6. The connecting profile 11 comprises several webs that are directed against the weather-side outer wall 631 of the sash profile. The connecting profile 11 includes a receiving channel 111 with at least a partially rough inner surface, which in the illustrated embodiment is grooved. The connecting profile 11 has a support spring 112 that bears against the support web 635 of the sash frame 6.
[0040] Furthermore, the connecting profile 11 has an engagement element 113 on its side facing the intermediate layer 72 of the filling element 7. The engagement element 113 engages in a complementary recess 74 of the intermediate layer 72. This provides an additional mechanical connection between the connecting profile and the filling element via the intermediate layer.
[0041] A fastening element 12 rests on the rebate base of the sash frame 6. In the illustrated embodiment, the fastening element 12 is designed as a two-legged, angled component made of a zinc die-cast alloy. The fastening element 12 is attached to the sash frame 6 by a fastening element designed as a fastening screw, which engages in a fastening channel 639 of the sash profile.
[0042] The fastening element 12 is connected to the connecting profile 11 by a further fastening screw that engages in the receiving channel 111 of the connecting profile 11. This screwing serves to permanently secure the fastening element 12 to the connecting profile 11.
[0043] It is understood that several such fastening elements 12 engage in the connecting profile 11 along the length of the profile section of the sash frame 6. Accordingly, several fastening screws can be used to fasten them.
[0044] The mechanical connection between the weather-facing cover plate 71 of the infill element 7 and the weather-facing outer wall 631 of the sash frame 6 provides a degree of flexibility. This prevents unwanted deformation of the infill element 7, particularly under temperature fluctuations. REHAU Industries SE & Co. KG Rehau, December 20, 2024
[0045] International symbol: 24,083 / 1 hg
[0046] Additionally, the weather-side cover plate 71 can also be bonded to the weather-side outer wall 631 of the sash frame 6 in the overlap area. Since the sealing element 638 seals the gap between the weather-side outer wall 63 of the sash profile and the weather-side cover plate 71 of the infill element 7, no water or dust can enter the gap. This contributes to the durability of the adhesive bond.
[0047] In the closed state of the door 1 according to the invention, the door leaf 14 according to the invention rests against the door frame 2 via seals.
[0048] The present invention will now be explained with reference to a further embodiment shown in Fig. 3. To avoid repetition, only the differences between the various embodiments will be discussed below. Otherwise, the explanations relating to the embodiment according to Figs. 1 and 2 apply accordingly. Identical reference numerals denote identical elements.
[0049] Figure 3 shows a cross-sectional view of a door leaf 4 according to a further embodiment of the present invention. The reinforcing element, the retaining strip 637, and the lock case 8 have been omitted.
[0050] In addition to the mechanical fastening of the infill element 7 via the connecting profile 11 and the fastening elements 12, in this embodiment of the door leaf 4 according to the invention, the infill element 7 is additionally pre-fixed in the leaf frame 6 by means of fastening clips 13, which facilitates the assembly of the door leaf 4 according to the invention. The fastening clips 13 are designed as metallic clamps. In a folded-over end region, the fastening clips 13 engage in a recess 114 in the connecting profile 11. A curve of the fastening clips 13 rests against the support web 635 on the weather-facing outer wall 631 of the leaf frame 6. Another end of the fastening clips 13 engages in the receiving channel 111 of the connecting profile 11.
[0051] During the assembly of the window sash according to the invention, the fastening clips 13 are placed on the sash frame 6. The fastening element 13 is already screwed to the sash frame 6. Now, the infill element 7 with the attached connecting profile 11 is pressed against the sash frame 6 until the bent ends of the fastening clips 13 engage behind the undercut 114. This achieves a pre-fix. REHAU Industries SE & Co. KG Rehau, December 20, 2024
[0052] International symbol: 24,083 / 1 hg
[0053] The final fastening is achieved by driving fastening screws for the respective fastening elements 12 into the receiving channel 111 of the connecting profile 11.
[0054] The invention has been explained in detail above with reference to the embodiment of the door according to the invention shown in the figures. The profile sections for the door frame and the door leaf are described as sections of hollow plastic profiles. These descriptions also apply accordingly to other types of profile frames, for example, those made of aluminum profiles, aluminum-plastic composite profiles, aluminum-wood composite profiles, wood-plastic composite profiles, and the like. It is therefore understood that the present invention is not limited to these embodiments, but that the scope of the present invention is defined by the claims.
[0055] - Patent claims -
Claims
REHAU Industries SE & Co. KG Rehau, December 20, 2024 International symbol: 24,083 / 1 hg Patent claims 1. Door leaf (4), comprising: (a) a sash frame (6) formed from several sections of a sash profile, wherein the sash frame (6) comprises a weather-side exterior wall (631) and a room-side exterior wall (632); and (b) a filling element (7) incorporated into the sash frame (6), wherein the filling element (7) comprises a weather-side cover plate (6), at least one intermediate layer (8) and a room-side cover plate (7); wherein the weather-side cover plate (6) of the filling element (7) at least partially covers the weather-side outer wall (631) of the sash frame (6), characterized in that the door leaf (4) extends further (c) a connecting profile (11) connected to the weather-side cover plate (6) of the infill element (7), and (d) comprising at least one fastening element (12) connected to the connecting profile (11) and attached to the sash frame (6).
2. Door leaf (4) according to claim 1 , characterized in that the leaf frame (6) is formed in a stepped manner on its weather-side outer wall (631), wherein the connecting profile (11) is supported at least partially on the step (634) of the weather-side outer wall (631) of the leaf frame (6).
3. Door leaf (4) according to claim 1 or claim 2, characterized in that the connecting profile (11) comprises a receiving channel (111) which preferably has at least a partially rough inner surface.
4. Door leaf (4) according to claim 3, characterized in that the fastening element (12) has a plug-in element that engages in the receiving channel (11) of the connecting profile (11). REHAU Industries SE & Co. KG Rehau, December 20, 2024 International symbol: 24,083 / 1 hg 5. Door leaf (4) according to claim 3 or claim 4, characterized in that at least one fastening screw engages in the receiving channel (111) of the connecting profile (11).
6. Door leaf (4) according to one of claims 1 to 5, characterized in that the connecting profile (11) has a support spring (635) which rests against the wing frame (6).
7. Door leaf (4) according to one of claims 1 to 6, characterized in that the door leaf (4) further comprises at least one fastening clip (13) which engages in the receiving channel (111) of the connecting profile (11).
8. Door leaf (4) according to claim 7, characterized in that the at least one fastening clip (13) engages in an undercut (114) in the connecting profile (11).
9. Door leaf (4) according to one of claims 1 to 8, characterized in that the fastening element (12) is attached to the wing frame (6) by at least one fastening means which engages in a fastening channel (639) of the wing profile.
10. Door leaf (4) according to one of claims 1 to 9, characterized in that the connecting profile (11) comprises on its side facing the at least one intermediate layer (72) of the filling element (7) an engagement element (113) which engages in a corresponding recess (74) of the at least one intermediate layer (72).
11. Door leaf (4) according to one of claims 1 to 10, characterized in that the leaf profile comprises a preferably extruded sealing element (638) on its weather-side outer wall (631), which seals the gap between the weather-side outer wall (631) of the leaf profile and the weather-side cover plate (71) of the infill element (7) at least sectionally.
12. Door (1), in particular front door, comprising a door frame (2) and a door leaf (4) rotatably mounted on the door frame (2) according to one of claims 1 to 11.