A DOOR AND A METHOD FOR ITS MANUFACTURE

Abstract: A door comprises a door frame having frame-members (1-4), which extend along the edges of the door. The door is clad on one flat side thereof with an outer panel (8) which is nailed to the frame members and also to at least one nailing batten (9, 10). The nailing batten has a thickness which is smaller than the thickness of the frame members. A continuous sheet (5) of insulating material provided with grooves (11, 12) for accommodating the nailing batten fills the hollow cavity located inwardly of the door-frame members. The insulating sheet (5) and the door-frame members (1-4) surrounding the insulating sheet are covered on each flat side thereof with a covering sheet (6, 7), to which they are glued. The door is manufactured by forming an insulating sheet (5) which fits into the space located inwardly of the door frame and which has a thickness corresponding to the thickness of the door frame, by forming in the insulating sheet one or more grooves (11, 12) whose depth is smaller than the thickness of the sheet, and by placing nailing battens (9, 10) in the grooves (11, 12) and gluing the insulating sheet (5), the nailing battens located in the grooves, and the frame-members (1-4) to the covering sheets (6, 7), and then nailing the outer panel (8) to the door structure thus obtained.

Description: A door and a method for its manufacture The present invention relates to a door of the kind which comprises a door frame having frame members which extend along the side surfaces and top and bottom edges of the door, and also of the kind which is clad with an outer panel on at least one flat side thereof, said panel being nailed to the frame members and also to at least one nailing batten, and in which door the cavi- ties defined between the door-frame members and the at least one nailing batten are filled with insulating material. The invention also relates to a preferred method for manufacturing the inventive door. Doors of the kind with which the present invention is concerned normally have a frame construction which comprises a plurality of frame members which are mutu¬ ally fastened together, e.g. nailed, to form a door frame, to which nailing battens are firmly attached. • When measured perpendicularly to the plane of the door, these nailing battens have a thickness which equals the thickness of the frame members. Battens intended to support a door-window frame when such a frame is in¬ cluded in the door structure are also prefixed, e.g. nailed, to adjacent frame members or nailing battens. The many cavities ormed between the frame members and battens of the frame construction are filled with pieces of insulating material, possibly in conjunction with gluing ύ cover sheet to one flat side of the frame construction. One drawback with the aforedescribed method of con¬ struction is that assemblage of the door frame can be both laborious and a complicated task, and necessitates the formation and manipulation of many separate in¬ sulating pieces of mutually different configuration. Nailing battens which have a thickness equal to the thickness of the frame members tend to be visible from the outside of the covering sheets, subsequent to having held together the frame structure and the cover sheets glued to the flat sides thereof in a press while the glue sets and hardens. This has the drawback of impairing the aesthetic appearance of the door, when only one side thereof is clad with an outer panel. Furthermore, such nailing battens are also capable of forming undesirable cold-bridges. The object of the present invention is to provide a novel door construction which is an improvement on known door constructions and which will eliminate the aforesaid drawbacks, at least to a significant extent. -It is proposed in accordance with the invention that to this end the nailing batten of a door of the kind described in the introduction has a thickness which, in a manner known per se, is smaller than the thick¬ ness of the frame members and the insulating pieces respectively; that said batten is accomodated bet- ween mutually opposing frame members in a channel or groove which is preformed in a separate sheet of insula¬ ting material on the side thereof which is intended to face the wood-panel cladding and which has a depth corre¬ sponding to the thickness ' of the nailing batten; that the separate insulating sheet has the same thickness as the frame members surrounding the door frame; and that said sheet and frame members are joined together indirectly by virtue of being glued to two covering sheets which cover mutually opposite flat sides of the insulating sheet and the frame members. A door of this construction can be manufactured quickly and rationally with good precision. It is comparatively well insulated and nailing battens incorporated in the structure do not imprint their presence on surfaces which are not covered with an outer panel. As beforementioned, the invention also relates to a novel and useful method for manufacturing a door which comprises a door frame having frame members which extend along the side, top and bottom edge surfaces of the door which is clad on at least one flat side there¬ of with an outer panel which is nailed firmly to the frame members and also to at least one nailing batten, and in which door the cavities defined between the door-frame members and the nailing batten are filled with insulating material and the insulating material and the frame-members surrounding said material are covered on each flat side with a covering sheet and glued together. The inventive method is characterized mainly by the steps of forming a free, separate sheet of insulating material which fits into and fills the space located within the door frame and the thickness of which sheet corresponds to the thickness of the door frame; providing the sheet with one or more grooves having a depth which is smaller than the thickness of said insulating sheet; forming nailing battens or strips which conform to the cross-sectional shape and the length of the groove; gluing the insulating sheet, the nailing batten located in said groove and the frame side-members to said covering sheets; and then nailing on the outer panel. This method enables the rational and economic manufcture of doors which are both aes¬ thetic in appearance and beneficial from the aspect of thermal insulation. Further characteristic features of the invention are set forth in the depending claims, while further advantages afforded by the invention will be apparent from the following description made with reference to the accompanying drawing. Figure 1 is a perspective, exploded view illustrating the construction of one exemplifying embodiment of an inventive door. Figure 2 is a perspective view of the insulating- sheet used in the door illustrated in Figure 1. Figure 3 is a perspective view of an insulating- sheet intended for use in an inventive door which is to be clad with vertically extending panel boards. The door illustrated in a perspective, exploded view in Figure 1 comprises a door frame built from individual frame members 1-4. The door frame embraces a sheet 5 of insulating material, for instance a rigid cellular plastics material, which is a single-piece structure and the configuration of which is best seen from Figure 2. The door frame has the same thickness as the insulating sheet 5. The reference numerals 6 and 7 identify top and bottom covering sheets, which e.g. are made of plywood or a hard wood-fibre sheet material and of which the top cover sheet is intended to be clad with an outer covering panel as indicated in broken lines at 8, the outer panel of the illustrated embodiment being formed from panelling boards. The panelling boards 8 are intended to be nailed to the door-frame structure with the aid of nails (not shown) which pass completely through the covering sheet 6 and into an appropriate one of the frame-members 1-4 and two nailing battens or strips 9,10. The nailing battens 9,10 have a thickness which is smaller than the thickness of the insulating sheet and are accommodated in corresponding grooves 5 11,12 (Figure 2) formed in the insulating sheet 5, for instance milled therein. The side edges of the insulating sheet have formed therein rectangular recesses 13 which are intended to 10 accommodate wooden lock mounting blocks 14 in which the door-opening and door-locking mechanism can be fitted at a later stage. The insulating sheet 5 also has formed therein an opening 15 which is fully surrounded by the insulating material and which is intended to 15 accommodate a window frame 16 comprising four separate, identical frame-members. The window frame 16 surrounds a window opening 17 in which window glass is fitted at a later stage. 20 When manufacturing the door illustrated in Figure 1, the covering sheet 7 is placed on a support surface and the upper surface of said sheet is coated with glue. The insulating sheet 5 and the individual, mutually separate frame-members 1-4 are then placed on the 25 covering sheet 7, the frame-members being supported by the edges of the sheet 5, therewith facilitating cor¬ rect positioning of the door components of the sheet 7. The wooden blocks 14 are then placed in the cavities embraced by the recesses 13 and the frame-members 1,2. ^ 30 One of said wooden blocks may optionally be replaced with a correspondingly shaped piece of insulating , material. The **frame-members forming the window frame 16 are then placed in the opening 15, and the nailing battens 9,10 are placed in the grooves 11,12, said battens conforming to the shape and longitudinal extension of said grooves. The other covering sheet 6, which has been coated with glue on the undersurface thereof, is then placed over the thus assembled struc- ture and the glue is allowed to set, preferably while applying pressure on the covering sheet 6, for instance in a press. Finally, the outer panel or panelling boards 8 is, or are, nailed to the door-frame structure with the use of nails which penetrate into the frame- members and the nailing battens. As indicated at 18, one or both of the covering sheets 6, 7 can be provided with an opening which corresponds essentially to the window opening 17. Figure 3 illustrates an alternative embodiment of an insulating sheet 5' which is also provided with reces¬ ses 13 for accommodating lock mounting blocks and which is intended for a door covered with vertical panelling boards. In this embodiment, the grooves 11',12' aσcom- modating the nailing battens extend transversely. When the insulating sheet 5' is intended for a door in which, for instance, vertical panelling boards are fitted on both sides thereof, grooves 11',12',12" for accommodating said nailing battens are provided in both flat sides of the insulating sheet 5', wherewith all grooves are spaced laterally from one another so as to enable one single, continuous sheet of insulating material to be used. The invention is not restricted to the aforedescribed embodiments but can be realized in any suitable manner that lies within the scope of the inventive concept defined in the following claims.

Claims: CLAIMS 1. A door comprising a door-frame having frame-members (1-4) which extend along the side surfaces and top and bottom edge surfaces of the door and which is clad with an outer panel (8) on at least one flat side thereof, said panel being nailed to the frame members and also to at least one nailing batten (9, 10), and in which door cavities defined between the door-frame members and the at least one nailing batten are filled with insulating material (5; 5') c h a r a c t e r i s e d in that the nailing batten (9, 10) has, in a manner known per se, a thickness which is smaller than the thickness 5 of the frame members (1-4) and the insulating pieces ( 5, 5') respectively; that said batten is accommodated between mutually opposing frame members in a channel or groove (11, 12; 11', 12', 12") which is preformed in a separate sheet (5, 5') of insulating material on the side ° thereof which is intended to face the panel cladding (8) and which has a depth corresponding to the thickness of the nailing batten; that the separate insulating sheet ( 5, 5 " ) has the same thickness as the frame members (1-4) surrounding the door frame; and that said sheet and frame 5 members are joined together indirectly by virtue of being glued to two covering sheets (6, 7) which cover mutually opposite flat sides of the insulating sheet and the frame members. 0 2. A door according to Claim 1, in which a window opening (17) provided in the door is surrounded by a window frame (16) which has the same thickness as the door frame (1-4) , characterized in that the window frame (16) is accommodated in an opening (15) formed in the separate insulating sheet, which opening is sur¬ rounded on all sides by the insulating material of said insulating sheet and the sides of which adjoin the outer sides of the window frame. 3. A door according to Claim 1 or 2, characterized in that the separate insulating sheet (5;5') is provided on at least one of its edges facing towards the side edges of the door with a recess (13) intended for accommodating a wooden lock-mounting block (14). 4. A door according to Claim 2 or 3, characterized in . that the window frame (16) or the separate frame- members forming said window frame and the lock-mounting block or blocks (14) are glued onto the covering sheets (6,7). 5. A door according to any one of Claims 1-4, which has an outer cladding panel (8) nailed to the door-frame members (1-4) and nailing battens on both of the flat sides of said door, characterized in that the grooves (11',12',12") in the separate insulating sheet (5') are spaced laterally from one another. 6. A method for manufacturing a door which comprises a door frame having frame members (1-4) which extend along the side, top and bottom edge surfaces of the door which is clad on at least one flat side thereof with an outer panel (8) which is nailed firmly to the frame members and also to at least one nailing batten (9, 10), and in which door the cavities defined between the door-frame members and the nailing batten are filled with insulating material (5; 5") and the insu¬ lating material and the frame-members surrounding said material are covered on each flat side with a covering sheet (6, 7) and glued together, c h a r a c¬ t e r i z e d by the steps of forming a free, separate sheet of insulating material (5; 5 ') which fits into and fills the space located within the door frame (1-4) and the thickness of which sheet corresponds to the thickness of the door frame; providing the sheet with one or more grooves (11, 12; 11', 12', 12") having a depth which is smaller than the thickness of said insulating sheet; forming nailing battens or strips (9, 10) which conform to the cross-sectional shape and the length of the groove; gluing the insulating sheet (5; . 5'), the nailing battens located in said grooves (11, 12; 11', 12', 12") and the frame side-members (1-4) to said covering sheets (6, 7); and then nailing on the outer panel (8) .

Inventors: NYGAARD JONNY, NYGAARD, JONNY
Applicants: NYGAARD JONNY, NYGAARD, JONNY
Application year: 1989
Main classification: E06B3
IPC codes: E06B3