AUTOMATED DOOR ASSEMBLY, PRESS, AND ADHESIVE THEREFOR

• US 20120027999A1
• Filed: 07/28/2011
• Published: 02/02/2012
• Est. Priority Date: 07/28/2010
• Status: Active Grant

• Current Assignee: Bei-Hong Liang, Bruce Fedio, Geoffrey Hardwick, George Cucchi, Michael MacDonald, Robert Ritchie
• Original Assignee: Bei-Hong Liang, Bruce Fedio, Geoffrey Hardwick, George Cucchi, Michael MacDonald, Robert Ritchie
• Inventors: Liang, Bei-Hong, MacDonald, Michael, Hardwick, Geoffrey, Ritchie, Robert, Cucchi, George, Fedio, Bruce
• Granted Patent: US 9,346,185 B2
• Time in Patent Office: Days
• US Class Current: 428/172
• CPC Class Codes: B27M 1/08 by multi-step processes
• CPC Class Codes: B27M 3/18 of furniture or of doors B27D5/003 takes precedence
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29D 99/00 Subject matter not provided for in other groups of this subclass
• CPC Class Codes: B30B 7/023 Feeding or discharging means
• CPC Class Codes: E06B 3/70 Door leaves wing frames E06B3/04
• 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 3/822 with an internal foursided frame
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1751 At least three articles
• CPC Class Codes: Y10T 428/24612 Composite web or sheet

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.

Claims

1. A door-making system, comprising:

at least one coating station for applying adhesive to at least one of a door frame having opposite first and second surfaces, a first door skin, and a second door skin;

at least one assembly station for joining the first and second door skins to the opposite first and second surfaces of the door frame, respectively, to form assembled doors;

a pressing station for pressing the assembled door, the pressing station comprising a first press and a second presses for alternately receiving assembled doors; and

at least one material handling device for transporting the assembled doors between the stations.

2. The door-making system of claim 1, wherein the at least one coating station comprises a first coating station for applying adhesive to the frame, a second coating station for applying adhesive to the first door skin, and a third adhesive station for applying adhesive to the second door skin.

3. The door-making system of claim 2, wherein the first and second door skins comprise at least one panel and the second and third coating stations apply a bead of adhesive to the panels of the first and second door skins respectively.

4. The door-making system of claim 1, wherein the door-making system is a synchronous system having a rate of movement and the pressing station performs a pressing operation on the assembled doors for a period of time that is twice the rate of movement.

5. The door-making system of claim 1, wherein the at least one assembly station comprises a first assembly station for joining the first door skin to the first surface of the door frame and a second assembly station for joining the second door skin to the second surface of the door frame.

6. The door-making system of claim 1, wherein the first and second presses each comprises an upper die having an upper convex surface and a lower die having a lower convex surface.

7. The door-making system of claim 6, wherein the upper and lower convex surfaces are integrally formed with the upper and lower dies, respectively.

8. The door-making system of claim 6, wherein the upper and lower convex surfaces are removably connected to the upper and lower dies, respectively.

9. The door-making system of claim 6, wherein the upper and lower convex surfaces are constructed and arranged for imparting a concave shape to at least central regions of the first and second door skins of the door assembly during pressing.

10. The door-making system of claim 1, wherein the first and second presses each comprises an upper die having an upper membrane attached thereto and a lower die having a lower membrane attached thereto, the upper and lower membranes for over compressing the central area of the first and second door skins.

11. A door pressing station, comprising:

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

12. The door pressing station of claim 11, wherein the upper and lower convex surfaces are constructed and arranged for imparting a concave shape to at least central regions of first and second door skins of the door assembly during pressing.

13. The door pressing station of claim 11, wherein the upper and lower convex surfaces are integrally formed with the upper and lower dies, respectively.

14. The door pressing station of claim 11, wherein the upper and lower convex surfaces are removably connected to the upper and lower dies, respectively.

15. A door made with the door pressing station of claim 11.

16. A method of making a door, comprising:

adhesively bonding first and second door skins to opposite first and second surfaces of door frames to assemble doors as part of a door production process; and

alternately receiving the assembled doors into at least first and second presses of a pressing station and pressing the assembled doors.

17. The method of claim 16, wherein the inline assembling comprises:

applying adhesive to at least one of the first door skin, the second door skin, and the door frame having opposite first and second surfaces;

joining the first and second door skins to the opposite first and second surfaces, respectively, to form the assembled doors.

18. The method of claim 16, wherein the door production process is a synchronous process having a rate of movement and pressing the assembled doors comprises a pressing operation for a period of time that is twice the rate of movement.

19. The method of claim 16, wherein the first and second presses each comprises a respective upper die having an upper convex surface and a respective lower die having a lower convex surface, the upper and lower convex surfaces facing one another to define a reduced-caliper portion of a mold cavity in which the door assemblies are received.

20. A door made with the method of claim 16.

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

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

pressing the assembled door between the upper and lower dies.

22. The method of claim 21, wherein said pressing comprises imparting a concave shape to at least central regions of first and second door skins of the door assembly.

23. A door made with the method of claim 21.