A PROCESS FOR PRODUCING DOORS AND OTHER BUILDING ELEMENTS, TOGETHER WITH AN ARRANGEMENT FOR CARRYING OUT THE PROCESS

Abstract: Process and arrangement for producing doors (3) and other similar building elements with a sheet-type format. The invention makes possible rational production of doors (3), etc. which comprise an inner insulation made of a plastic material, preferably polyurethane. The process is effected by supplying plastic material at a flowing consistency to one end (1A) of a hollow moulding frame (1) equipped with a core, and causing the plastic material to fill the moulding frame (1) gradually towards its other end (1B) so that the core (5) is surrounded by an imbedded in the said plastic material.

Description: A Process for Producing Doors and other Building Elements, together with an Arrangement for Carrying Out the Process The present invention relates to a process for pro¬ ducing doors and other building elements with a sheet-type format. The invention also relates to an arrangement for carrying out the said process. The main object of the present invention is firstly to provide a process of the above-mentioned type which makes possible the rational production of doors and other building elements with a sheet-type format, and which com¬ prise an inner insulation of a preferably expanding plas- tic moulding material, preferably polyurethane. The said object is accomplished by means of a process according to the present invention which is essentially characterised in that a plastic material is supplied at flowing consistency to one end of a hollow moulding frame equipped with a core, and the plastic material is caused to fill the moulding frame progressively towards its other end so that the core is surrounded by and imbedded in the said plastic material. A further object of the present invention is to pro- vide an arrangement with which the said process can be carried out. The said further object is accomplished by means of an arrangement according to the present invention which is essentially charaaterised in that a hollow moulding frame has means for supporting a core placed in the cavity of the mould, and that an inlet opening intended for the supply of a plastic material in a flowing form is located at one end of the moulding frame. The invention is described below by way of a pre- ferred embodiment example, with reference to the accom¬ panying drawings, on which Figure 1 shows a building element produced according to the present invention, in a partially sectioned state, 'SURET OMPI Figure 2 is a perspective view of a frame which is suitable for producing the said building element, with its associated core, and Figure 3 is a longitudinal section through the said frame. A frame which is designated numeral 1 on the draw¬ ings and is preferably made of wooden material is formed of a four-sided outer door shell with an inner cavity 2, and displays substantially the circumferential shape which it is desired to give the envisaged building element 3 with a sheet-type external format which it is intendedto produce with the aid of the frame 1, and is designed to function as a moulding frame 4- when producing the said building element 3; this element will be exemplified sim- ply as a door 3 in the following. One or more cores 5 » made of a suitable material such as a wooden material for example, which enables the heat to be conducted away ef¬ fectively during the moulding process of the door 3 from the plastic moulding material being supplied to the mould - and from which it is intended to produce the door 3, are supported in the inner cavity 2 in the moulding frame. A core 5 may be supported by means of a plurality of an¬ choring elements 6, 7 . 8 which can be connected to the two longitudinally-extending side pieces 9 and 10 respec- tively of the frame 1, on the respective side surfaces9A and 10A which face in towards the cavity 2. The said an ¬ choring elements 6 - 8, which can be connected to the core 5 at its respective corner zones A, 5B and the central zones5C respectively by means of bolt connections 11 or in some other suitable way, are provided as supports for a plurality of hinges and/or locking devices for the door 3 produced. An anchoring element 6 - 8 may consist of a metal plate 12 which is screwed securely to the frame 1 and from which a number of arms 13 project, to the free ends of which arms the said cores 5 can be connected. OMPI At one end 1A the frame 1 has a channel-shaped mat¬ erial receiving part 14- which extends across the whole width of the frame, as shown in Figure 2. The said part 14- is formed in the intermediate space between one short side piece 15 of the frame, which has at least one inlet opening 16 for plastic moulding material, and a barrier 7 ? which may consist of a strip of wood, extending across the frame 3 and situated spaced apart from the said side part 15. Expediently, the said barrier 1 and the frame end part 15 are the same height, viewed in the direction of the thickness of the door. At the other end 1B of the frame, which faces away from the above-mentioned end 1A, a plurality of prefer¬ ably bore-like outlet holes 18 extend through a frame end part 19 which forms the other short side piece of the frame. Expediently, the said holes 18 are disposed in a row as shown on the drawing in Figure σ The said holes 18 are intended for venting air, gas, etc. which is formed or is present in the cavity 2 in the frame, during the moulding process of the door 3. Facing elements 20 and 21 respectively in the form of sheets are intended, amongst other things, to form the said moulding frame 4-, covering over the cavity 2 inside the frame across both sides 10 and 1D of the frame, res- pectively. Expediently, the said facing is for ed by two separate metal sheets 20, 21 with their edges 22 and 23 respectively bent so that they are adapted to engage round the said frame 1. For example, copper plates provided with suitable shaping may be used. To obtain suitable spacing between the frame 1 and the two said facing ele¬ ments 20, 21, spacer elements 24- and 25 respectively, for example in the form of blocks, are arranged in the corner regions of the frame and on the frame parts 9, 10, 15, 19 respectively. Due to the provision of the said spacer elements 24-, 25, between the respective facing elements 20, 21 and the barrier 17 slit-shaped openings 26 are OΛ.P! formed; these are designed for the supply of plastic moulding material from the material receiving part 14- to the interior 2 of the mould. The facing elements 20, 21 are temporarily connected to the frame 1 around the circumference thereof, so that they are held together and form a mould 4- which it is possible to fill with plastic moulding material during the production stage of the door; the said temporary con¬ nection may be effected by means of strips of tape 27 for example, as shown in Figure 1, which can be removed after¬ wards from the moulded door 3. A door 3 is produced in that a frame 1 with a core 5 accommodated in its inner cavity 2 is enclosed by facing elements 20, 21 over its respective side faces, after which the said frame 1 and the facing elements 20, 21 are connected so that they form a substantially leak-tight moulding frame 4-. Suitable plastic material, preferably polyurethane foam plastic, is supplied at a flowing con¬ sistency to the said mould 4- by introducing the material in the direction of the arrow 28 shown in Figure 3, into the channel-shaped space in the part 14-. The plastic moulding material flows in the direction of the arrows 29, through the slit-shaped openings 26 and into the cavity 2 inside the mould, and ^ gradually fills the said cavity 2 as the material flows in the direction of the arrows 30 towards the end 1B of the frame. Air, gas, etc. flows out of the said cavity 2 through the outlet holes 18. An even distribution of the plastic material inside the cav¬ ity 2 of the mould is obtained due to the fact that the reaction heat from the plastic moulding material is taken up by the core 5, thus preventing the breaking down of the plastic moulding material due to too high a tempera¬ ture. When sufficient plastic material has been supplied to the moulding frame the supply is discontinued and the plastic is then allowed to harden. After it has hardened the tape 27 is removed and suitable covering strip elements OMPI in the form of strips of wood, for example, are connected to the door 3 produced, after which openings for hinges, etc. can be made through the said covering strip elements, the frame 1 and the anchoring elements 6 - 8. The invention is not limited to the embodiment ex¬ ample of the process and the arrangement for producing a door or other building element with a sheet-type format described above and shown on the drawings, but can be modified within the framework of the following Patent Claims. OMPI , WiP0

Claims: P a t e n t C l a i m s 1. A process for producing doors (3) and other build¬ ing elements wit a sheet-type format, characterised in that plastic material is supplied at flowing consistency to one end (1A) of a hollow moulding frame (1) equipped with a core, and the plastic material is caused to fill the moulding frame (1) gradually towards its other end (1B) so that the core (5) is surrounded by and im¬ bedded in the said plastic material. 2. A process according to Patent Claim 1, character- ised in that the plastic material is supplied at one end (1A) of the moulding frame via a -_number- ' of slit-shaped openings (26). 3. A process according to Patent Claim 2, character¬ ised in that the core (5) is made to take up heat from the plastic material during the supply phase thereof. 4-. A process according to either of Patent Claims 2-3, characterised in that air and/or gas from the plastic material being supplied to the moulding frame (1) isvented via a plurality of outlet holes (18) opening from the in- terior (2) of the frame and located in the other end (1B) which faces away from the said first end (1A). 5. An arrangement for producing doors (3) and other building elements with a sheet-type format according to any of the above Patent Claims, characterised in that a hollow moulding frame (1) has means (6, 7, 8) for support¬ ing a core (5) accommodated in the cavity (2) inside the frame, and that an inlet opening (16, 26) intended forthe supply of a plastic material in a flowing form is located at one end (1A) of the frame. 6. An arrangement according to Patent Claim 5, characterised in that the moulding frame (1) comprises an outer, four-sided frame (1) constructed in the cirσum- ferential shape of the building element (3) which it is intended to produce, with a cavity (2) formed between the inside (2) of the frame and a plurality of facing elements (20, 21) adjoining the sides, which can be applied to the 5 frame (1) and held spaced apart therefrom by means of spacer elements (24-, 25), in which cavity (2) the said core (5) is accommodated, and the said cavity being design¬ ed to be -Tilled with plastic material. 7. An arrangement according to Patent Claim 6, 0 characterised in that at one end (1A) of the frame there is a ■ number of slit-shaped material inlet openings (26) which are formed between the said facing elements (20, 21) and a barrier (17) extending across the frame (1) which, together with one end part (15) of the frame, defines a 5 channel-shaped material receiving part (14-) into which debouching a material inlet opening (16) which extends through the said frame end part (15). 8. An arrangement according to Patent Claim 7, characterised in that a frame end part (19) located at the o other end (1B) has a plurality of outlet holes (18) for air and/or gas, for example in the form of bores (18)dis- posed in a row. 9. An arrangement according to any of Patent Claims 5 - 8, characterised in that the core (5) is formed of at 5 least one sheet (5) of wooden material or some other suit¬ able material which is capable of taking up heat from the plastic material in which the said core (5) is imbedded. 10. An arrangement according to any of Patent Claims 5 - 9, characterised in that the core (5) is supported on 0 the frame (1) by means of a plurality of anchoring ele¬ ments (6 - 8) connected to the frame and designed to sup¬ port hinges and/or locking devices, preferably at the cor¬ ner and central zones (5A, 53 and.5C respectively) of the core.

Inventors: BENGTSSON FRED BERNHARD, BENGTSSON, FRED, BERNHARD
Applicants: THERMACORE AB, AB THERMACORE
Application year: 1983
Main classification: B29D27
IPC codes: B29C70, E06B3