AUTOMATED DOOR ASSEMBLY, PRESS, AND ADHESIVE THEREFOR

• US 20130340926A1
• Filed: 08/01/2013
• Published: 12/26/2013
• Est. Priority Date: 07/28/2010
• Status: Active Grant

• Current Assignee: Masonite Corporation (Owens Corning)
• Original Assignee: Masonite Corporation (Owens Corning)
• Inventors: LIANG, Bei-Hong, CUCCHI, George
• Granted Patent: US 9,314,983 B2
• Time in Patent Office: Days
• US Class Current: 156/196
• CPC Class Codes: B27D 3/00 Veneer presses; Press plates; Plywood presses presses in general B30B ; presses for wood fibre sheets B27N3/08, B27N3/24, B27N3/26
• CPC Class Codes: B29D 99/00 Subject matter not provided for in other groups of this subclass
• CPC Class Codes: B30B 5/02 wherein the pressing means is in the form of a flexible element, e.g. diaphragm, urged by fluid pressure
• CPC Class Codes: B30B 5/04 wherein the pressing means is in the form of an endless band
• CPC Class Codes: B30B 7/023 Feeding or discharging means
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2479/00 Furniture
• CPC Class Codes: B32B 5/06 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 7/14 applied in spaced arrangements, e.g. in stripes
• CPC Class Codes: E06B 2003/704 of mineral material which is not further specified
• CPC Class Codes: E06B 3/7001 Coverings therefor; Door leaves imitating traditional raised panel doors, e.g. engraved or embossed surfaces, with trim strips applied to the surfaces
• CPC Class Codes: E06B 3/7015 characterised by the filling between two external panels fireproof doors E06B5/16; noise insulating doors E06B5/20
• CPC Class Codes: E06B 3/822 with an internal foursided frame
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina

Abstract

Provided is a system and method of making a door having first and second door skins and an internal frame. The top and bottom surfaces of the frame are coated with an adhesive and the frame is placed on a first door skin. The second door skin is then placed on the opposite surface of the frame. The assembled components are then pressed to bond the first and second door skins to the frame with a press having upper and lower dies configured to impart a larger compression force toward a central area of the door skins. Wear resistant belts or membranes are provided to protect the door skins from being marred by the upper and lower dies during the pressing process.

Claims

1. A door pressing station, comprising:

at least one press comprising an upper die having an upper surface and a lower die having a lower surface, the upper and lower surfaces facing one another to define a mold cavity in which a door assembly is received for a pressing process,

a first wear resistant membrane disposed along said upper surface, and

a second wear resistant membrane disposed along said lower surface,

wherein said first and second wear resistant membranes prevent hardened steel forming the upper and lower dies from marring doors that are acted upon by the upper and lower dies during said pressing process.

2. The door pressing station of claim 1, wherein the first and second wear resistant membranes are constructed and arranged for imparting a concave shape to at least a central region of first and second door skins of the door assembly during said pressing process.

3. The door pressing station of claim 1, wherein the first and second wear resistant membranes are first and second wear resistant membranes are formed of the same material.

4. The door pressing station of claim 1, wherein the first and second wear resistant membranes are formed as a continuous belt with a central core having a higher durometer than an outer layer.

5. The door pressing station of claim 1, wherein the wear resistant membranes are removable fixed to the upper and lower dies.

6. The door pressing station of claim 1, wherein the wear resistant membranes are disposed to move relative to the upper and lower dies along a direction of travel of said doors.

8. The door pressing station of claim 1, wherein the wear resistant membrane is constructed and arranged for imparting a concave shape to at least a central region of a door skin of the door assembly during said pressing process.

7. A door pressing station, comprising:

at least one press comprising an upper die having an upper surface,

a wear resistant membrane disposed along said upper surface,

wherein said wear resistant membrane prevents hardened steel forming the upper die from marring doors that are acted upon by the upper die during a pressing process.

9. A method of pressing an assembled door, comprising:

providing a press comprising an upper die having an upper surface and a lower die having a lower surface, the upper and lower surfaces facing one another to define a mold cavity in which a door assembly is received for a pressing process;

providing wear resistant membranes along said upper and lower surfaces to prevent hardened steel forming the upper and lower dies from marring doors that are acted upon by the upper and lower dies during said pressing process;

loading an assembled door in said press; and

pressing the assembled door between the upper and lower dies.

10. The method of claim 21, further comprising the step of imparting a concave shape to at least a central region of first and second door skins of the door assembly.