Automated door assembly and methods, press used therewith, and adhesive therefor
First Claim
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1. A method of making doors, comprising the steps of:
- providing a first pressing station comprisinga first press including a first set of platens, anda second press including a second set of platens, each set of platens having at least one platen movable relative to the other platen between an open state and a closed state;
providing a second pressing station comprisinga third press including a third set of platens, anda fourth press including a fourth set of platens, each set of platens respectively having at least one platen movable relative to the other platen of the set of platens between an open state and a closed state;
successively delivering assembled doors in a layup state to the first and second pressing stations;
discharging a pressed first assembled door from the first press of the first pressing station and loading a second assembled door in the layup state into the first press of the first pressing station while the first press is in operative alignment with first loading and discharging devices, and simultaneously pressing a third assembled door in the second press of the first pressing station;
moving the second press vertically into operative alignment with the first loading and discharging devices; and
discharging the pressed third assembled door from the second press and loading a fourth assembled door in the layup state into the second press while the second press is in operative alignment with the first loading and discharging devices, and simultaneously pressing the second assembled door in the first press;
discharging a pressed fifth assembled door from the third press of the second pressing station and loading a sixth assembled door in the layup state into the third press of the second pressing station while the third press is in operative alignment with second loading and discharging devices, and simultaneously pressing a seventh assembled door in the fourth press of the second pressing station;
moving the fourth press vertically into operative alignment with the second loading and discharging devices;
discharging the pressed seventh assembled door from the fourth press and loading an eighth assembled door in the layup state into the fourth press while the fourth press is in operative alignment with the second loading and discharging devices, and simultaneously pressing the sixth assembled door in the third press; and
transporting the assembled doors away from the first and the second discharging devices on a single conveyor.
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Abstract
A door pressing system for pressing interior passage doors, exterior entry doors, bi-fold doors, and/or closet doors features a multi-door pressing station including first and second presses, a loading device, and a discharging device. The pressing station is configured to alternatively move the first and second presses into operative alignment with the loading and discharging devices. The press in operative alignment delivers a pressed assembled door to the discharging device and receives an assembled door layup to be pressed from the loading device. The other press that is out of operatively alignment presses an assembled door received therein. Additional methods and systems are also provided.
64 Citations
17 Claims
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1. A method of making doors, comprising the steps of:
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providing a first pressing station comprising a first press including a first set of platens, and a second press including a second set of platens, each set of platens having at least one platen movable relative to the other platen between an open state and a closed state; providing a second pressing station comprising a third press including a third set of platens, and a fourth press including a fourth set of platens, each set of platens respectively having at least one platen movable relative to the other platen of the set of platens between an open state and a closed state; successively delivering assembled doors in a layup state to the first and second pressing stations; discharging a pressed first assembled door from the first press of the first pressing station and loading a second assembled door in the layup state into the first press of the first pressing station while the first press is in operative alignment with first loading and discharging devices, and simultaneously pressing a third assembled door in the second press of the first pressing station; moving the second press vertically into operative alignment with the first loading and discharging devices; and discharging the pressed third assembled door from the second press and loading a fourth assembled door in the layup state into the second press while the second press is in operative alignment with the first loading and discharging devices, and simultaneously pressing the second assembled door in the first press; discharging a pressed fifth assembled door from the third press of the second pressing station and loading a sixth assembled door in the layup state into the third press of the second pressing station while the third press is in operative alignment with second loading and discharging devices, and simultaneously pressing a seventh assembled door in the fourth press of the second pressing station; moving the fourth press vertically into operative alignment with the second loading and discharging devices; discharging the pressed seventh assembled door from the fourth press and loading an eighth assembled door in the layup state into the fourth press while the fourth press is in operative alignment with the second loading and discharging devices, and simultaneously pressing the sixth assembled door in the third press; and transporting the assembled doors away from the first and the second discharging devices on a single conveyor. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of making doors, comprising the steps of:
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providing a first pressing station comprising a first press including a first set of platens, and a second press including a second set of platens, each set of platens having at least one platen movable relative to the other platen between an open state and a closed state; providing a second pressing station comprising a third press including a third set of platens, and a fourth press including a fourth set of platens, each set of platens respectively having at least one platen movable relative to the other platen of the set of platens between an open state and a closed state; successively delivering assembled doors in a layup state to the first and second pressing stations; discharging a pressed first assembled door from the first press of the first pressing station and loading a second assembled door in the layup state into the first press of the first pressing station while the first press is in operative alignment with first loading and discharging devices, and simultaneously pressing a third assembled door in the second press of the first pressing station; moving the second press vertically into operative alignment with the first loading and discharging devices; and discharging the pressed third assembled door from the second press and loading a fourth assembled door in the layup state into the second press while the second press is in operative alignment with the first loading and discharging devices, and simultaneously pressing the second assembled door in the first press; discharging a pressed fifth assembled door from the third press of the second pressing station and loading a sixth assembled door in the layup state into the third press of the second pressing station while the third press is in operative alignment with second loading and discharging devices, and simultaneously pressing a seventh assembled door in the fourth press of the second pressing station; moving the fourth press vertically into operative alignment with the second loading and discharging devices; discharging the pressed seventh assembled door from the fourth press and loading an eighth assembled door in the layup state into the fourth press while the fourth press is in operative alignment with the second loading and discharging devices, and simultaneously pressing the sixth assembled door in the third press; holding the assembled doors that have been pressed in the first pressing station in a first accumulator downstream of the first pressing station while applied adhesive develops bond strength; holding the assembled doors that have been pressed in the second pressing station in a second accumulator downstream of the second pressing station while applied adhesive develops bond strength; and transporting the assembled doors away from the first and second accumulators by a single conveyor, wherein the first discharging device comprises a first conveyor for transporting the assembled doors from the first pressing station to the first accumulator, and wherein the second discharging device comprises a second conveyor for transporting the assembled doors from the second pressing station to the second accumulator. - View Dependent Claims (12, 13, 14, 15, 16, 17)
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Specification
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Current AssigneeMasonite Corporation
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Original AssigneeMasonite Corporation
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InventorsCucchi, George, Liang, Bei-Hong, MacDonald, Michael
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Primary Examiner(s)Goff, II, John L
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Application NumberUS15/445,040Publication NumberTime in Patent Office749 DaysField of SearchUS Class CurrentCPC Class CodesB27D 3/02 with a plurality of press p...B27D 5/003 securing a veneer strip to ...B27M 3/18 of furniture or of doors B2...B30B 7/023 Feeding or discharging meansB32B 37/18 involving the assembly of d...E06B 3/7017 of grating typeE06B 3/72 consisting of frame and pan...E06B 3/822 with an internal foursided ...
