AUTOMATED DOOR ASSEMBLY, PRESS, AND ADHESIVE THEREFOR

• US 20150027630A1
• Filed: 07/25/2014
• Published: 01/29/2015
• Est. Priority Date: 07/25/2013
• Status: Active Grant

• Current Assignee: Masonite Corporation
• Original Assignee: Masonite Corporation
• Inventors: CUCCHI, George, LIANG, Bei-Hong
• Granted Patent: US 9,511,573 B2
• Time in Patent Office: Days
• US Class Current: 156/306.6
• CPC Class Codes: B30B 15/062 Press plates
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 37/10 characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 37/1284 Application of adhesive
• CPC Class Codes: B32B 37/18 involving the assembly of discrete sheets or panels only
• CPC Class Codes: B32B 39/00 Layout of apparatus or plants, e.g. modular laminating systems
• CPC Class Codes: E06B 2003/7019 of corrugated type
• CPC Class Codes: E06B 2003/7025 of cork; of wood or similar fibres
• 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 156/1798 with liquid adhesive or adhesive activator applying means

Abstract

A system and method for 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 pressed having platens. Movable shims may be used to vary the pressed force and pressing area.

Claims

1. A door press for pressing door assemblies of different sizes, comprising:

a first die comprising a first fixed surface;

a plurality of first movable shims having first movable shim surfaces, the first movable shims being movably connected to the first die to move between at least a raised position in which the first movable shim surfaces are substantially flush with the first fixed surface and a lowered position in which the first movable shim surfaces are recessed into the first die relative to the first fixed surface; and

a second die comprising a second fixed surface facing the first fixed surface, at least one of the first and second dies being movable towards and away from the other for pressing a door assembly between the first and second dies.

2. The door press of claim 1, further comprising a first fixed shim defining the first fixed surface of the first die.

3. The door press of claim 1, wherein the first fixed shim is central to the first movable shims and non-movable relative to the first die.

4. The door press of claim 1, wherein the first fixed surface has opposite ends and opposite sides, and the plurality of first movable shims comprises:

a first length-extension shim situated at one of the ends of the first fixed surface, and

a first width-extension shim situated at one of the sides of the first fixed surface.

5. The door press of claim 4, wherein the first length-extension shim and the first width-extension shim are independently movable relative to one another between the raised and lowered positions.

6. The door press of claim 1, wherein the first fixed surface has opposite ends and opposite sides, and wherein the plurality of first movable shims comprises:

first and second length-extension shims respectively situated at the opposite ends of the first fixed surface, and

first and second width-extension shims respectively situated at the opposite sides of the first fixed surface.

7. The door press of claim 6, wherein the first length-extension shim, the second length-extension shim, the first width extension shim, and the second width-extension shim are independently movable relative to one another between the raised and lowered positions.

8. The door press of claim 6, wherein the plurality of first movable shims further comprises:

third and fourth width-extension shims respectively situated on opposite sides of the first and second width-extension shims relative to the first fixed surface.

9. The door press of claim 8, wherein the first length-extension shim, the second length-extension shim, the first width extension shim, the second width-extension shim, the third width-extension shim, and the fourth width-extension shim are independently movable relative to one another between the raised and lowered positions.

10. The door press of claim 1, further comprising a plurality of second movable shims having second movable shim surfaces, the second movable shims being movably connected to the second die to move between at least a raised position in which the second movable shim surfaces are substantially coplanar with the second fixed surface and a lowered position in which the second movable shim surfaces are recessed into the second die relative to the second fixed surface.

11. The door press of claim 10, further comprising a second fixed shim defining the second fixed surface of the second die.

12. The door press of claim 11, wherein the second fixed shim is central to the second movable shims and non-movable relative to the second die.

13. The door press of claim 1, further comprising a hydraulic system for moving the first movable shims between the lowered and raised positions.

14. The door press of claim 1, wherein the first and second fixed surfaces are convex.

15. A door-making system, comprising:

at least one adhesive 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 an assembled door;

a door press comprising

a first die comprising a first fixed surface;

a plurality of first movable shims having first movable shim surfaces, the first movable shims being movably connected to the first die to move between at least a raised position in which the first movable shim surfaces are substantially flush with the first fixed surface and a lowered position in which the first movable shim surfaces are recessed into the first die relative to the first fixed surface; and

a second die comprising a second fixed surface facing the first fixed surface, at least one of the first and second dies being movable towards and away from the other for pressing a door assembly between the first and second dies; and

at least one material handling device for transporting the assembled doors to and from the door press.

16. A method of pressing a door assembly, comprising:

providing a door press comprising

a first die comprising a first fixed surface;

a plurality of first movable shims having first movable shim surfaces, the first movable shims being movably connected to the first die to move between at least a raised position in which the first movable shim surfaces are substantially flush with the first fixed surface and a lowered position in which the first movable shim surfaces are recessed into the first die relative to the first fixed surface; and

a second die comprising a second fixed surface facing the first fixed surface, at least one of the first and second dies being movable towards and away from the other for pressing a door assembly between the first and second dies; and

selectively adjusting the first movable shims in the raised position or the lower position so that a combined area of the first fixed surface and the first movable shim surfaces of the first movable shims in the raised position corresponds to a surface area of a face of the door assembly; and

pressing the door assembly in the press.

17. The method of claim 16, wherein the first fixed surface and the first movable shim surfaces of the first movable shims in the raised position collective form a surface area with a perimeter that is about 4 inches inward of a perimeter of the face of the door assembly.

18. The method of claim 16, wherein the door press further comprises a first fixed shim defining the first fixed surface of the first die.

19. The method of claim 18, wherein the first fixed shim is central to the first movable shims and non-movable relative to the first die.

20. The method of claim 18, wherein the first fixed surface has opposite ends and opposite sides, and the plurality of first movable shims comprises:

a first length-extension shim situated at one of the ends of the first fixed surface, and

a first width-extension shim situated at one of the sides of the first fixed surface.