AUTOMATED DOOR ASSEMBLY AND METHODS, PRESS USED THEREWITH, AND ADHESIVE THEREFOR

• US 20140261991A1
• Filed: 03/17/2014
• Published: 09/18/2014
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Masonite Corporation
• Original Assignee: Masonite Corporation
• Inventors: CUCCHI, George, LIANG, Bei-Hong, MACDONALD, Michael
• Granted Patent: US 9,579,818 B2
• Time in Patent Office: Days
• US Class Current: 156/228
• CPC Class Codes: B27D 3/02 with a plurality of press plates, i.e. multi- platen hot presses
• CPC Class Codes: B27D 5/003 securing a veneer strip to a panel edge fitting a tenonned strip to a grooved panel edge B27M3/0026
• CPC Class Codes: B27M 3/18 of furniture or of doors B27D5/003 takes precedence
• CPC Class Codes: B30B 7/023 Feeding or discharging means
• CPC Class Codes: B32B 37/18 involving the assembly of discrete sheets or panels only
• CPC Class Codes: E06B 3/7017 of grating type
• CPC Class Codes: E06B 3/72 consisting of frame and panels , e.g. of raised panel type E06B3/7001 - E06B3/7015 and E06B3/82 take precedence
• CPC Class Codes: E06B 3/822 with an internal foursided frame

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.

Claims

1. A system for making interior passage doors, exterior entry doors, bi-fold doors, and/or closet doors, comprising:

a multi-door 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 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;

a loading material handling and movement device configured to deliver assembled doors in a layup state to the multi-door pressing station; and

a discharging material handling and movement device configured to receive the assembled doors that have been pressed by the multi-door pressing station,

the multi-door pressing station configured to alternatingly move the first and second presses between (i) a loading/unloading position, in which one of the first and second presses is in the open state and operative alignment with the loading and discharging material handling and movement devices to receive at least a first of the assembled doors in the layup state delivered by the loading material handling and movement device and to discharge at least a second of the assembled doors that has been pressed to the discharging material handling and movement device, and (ii) a pressing position, in which the other of the first and second presses is in the closed state for pressing a third of the assembled doors and is out of operative alignment with the loading and discharging material handling and movement devices.

2. The system of claim 1, wherein the first and second presses are movable vertically between the loading/unloading position and the pressing position.

3. The system of claim 1, further comprising hydraulics for moving the first and second presses vertically between the loading/unloading position and the pressing position.

4. The system of claim 1, wherein the loading material handling and movement device is configured to successively delivery the assembled doors in the layup state to the multi-door pressing station, and wherein the multi-door pressing station is configured to alternatively move the first and second presses after each individual assembled door in the layup state is delivered by the loading material handling and movement device.

5. The system of claim 1, wherein the loading material handling and movement device and the discharging material handling and movement device comprise a conveyor.

6. The system of claim 1, further comprising a non-linear accumulator downstream of the multi-door pressing station, the non-linear accumulator being configured to hold the doors while the applied adhesive develops bond strength.

7. The system of claim 6, wherein the non-linear accumulator comprises a star conveyor.

8. The system of claim 1, further comprising:

a frame assembly station configured to apply adhesive to door frame components and to frame the door frame components and applied adhesive into door frames; and

a door assembly station configured to secure first and second door skins on opposites surfaces of the door frames to provide assembled doors.

9. The system of claim 8, wherein the first and second presses are movable vertically between the loading/unloading position and the pressing position.

10. The system of claim 8, further comprising hydraulics for moving the first and second presses vertically between the loading/unloading position and the pressing position.

11. The system of claim 8, wherein the loading material handling and movement device is configured to successively delivery the assembled doors in the layup state to the multi-door pressing station, and wherein the multi-door pressing station is configured to alternatively move the first and second presses after each individual assembled door in the layup state is delivered by the loading material handling and movement device.

12. The system of claim 8, wherein the loading material handling and movement device and the discharging material handling and movement device comprise a conveyor.

13. The system of claim 8, further comprising a non-linear accumulator downstream of the multi-door pressing station, the non-linear accumulator being configured to hold the assembled doors that have been pressed while the applied adhesive develops bond strength.

14. The system of claim 13, wherein the non-linear accumulator comprises a star conveyor.

15. A method of making doors, comprising:

successively delivering assembled doors in a layup state to a vertically movable multi-door pressing station comprising cooperating first and second presses;

discharging a pressed first assembled door from the first press of the multi-door pressing station and loading a second assembled door in the layup state into the first press of the multi-door pressing station while the first press is in operative alignment with loading and discharging material handling and movement devices, and simultaneously pressing a third assembled door in the second press of the multi-door pressing station;

moving the second press vertically into operative alignment with the loading and discharging material handling and movement 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 loading and discharging material handling and movement devices, and simultaneously pressing the second assembled door in the first press.

16. The method of claim 15, further comprising:

applying adhesive to door frame components and framing the door frame components and applied adhesive into door frames;

securing first and second door skins on opposites surfaces of the door frames to provide the assembled doors in the layup state.

17. A system is provided for making door frames for interior passage doors, exterior entry doors, closet doors, and/or bi-fold door, comprising:

a core attachment station for connecting an expandable core to a top rail and a bottom rail;

a robotic system comprising first and second grippers configured to grip the top rail and the bottom rail, respectively, and to draw the top and bottom rails apart from one another so as to expand the connected expandable core; and

a framing station configured to connect first and second stiles to the top and bottom rails and thereby form a door frame.

18. The system of claim 17, wherein the robotic system is configured to connect the first and second stiles to the top and bottom rails to form the door frame.

19. The system of claim 17, wherein the door frame has four corners, and wherein the framing station comprises a jig system configured to support and hold the door frame at the four corners.

20. The system of claim 19, wherein the jig system comprises clamps each comprising at least one respective nozzle for applying adhesive to associated edges of the stiles and rails where the stiles and rails abut one another.

21. The system of claim 17, wherein the framing station is configured to apply mechanical fasteners to connect the first and second stiles to the top and bottom rails.