Method for the manufacture of an improved door assembly

Abstract

 This invention concerns a method for assembling a door having a wing profile (1) and a panel (2) with an inside surface (5), an outside surface (4) and a core (6), comprising the step of removing a part of said panel (2) from around its peripheral edges, said part being able to contain said wing profile (1), characterised in that said wing profile (1) is eliminated from view from a viewing direction being perpendicular to and going outward from said outside surface (4).

Description

Field of the invention

[0001] This invention relates to a novel method for the construction of an improved door assembly comprising wing profiles and a panel. The method is such that the construction of the door can be performed in any craftsman's workshop.

Technological background

[0002] Composite doors are usually produced by the carpenter by mounting frame profiles, wing profiles, glass laths, joints and a panel together. This kind of construction has the disadvantage that the wing profiles are clearly visible on the outside of the door assembly. This is even more accentuated by the (generally black) joints. The resulting general picture of the door is unattractive and not aesthetic.

[0003] Carpenters usually try to cover the wing profiles by covering them with a panel, thus rendering the wing profiles invisible from the outside. The profiles available nowadays however are not designed to allow this in an easy manner and do not allow a swift and standardised industrial manufacture of quality covering panels providing perfect finishing.

[0004] The result is that such a door gets more expensive due to the work involved, since a new, custom panel has to be made for every door assembly to provide a satisfying quality. The end product is also not ideally finished, and depends highly on the carpenter's expertise.

Aims of the invention

[0005] The aim of the present invention is to provide an assembly kit for building a door with wing profiles invisible from the outside. Said door should be easily buildable by a carpenter in his workshop. A further aim is that said assembly kit is standardised, i.e. custom adjustments and component use are unnecessary.

[0006] A further aim of the present invention is to provide a method for the manufacture of a door with wing profiles invisible from the outside.

General description of the present invention

[0007] A first aspect of the present invention is a method for assembling a door having a wing profile and a panel with an inside surface, an outside surface and a core, comprising the step of removing a part of said panel from around its peripheral edges, said part being able to contain said wing profile, characterised in that said wing profile is eliminated from view from a viewing direction being perpendicular to and going outward from said outside surface.

[0008] Preferably, said part comprises the complete peripheral edges of the inside surface, and advantageously at least part of the peripheral edges of the core.

[0009] The method according to the invention can further comprise the step of fastening a wing profile on any of the peripheral edges of the panel, resulting in a door assembly. Said fastening step comprises preferably a gluing operation, but is not limited to that.

[0010] The method according to the present invention preferably further comprises the step of attaching accessories such as door knobs, locks and hinges to the door assembly.

[0011] The core can be an isolating material.

[0012] The wing profiles can be thermally interrupted.

[0013] In a preferred embodiment, the wing profiles comprise a protection lip that protects the peripheral edges of the outer surface of the panel.

Detailed description of the present invention

[0014] The assembly kit according to the present invention comprises a metal profile, a door frame provided to fit said metal profile, and a panel. Said metal profile can be thermally interrupted. Said panel can comprise decorative parts, glass panels, etc.

[0015] The invention will be further clarified with non-limiting figures and examples, which do not restrict the scope of the invention as claimed.

Short description of the drawings:

[0016] 

Figure 1 describes a transversal section of a door assembly according to the invention, showing the placement of the panel, wing profiles and door frame.

Figure 2 describes a section of the panel as used in the invention (figure 2A describes an unprepared panel, figure 2B and 2C a panel from which, according to the method of the invention, an part has been cut out at the peripheral edges).

Figure 3 shows the assembly of the wing profiles and the panel to form a door assembly according to the method of the invention.

Description of a door assembly kit according to the present invention.

[0017] Figure 1 shows a door assembled according to the present invention. The assembly kit according to the invention comprises at least 2 elements: an improved wing profile 1 to construct the door and a door panel 2 according to the invention. Accessories such as doorknobs, locks and hinges can be included in an assembly kit according to the present invention. Further, frame profiles 3 to form the door frame, are necessary to place the door in a doorway.

[0018] The frame profile 3 and accessories can be any kind of frame profile and accessory as used in the prior art.

[0019] The improved wing profiles 1 are such that, after the assembly of wing profiles 1 and door panel 2, the wing profiles 1 are obscured from view by outer surface 4 of the panel 2. The wing profile 1 can comprise a protecting lip 7, that protects the peripheral edge of the outer surface of the panel. Preferably, the wing profiles are made of metal. A preferred metal is aluminium, since this material is lightweight, easily mouldable and provides a sturdy and high strength door assembly.

[0020] The door panel 2 comprises an inner surface 5, an outer surface 4 and a core material 6. The inner 5 as well as the outer surface 4 can be made of any type of construction material, adapted to the use of the door or to the wishes of the client. Preferred materials for the construction of the inner and outer surface are wood, metals such as aluminium, and plastics. The inner and outer surface can be decorated with motifs and/or ornamental designs. The panel core 6 can be made of any material in any conformation capable of supporting the inner and outer surface of the panel. Preferred embodiments are isolating foams, massive wood, cardboard or other materials in honeycomb structures.

[0021] The core 6 can be a combination of different materials and/or different structures. For example, a fire retarding structure and/or material can be used.

Example 1: Construction of a door assembly using an assembly kit of the present invention.

[0022] The mounting of an assembly kit according to the invention can be divided into several phases.

[0023] First, the panel 2, comprising the outer 4 and inner surface 5 and the core 6, is sawn to the desired dimensions. A panel such as in figure 2A is obtained.

[0024] Then, the panel 2 is cut to match the wing profiles: an external part of the inner surface 5 and at least part of the core 6, both parts at the peripheral edges of said panel 2, are cut away. The result is a panel 2 with an outer surface 4 that is larger than the inner surface 5 and at least part of the core 6. The panel has to match the topography of the wing profiles, so that the wing profiles 1 can be mounted around the peripheral edge 8 of the panel 2, covering all the edges 9 of the inner surface and the core. When the wing profiles 1 comprise protecting lips 7, the lips 7 should cover the peripheral edge 8 of the outer surface 4.

[0025] The next step is to cut the wing profiles 1 to the desired dimensions, and to provide the profiles with all the necessary cut-outs and/or holes to attach the accessories (doorknob, hinges,...).

[0026] Next, the wing profiles 1 and the panel 2 are assembled using a convenient glue. This can be seen in figure 3. The wing profiles 1 can be connected to each other using corner links 10. The attachment of the accessories (preceded if necessary by preparing the panel-profiles assembly for the accessories), is the final step in mounting the door.

[0027] The further steps are known by the person skilled in the art: the door frame has to be mounted, the door is placed in the door frame, locks and hinges are adjusted and, possibly after the placement of rubber joints the door can be suspended with the hinges.

[0028] The door assembly obtained has the advantages that the wing profiles are not visible from the outside. The door is self-carrying, and extra robust resulting from the use of the sturdy wing profiles and the panel.

Claims

1. Method for assembling a door having a wing profile and a panel with an inside surface, an outside surface and a core, comprising the step of removing a part of said panel from around its peripheral edges, said part being able to contain said wing profile, characterised in that said wing profile is eliminated from view from a viewing direction being perpendicular to and going outward from said outside surface.

2. Method as in claim 1, characterised in that said part comprises the complete peripheral edges of the inside surface.

3. Method as in claim 2, characterised in that said part further comprises at least part of the peripheral edges of the core.

4. Method as in any of the claims 1 to 3, further comprising the step of fastening a wing profile on any of the peripheral edges of the panel, resulting in a door assembly.

5. Method as in claim 4, characterised in that said wing profile is glued on the panel.

6. Method as in any of the claims 1 to 5, characterised in that it further comprises the step of attaching accessories to the door assembly.

7. Method as in any of the claims 1 to 6, characterised in that the core is an isolating material.

8. Method as in any of the claims 1 to 7, characterised in that the wing profiles are thermally interrupted.

9. Method as in any of the claims 1 to 8, characterised in that the wing profile comprises a protection lip that protects the peripheral edges of the outer surface of the panel.

Drawing