Automated door assembly system and method

  • US 8,991,462 B2
  • Filed: 02/28/2012
  • Issued: 03/31/2015
  • Est. Priority Date: 09/16/2003
  • Status: Active Grant
First Claim
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1. A door making system, comprising:

  • a first station configured to receive a first plurality of stacked door facings having respective first exterior surfaces disposed face up and respective first interior surfaces disposed face down and stacked on corresponding first exterior surfaces of adjacent door facings of the first plurality of stacked door facings;

    a second station configured to receive a second plurality of stacked door facings having respective second exterior surfaces disposed face up and respective second interior surfaces disposed face down and stacked on corresponding second exterior surfaces of adjacent door facings of the second plurality of stacked door facings;

    a door facing inverter configured to receive a first door facing unstacked from the first plurality of stacked door facings and conveyed from the first station with the first exterior surface disposed face up and the first interior surface disposed face down, and to flip the first door facing to dispose the first exterior surface face down and the first interior surface face up;

    a third station configured to receive the flipped first door facing and to coat adhesive on at least a portion of the face-up first interior surface of the first door facing;

    a fourth station configured to position stiles and rails of a doorframe onto the adhesive-coated face-up first interior surface;

    a fifth station configured to receive the first door facing with the doorframe thereon and to position a core component in contact with the adhesive-coated face-up first interior surface so that the doorframe is located around the core component;

    a sixth station configured to receive the first door facing with the doorframe and the core component thereon and to coat adhesive on at least a portion of upwardly facing surfaces of the doorframe and the core component;

    a transfer mechanism configured to receive a second door facing unstacked from the second plurality of stacked door facings and conveyed from the second station with the second exterior surface disposed face up and the second interior surface disposed face down, and to position the face-down second interior surface into contact with the adhesive-coated upwardly facing surfaces of the doorframe and the core component to form a door assembly; and

    a compression station configured to compress the door assembly.

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