CORE AND METHOD FOR AUTOMATED HOLLOW DOOR AND PANEL ASSEMBLY

Abstract

This invention relates to a core for hollow door manufacture comprising a method whereby the mechanical arrangement of the core glue applicators produces multi sized closed cell filler material once severed and expanded wherein a combination of both contracting and expanding cells presents as a centrally aligned column of contracting cells while other cells expand utilizing adhesively affixed non rigid flexible single face corrugated material.

Claims

1. A method for making a core component for a door or panel comprising the steps of adhesively affixing non rigid flexible single face corrugated sheets into stacks wherein the adhesive layout on a said sheet is dimensionally unevenly intersected by its a corresponding sheet thus forming, on severing a strip off stack and expansion of said strip, a central column of horizontally contracting narrow oblong cells while at the same time presenting other horizontally and vertically expanding cells whereby disposing an expanded core within a known art door frame and components having stile and rail members and adhesively secure a first and second door skin of flat or molded panels to opposite sides of the frame and thereby enclosing the core.

2. The method of claim 1 wherein the disposing step comprises adhesively affixing sheets with unevenly intersected adhesion points by stacking a plurality of flexible single face sheets to form the said stack, severing a strip or core wherein the arrangement of two specific adhesion points typically 230 mm apart but not limited to that distance on a sheet is unevenly intersected by two non corresponding adhesion points of typically 250 mm but not limited to that size on the following sheet, method and alternate stacking multiples of said sheets ideally but not limited to twenty two flexible single face corrugated sheets.

3. The method of claim 2 wherein the said first sheet material is also unevenly intersected by a third size of 280 mm spaced glue application on second sheet as shown.

4. A core made by a method comprising the steps of adhesively affixing non rigid flexible single face corrugated sheets into stacks wherein the adhesive layout on a said sheet is dimensionally unevenly intersected by its a corresponding sheet thus forming, on severing a strip off stack and expansion of said strip, a central column of horizontally contracting narrow oblong cells while at the same time presenting other horizontally and vertically expanding cells whereby disposing an expanded core within a known art door frame and components having stile and rail members and adhesively secure a first and second door skin of flat or molded panels to opposite sides of the frame and thereby enclosing the core. wherein the disposing step comprises adhesively affixing sheets with unevenly intersected adhesion points by stacking a plurality of flexible single face sheets to form the said stack, severing a strip or core wherein the arrangement of two specific adhesion points typically 230 mm apart but not limited to that distance on a sheet is unevenly intersected by two non corresponding adhesion points of typically 250 mm but not limited to that size on the following sheet, method and alternate stacking multiples of said sheets ideally but not limited to twenty two flexible single face corrugated sheets, wherein the said first sheet material is also unevenly intersected by a third size of 280 mm spaced glue application on second sheet as shown, the core comprised of adhesively stacked non rigid flexible single face corrugated sheet material wherein the disposing step comprises the spatial arrangement of two sets of adhesive points as shown.

5. The method of claim 1 comprising the step of adhesively securing said expanded core to door rail members and coating edge of said core to bond to said door skins.

6. The core made by the method of claim 1 wherein the said central column of longitudinal cells are oblong in shape contract on expansion of said core into said door frame as a direct result of the said non rigid flexible single face corrugated sheet material and method in claim 2.

7. The core made by the method of claim 1, wherein the cells on expansion of the said core present open cells of multiple shapes both contracting and expanding on expansion of the core disposed of by the nature of the said flexible material introduced to the spatial layout of two sets of glue adhesion point applicators in claim 2 as shown.

8. A core made by a method comprising the steps of adhesively affixing non rigid flexible single face corrugated sheets into stacks wherein the adhesive layout on a said sheet is dimensionally unevenly intersected by its a corresponding sheet thus forming, on severing a strip off stack and expansion of said strip, a central column of horizontally contracting narrow oblong cells while at the same time presenting other horizontally and vertically expanding cells whereby disposing and exanded core within a known art door frame and components having stile and rail members and adhesively secure a first and second door skin of flat or molded panels to opposite sides of the frame and thereby enclosing the core, wherein the method of stacking multiple sets of said sheet material B and C as shown whereby said base sheet A as shown is laid down adhesive free corrugated face up and thereafter sets of sheets B and C alternately stacked adhesively affixed Sheet B as corrugated face down followed by said sheet C adhesively fixed stacked corrugated face down as shown herein thereby sealing the stack with adhesively affixed said sheet B.

9. A core made by a method comprising the steps of adhesively affixing non rigid flexible single face corrugated sheets into stacks wherein the adhesive layout on a said sheet is dimensionally unevenly intersected by its a corresponding sheet thus forming, on severing a strip off stack and expansion of said strip a central column of horizontally contracting narrow oblong cells while at the same time presenting other horizontally and vertically expanding cells whereby disposing an expanded core within a known art door frame and components having stile and rail members adhesively secure a first and second door skin of flat or molded panels to opposite sides of the frame and thereby enclosing the core, wherein the method of stacking multiple sets of said sheet material B and C as shown whereby material B adhesion and corrugation face up as shown is laid down followed by material C adhesion face up corrugation face down as shown whereafter said base sheet A as shown is laid down adhesive free corrugated face down thereby sealing the stack.

10. A door comprising inner and outer skin said skins having panels formed wherein each outlined by raised moldings on the interior surface of the skin, a peripheral frame and lock block secured said skins and a core component made by a method comprising the steps of adhesively affixing non rigid flexible single face corrugated sheets into stacks wherein the adhesive layout on a said sheet is dimensionally unevely intersected by its a corresponding sheet thus forming, on severing a strip off stack and expansion of said strip, a central column of horizontally contracting narrow oblong cells while at the same time presenting other horizontally and vertically expanding cells whereby disposing an expanded core within a known art door frame and components having stile and rail members and adhesively secure a first and second door skin of flat or molded panels to opposite sides of the frame and thereby enclosing the core, and method as shown to separate the said door skins in a spatial arrangement.

11. A door comprising inner and outer skins said skins having flat interior surfaces, a peripheral frame and lock block secured said skins and a core component made a method comprising the steps of adhesively affixing non rigid flexible single face corrugated sheets into stacks wherein the adhesive layout on a said sheet is dimensionally unevenly intersected by its a corresponding sheet thus forming, on severing a strip off stack and expansion of said strip, a central column of horizontally contracting narrow oblong cells while at the same time presenting other horizontally and vertically expanding cells whereby disposing an expanded core within a known art door frame and components having stile and rail members and adhesively secure a first and second door skin of flat or molded panels to opposite sides of the frame and thereby enclosing the core, and method as shown to separate the said door skins in a spatial arrangement.

12. A core made by a method comprising the steps of adhesively affixing non rigid flexible single face corrugated sheets into stacks wherein the adhesive layout on a said sheet is dimensionally unevenly intersected by its a corresponding sheet thus forming, on severing a strip off stack and expansion of said strip, a central column of horizontally contracting narrow oblong cells while at the same time presenting other horizontally and vertically expanding cells whereby disposing an expanded core within a known art door frame and components having stile and rail members and adhesively secure a first and second door skin of flat or molded panels to opposite sides of the frame and thereby enclosing the core, the core once severed from stack as herein once expanded is ready to use as a filler material whereby no further tolerance sanding of the severed surface is required.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0053] It is understood that the embodiments shown in the drawings are for the purpose of illustrating the preferred present embodiments and not limited to the precise arrangements shown in the drawings.

[0054] FIG. 1 is an internal perspective view of an example of a hollow core panel door “A” using this invention and with a portion of the molded panel skin removed for illustration of core 7.

[0055] FIG. 2 is an internal perspective view of a hollow core exterior flat skin door “B” using this invention and with a portion of the doorskin removed for illustration of core 7.

[0056] FIG. 3 is an end view of the adhesively assembled stack 23 from which core 7 in its unexpanded form illustrating the use of non rigid single face corrugated material comprising the body of the filler material.

[0057] FIG. 4 is an expanded view of the adhesively assembled core 7 constructed in flexible single face corrugated material of ideally twenty two sheets comprising ideally ten vertically arranged narrow cells 15 where the open cells on either end 19 of each last narrow oblong is attached to the rails 24 thereby facilitating on expansion the vertical arrangement of ten elongated narrow centrally aligned cells 14.

[0058] FIG. 5 is a view of core 7 material formed by surface adhesion of the single face corrugated material A, B and C and a plurality of specifically arranged adhesive lines 20 and 21 on each B and C surface within this invention laminated material C to seal the stack.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0059] Herein the preferred embodiment described is not intended to be exhaustive or to limit the application to the precise form disclosed herein. It is chosen to graphically demonstrate the method and material assembly principles of this invention and its application and practical use to illustrate the exemplary embodiments of the invention.

EXAMPLES

[0060] Hollow core door panel door “A” and flat skin door “B” is illustrated in FIG. 1-2 respectively includes an inner doorskin 1 and outer doorskin 2 joined by a peripheral frame 3 having two spaced parallel side stiles 4, upper rail 5 and a lower rail 6. Core 7 is placed in Door B and core 7 is placed respectively between the doorskins 1 and 2 within the peripheral door frame 3. Door “A” and “B” also includes a lock block 8 placed adjacent to the frame vertical side stiles 4 and into which the lock set is fitted.

[0061] FIG. 1 panel door “A” illustrates formed into each doorskin 1 and 2 is a series of molded raised or indented panels 9 each outlined by a raised or indented molding 10 formed in the surface of the doorskin. Door A is shown with a series of panels 11.

[0062] FIG. 1 Core 7 is vertically expanded and either loose laid or affixed to rails 5 and 6 as shown FIG. 4 as with respect to the Door “A” and overlies panels 11 and raised or indented moldings 9 of inner door skin 1.

[0063] Filler 7 is vertically expanded with respect to door “A” and overlies flush with frames in relation to panels 9 and moldings 10 of inner door skin 1. Core 7 at optimum expansion forms a vertically and centrally arranged series of ideally ten elongated narrow centrally aligned cells 15 but not limited to that number of narrow oblong shapes 15 located overlying middle length of the doorskin 1.

[0064] FIG. 2 illustrates flat skin door construction Door “B” where core 7 is vertically expanded and affixed 19 to rails 5 and 6 as shown in FIG. 4 with respect to door size B and overlies flat doorskin of inner door skin 1.

[0065] FIGS. 1 and 2 in Both Door A and B:

[0066] Filler 7 is of elongated narrow centrally aligned cell 14 showing oblong 15 and triangle 16 within central elongated narrow centrally aligned cell 14 and comprising adhesive arrangement 20 and 21 on material B and C as illustrated in FIG. 5 in application Doors “A” and “B” and FIG. 3-4 in its unexpanded form and expanded form respectively.

[0067] It is the use of a number of ideally twenty two ply of flexible void material but not limited to that number of single face corrugated material 18 in Stack FIG. 3 and ideally ten but not limited to that number central elongated narrow centrally aligned cell 14 cell size 15 and 16 of core 7 formed by the relationship between the positioning of the seven glue points 20 and four glue points 21 illustrated in FIG. 5 that permits the positioning of the elongated narrow more compact cells as illustrated 14 as a narrow oblong 15 and as a triangular shape 16 on either side of 15 to be placed along the vertical length of the inner doorskin 1 and sandwiched between doorskin 2 to cause a substantially improved support portion of the central axis of the Door “A” and “B” to be supported.

[0068] Filler 7 is made of ideally twenty two flexible single faced corrugated paper sheets 18 FIG. 3 showing stacked and adhesively affixed sheets 20 and 21 in the specific format illustrated in FIG. 5 where the centre clusters of open end cells present when expanded elongate as distinct narrow oblong 15 with triangle shape 16 on each side of the oblong 15 along the central length of the filler material. This method and schematic layout of laminating and stacking of material results in the expanded core in FIG. 4.

[0069] FIG. 5. Filler 7 is laminated FIG. 5 in a method and sequence of unlaminated sheet A stacked corrugated face up followed by Sheet B laminated as shown 20 and stacked face down followed by multiple stacking of preferably single face corrugated sheets 20 and 21 and stack closed by one corrugated face down laminated sheet 20 to seal the stack. The stack FIG. 3 is pressed, cured and cut cross section to form individual ready to use strips 13 from the stack. (One shown)

[0070] Filler 7 laid up in door “A” and “B” pressed and trimmed within known art.

[0071] FIG. 3 illustrates unexpanded view of individual strip 13 the method assembly of the stack 23 from which strip 13 is transversely severed whereby Materials B and C are presented for adhesion 20 and 21 on each alternate surface stacked adhesively FIG. 5 in a continuous cycle to required size. (0047) FIG. 5 where sheets Material B is presented for adhesion 20 stacked corrugated face down and Material C presented for adhesion 21 corrugated face up are laid down adhesively stacked in a continuous cycle of Materials B and C until the required customer specification is met, ideally but not limited to twenty two ply.

[0072] Stack is sealed with Material B presented for surface adhesion 20 corrugated face down to seal the said stack, pressed and from which strip 13 is severed and presented expanded as a void filler.

[0073] Core 7 method herein presented when expanded FIG. 4 whereby ideally ten but not limited to elongated narrow centrally aligned cells 14 consist of narrow oblongs 15 and triangle 16 shapes on either side of oblong 15 are presented.

[0074] FIG. 4 is an expanded view of core 7 showing method of fixing 19 to upper and lower rails 5 and 6 of the ideally assembled but not limited to core constructed in flexible material ideally but not limited to 1160 mm wide twenty two ply material with ten vertically arranged narrow cells 15 where the open cells on either end of each last narrow oblong is attached to the rails as shown 19 thereby displaying the vertical arrangement of ideally but not limited to ten elongated narrow centrally aligned cells longitudinally positioned along the length of the core illustrating the contraction of the centrally aligned elongated narrow cells 14 to narrow oblong shapes 15 with a triangle shape 16 on either side within the column when expanded.

[0075] Illustrating assembly method of stack FIG. 3 adhesive fixing process and method in FIG. 5 and assembly FIG. 3.

[0076] FIG. 5 illustrates Material A stacked adhesive free corrugated face up and thereafter Material B surface laminated 20 and stacked corrugated face down thereafter Material C stacked adhesive 21 stacked corrugated face up and the positioning of the adhesive layout 20 and 21 on alternate surfaces of Materials B and C stacked continuously as Material B illustrate positioning of seven glue 20 adhesion points and on Material C illustrate positioning of four glue 21 adhesion points.

[0077] The stacking thereafter of materials B and C in sequence FIG. 3 results in the unique formation when filler 7 expanded as shown in FIG. 4 of ideally ten elongated narrow 14 centrally aligned cells arranged on the vertical axis void material with the method of completing the stack with surface laminated Material B adhesion layout 20 to seal the stack 23.

INDUSTRIAL APPLICABILITY

[0078] It is intended that this invention covers all modifications and variations as may be applicable to the embodiment principles set out above provided any variation comes within the scope of the claims to follow and their equivalents.

[0079] It is understood that the invention is not to be limited to the precise form disclosed in the preferred embodiment but may be modified without departing from the scope of the invention as defined in the claims to follow herein.

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