DE102018108835A1 - Door leaf, door and method of manufacturing the door leaf - Google Patents

Abstract

A door leaf (23) with a frame comprising at least one frame spar (7), wherein the door wing (23) has a plate-shaped door panel (1), which door panel (1) has at least one inner shell (2), an outer shell (3) and one therebetween arranged insulating layer (4), wherein the door panel (1) has an edge-side recess (31) which is arranged between the inner shell (2) and the outer shell (3), wherein the frame spar (3) at least partially in the recess (31 ) and wherein the frame spar (3) is fixed mechanically in the recess (31) and is non-positively connected to the door panel (1), as well as a door with the door leaf and a method for producing the door leaf.

Description

The present invention relates to a door leaf according to the preamble of claim 1, as well as a door and a method for producing the door leaf.

Door leaves from the prior art are often additionally glued. This affects u.a. the fixing of the door panels to a frame. The disadvantage of this is that the curing times of the adhesive often take a larger amount of production time. In many constructions, the gluing must also take place in a lying position, so that the production process u.U. can be blocked. Therefore, purely mechanical solutions for the connection between the door and the frame are to be preferred.

A generic door is in the EP 3 269 915 A1 described. In this case, L-shaped frame beams, which are referred to in the aforementioned document as a sash profile, initially assembled into a frame. Subsequently, the plate-shaped door panel is inserted into the frame and parallel to the surface normal of the plate plane of the door panel is screwed through a shell of the door panel through. At the same time one of the shells of the door panel is covered by the frame spar.

In this construction, it was primarily ensured that the frame spars do not have to be glued to the filling. The wings can thus be further processed immediately. A lengthy curing time, as for glued wings, is not required. This is made possible by the aforementioned special installation sequence and filling screw connection.

The production method of EP 3 269 915 A1 Although it is suitable for a one-sided wing covering construction, but not for a two-sided wing-covering construction in which the sash profile or the frame spar is covered on both sides of the door panel. A screw connection to the inner shell is not acceptable for optical reasons.

The state of the art of a two-sided wing-covered variant also includes the DE 10 2004 057 162 , Here, the individual frame spars are inserted into the finished filling and only then connected to a frame. The advantage is that the filling can be made, for example, by a filling manufacturer, while the door manufacturers then make the frames around the filling and mount the fittings.

A disadvantage of this construction is that the shells which are referred to in the document as paneling are made with undersize so be made with a special filling thickness, whereby the insertion of the frame spars turns out to be very difficult due to the clamping pressure. In addition, the shells must be glued to the bars, which should be avoided as described above. This is particularly expensive and the long curing time of the adhesive connection, the assembly process is interrupted. The interstate door panels take up considerable space, since these must harden lying.

It is therefore an object of the present invention to improve the aforementioned constructive solutions and in particular to provide a door leaf and a method for its production in which a two-sided wing covering construction without the use of adhesive can be realized.

The present invention solves this problem by a door leaf with the features of claim 1 and by a method for its production with the features of claim 22. Furthermore, according to the invention is a door with the features of claim 21st

An inventive door leaf comprises a frame with at least one frame spar, as well as a plate-shaped door panel.

The door panel has at least one inner shell, an outer shell and an insulating layer arranged therebetween. Other intermediate shells, insulating layers, dilatation compensating layers, inserts for anchoring mechanical connecting elements and the like may optionally also be provided.

The door panel also has an edge-side recess, which is arranged between the inner shell and the outer shell, wherein the frame spar is at least partially disposed in the recess.

In comparison to the glued door variants in which there is a material connection between the frame and the door panel, the frame spar of the present invention is mechanically fixed in the recess and connected non-positively with the door panel.

In this door leaf construction, the door panel can cover both sides of the frame spars.

At first the filling can be made completely. The filling attachment in the frame is purely mechanical, ie without gluing. This results in assembly and cost advantages.

Advantageous embodiments of the invention are the subject of the dependent claims.

The frame spar can advantageously be adhesively bonded and preferably releasably connected to the door panel.

The fixing of the frame spar in the recess can be effected by at least one mechanical connecting element. This is particularly advantageous for a reliable fixation of the frame with the door panel without causing an unintentional displacement of the door panel within the frame. A suitable mechanical connecting element can be designed as a screw, pin, bolt and / or rivet.

The recess is preferably groove-shaped so that there is a surface connection between the frame spar and the door panel.

The frame spar can be inserted in a direction parallel to the plate plane of the plate-shaped door panel in the groove-shaped recess, so that the frame spar can be covered on both sides by the door panel.

The connecting element may be arranged in a direction parallel to the plate plane of the plate-shaped door panel in the door leaf, so that no screw heads or the like protrude along the visible sides of the door panel.

The door leaf may have an insert part, for example a solid or hollow profile, for anchoring the connecting element, wherein the insert part is arranged in the groove-shaped recess.

The insert part can also be arranged only at a few selected positions in the recess or extend along the entire groove-shaped recess.

The arrangement of the connecting element in the Einlegteil may have a greater Auszugswert than an arrangement of the connecting element in the insulating material of the insulating layer, wherein the insert is not attributable to the insulating material of the insulating layer in the context of the present invention, even if it itself may have insulating properties.

The aforementioned Auszugswert the Einlegteils may be at least 20%, preferably at least 50% higher than in an arrangement of the connecting element in the insulating material of the insulating layer.

The insulating material of the insulating layer and / or the Einlegteil may advantageously consist of rigid polyurethane foam. This material is particularly suitable for anchoring fasteners.

The insulation material can also consist of PU foam or polystyrene foam. This material usually has good insulation values, but is unsuitable for anchoring fasteners due to its low hardness.

The frame spar can advantageously consist of composite material, in particular of metal and plastic profiles.

The groove-shaped recess may advantageously have a groove bottom and two side surfaces which extend obliquely, in particular perpendicular to the groove bottom and wherein the frame spar is formed L-shaped. The frame spar may have with a web on a first leg of the L-shaped frame spar with at least one web end for abutment with a first of the two side walls of the groove-shaped recess. The frame spar may also have a contact surface on a second leg of the L-shaped frame spar for abutment with the second of the two side walls of the groove-shaped recess.

The system between the side walls is done with a game. This may preferably be 0.2 to 2 mm. Thus, the frame spar can rest on one side on a side wall and the game only be present to the second side wall or the frame spar can have a game to each of the two side walls. The term "attachment" in this case may, according to the definition of the present invention, comprise a small spacing, which is expressed in the game.

The groove bottom can advantageously be formed step-shaped with two substantially mutually parallel bottom surfaces. The groove-shaped recess may preferably be formed as a first groove-shaped recess. One of the bottom surfaces may be formed as a groove bottom of a second recess, which is part of the first groove-shaped recess, wherein the insert part is arranged within the second recess. The second recess is part of the first groove-shaped recess. In this way, advantageously, the static-carrying part of the frame spar can be arranged on one side of the recess, which forms the inside of the door and accommodates fitting parts such as door hinges and locks.

The side walls of the recess may be formed by the inner shell and the outer shell, wherein the frame spar at least one side is spaced from the inner or outer shell. As a result, a sufficient clearance against dilatation of the materials of the filling, in particular the outer and the inner shells is achieved, which may occur, for example, in sunlight and it facilitates the introduction and assembly of the frame spar in the recess.

The door leaf can advantageously have a covering profile for at least partially covering the mechanical connecting element, which cover profile can be fixed to the frame rail and / or to the outer or inner shell. As a result, a marginal haptic and visually appealing surface can be achieved and the connecting means is better protected against environmental influences.

The door leaf can advantageously have at least one sealing element, in particular a sealing profile and / or a sealing stop, which can be fixed to the frame spar and which, together with the frame spar, at least partially forms a flat fold.

The inner and / or outer shell may extend beyond the frame spar or terminate with this. As a result, the respective shell can hide the frame spar in the viewing direction, relative to a surface normal of the plate plane of the door panel.

Furthermore, according to the invention, a door is provided with a window frame and a door leaf according to the invention connected to the window frame.

1. a. Bereitstellen der Rahmenholme und der Türfüllung;
2. b. Zusammenfügen, insbesondere Einstecken, der Rahmenholme in die Türfüllung; und
3. c. Verbinden der Rahmenholme zu einem Rahmen
4. d. Verbinden der Rahmenholme mit der Türfüllung , insbesondere mittels zumindest eines mechanischen Verbindungsmittels.

A method for producing a door leaf according to the invention is characterized by the following steps:

1. a. Providing the frame spars and the door panel;
2. b. Assembling, in particular inserting, the frame beams into the door panel; and
3. c. Connecting the frame rails to a frame
4. d. Connecting the frame beams with the door panel, in particular by means of at least one mechanical connection means.

The aforementioned method enables adhesive-free production of a door leaf. The joining in step b takes place without fixing as a kind of pre-positioning which allows a subsequent recentering of the door panel after the provision of the frame. The actual fixing between the door panel and the frame takes place in step d).

Advantageous embodiments of the method are the subject of the dependent claims.

Preferably, the mechanical connection means can be anchored without passing through the inner and / or outer shell in the door panel. This avoids e.g. Re-cutting in the event of accidental mispositioning and reducing the scrap rate during production. In addition, such positions of the connecting elements are undesirable by the customer. Furthermore, the dilation of the shells is not hindered or restricted.

In a further optional step, the connecting means for connecting the frame spars to the door panel can be covered with the aid of one or more cover profiles.

In addition, in an additional step, a flat fold can be formed by fixing sealing means to the frame spar.

The respective frame spar can advantageously be inserted in step b) into a respective recess in the door panel in a direction parallel to the plate plane of the plate-shaped door panel in the recess.

The connecting element can advantageously be introduced and fixed in step d) in a direction parallel to the plane of the plate-shaped door panel in the door leaf.

• 1 Schnitt durch den Randbereich einer Füllung des erfindungsgemäßem Türflügels;
• 2 Schnitt durch einen Rahmenholm des erfindungsgemäßen Türflügels;
• 3 Schnitt einer Montageanordnung umfassend den Rahmenholm der 2 und die Füllung der 1;
• 4 Schnitt der Montageanordnung der 3 wobei der Rahmenholm und die Füllung miteinander fixiert sind;
• 5 Schnitt der Montageanordnung mit weiteren ergänzenden Profilen des Türflügels; und
• 6 Schnitt eines Türausschnitts einem Ausschnitt des Türflügels und einem Ausschnitt eines Blendrahmens.

The invention will be explained in detail below with reference to an embodiment using the accompanying figures. Show it:

• 1 Section through the edge region of a filling of the inventive door leaf;
• 2 Section through a frame spar of the door panel according to the invention;
• 3 Section of a mounting arrangement comprising the frame spar of 2 and the filling of 1 ;
• 4 Cut the mounting arrangement of the 3 wherein the frame spar and the filling are fixed together;
• 5 Section of the mounting arrangement with further complementary profiles of the door leaf; and
• 6 Section of a door cutout a section of the door leaf and a section of a window frame.

1 shows a section through the edge region of a prefabricated door panel 1 , which is designed as a multilayer plate. The door panel 1 includes at least one inner shell 2 , at least one outer shell 3 and at least one damp course 4 , It may preferably be formed as a sandwich plate and / or sandwich panel.

The terms "inside" and "outside" refer, for example, to an interior of a building, which is the door panel 1 delimits a door provided with the door from the environment or an outdoor area. Here is the inner shell 2 the shell of the door panel 1 that's going to be more positive y Coordinates with respect to the coordinate system in 1 is arranged. Accordingly, the outer shell 3 the shell of the door panel 1 that are in the negative direction y Coordinates with respect to the coordinate system in 1 is arranged.

The door panel 1 has a stepped edge area 6 on. The stepped edge area 6 is preferably located on at least three sides, based on the plane of the door panel 1 , On a fourth side (bottom horizontally at the built-in door) can the frame area 6 be designed differently, for example, if a so-called base profile is used for the door. Here then corresponds to the edge region in approximately the contour of the base profile.

The stepped edge area 6 the door panel 1 has a first edge-side groove-shaped recess 31 preferably along the entire length of a side region of the door panel 1 extends. The recess 31 is through the inner shell and the outer shell 2 . 3 and through a groove bottom 32 , which by the insulating material of the insulating layer 4 is formed, limited.

The groove bottom 32 is stepped with a first bottom surface 33 and a second floor surface 34 , which are opposite the first floor surface 33 deeper offset in the insulating layer 4 is arranged so that within the first groove-shaped recess 31 a second U-shaped recess 35 is arranged, which on at least two sides by the insulating material of the insulating layer 4 and on a third side through the inner shell 2 is limited.

The inner shell 2 and the outer shell 3 may preferably consist of metallic plates, preferably of aluminum. Other materials such as plastic, wood, composite materials such as metal and plastic, and the like can also be used in the context of the present invention. The size of the inner shell 2 can be compared to the size of the outer shell 3 vary. This can affect both the size of the plate surface and / or the plate thickness. Preferably, the plate thickness of the inner and outer shell 2 and 3 but also be the same size.

Between the cups 2 and 3 there is at least the aforementioned insulating layer 4 , which is glued to the inner and outer shell. This insulating layer 4 has a high thermal insulation value. This may preferably be between 0.022 and 0.078 W / (m * K).

The insulating layer can also be designed to be flexible in order to compensate for thermal expansion of the shells. The preferred elongation at break is greater than 150% after DIN 53571 in the current version currently April 2018.

To anchor the filling with a screw connection, this can have high pull-out values of at least 400 N, preferably from 900 to 1300 N. The extraction values refer to the material of the filling in combination with a connecting element, which is a sheet metal, wood or mounting screw with a diameter of 3.9 to 7.5 mm.

This does not exclude the alternative use of other fasteners, but serves to describe the material properties of the insulating material and / or the material of the insert as a reference.

The insulating layer can thus be formed only in one piece from a thermally insulating material. In this case, the insulating layer may be formed, for example, as a dimensionally stable heat-insulating plastic plate, in particular as a plastic foam plate, which forms sufficient resistance for anchoring a mechanical connecting element, in particular a screw or a rivet.

If these properties can not be adequately provided with a material, then the insulating layer can 4 also be composed of several materials with the required properties.

As the insulating material may preferably a foam, such as PU foam or polystyrene foam, which is typically characterized by a high thermal insulation used. This may also preferably with one or more fastening segments, in particular with one or more inserts and / or Einlegprofilen 5 , are combined for the anchoring of a mechanical connection means, in particular for a screw connection.

The fastening segment, in particular the or the Einlegteile or Einlegprofile 5 thus form a mounting area, in particular a screwed area 26 , out. As material for the Einlegteile and / or Einlegprofile offer themselves in addition to hard plastics and / or plastics with high Auszugswerten, especially PVC, rigid polyurethane foam, fiber reinforced plastic, especially carbon fiber reinforced plastic and wood and / or metal. The Einlegteile and / or profiles may also be equipped with hollow chambers and / or screw channels.

In addition, it is also possible to provide at least one flexible layer, for example made of elastic synthetic material, such as cellular rubber or a closed-cellular foam-like elastomer, over the whole area or partially to compensate for expansion (dilatation) and / or bulges. This layer may preferably be between the insulating layer 4 on the outer shell 3 be arranged. The aforementioned strains may due to temperature differences on both sides of the door and the associated highly different thermal expansion of the two shells 2 and 3 arise. Due to its properties, the flexible layer compensates for the thermal expansion of the outer shell 3 on the outside of the door leaf. For a detailed description of the properties and the function of the aforementioned layer, which is often described as a compensation layer, is at this point on the DE 203 14 017 U1 directed.

The individual layers / parts of the door panel are glued together and preferably completely prefabricated.

In 2 becomes a frame spar 7 provided. This may preferably have a first profile 8th , preferably a metallic profile, in particular an aluminum profile, and a second profile 13 , preferably a plastic profile. Both profiles are sheared together as a composite profile. A non-skid connection or a frame spar of other materials (plastic, wood, metal, eg steel) and material combinations are also possible.

Preferably, the first profile 8th at least one, preferably two, hollow chambers 9 on. Further preferably, on the first profile 8th a functional groove 10 be provided for concealed receiving fasteners.

Advantageously, the first profile 8th at the transition to the second profile 13 a fastening bridge 11 for mounting one or more fittings, such as locks and / or hinges on. The fastening bridge 11 offers increased pull-out values for screw connections and is located in the middle area of the door panel 1 , ie about 35 to 65% of the plate thickness of the door panel 1 ,

The second profile 13 serves, in particular in its preferred embodiment as a plastic profile, the thermal insulation and as a spacer for the outer shell 3 , The second profile 13 can by a pressing process frictionally and positively via the fastening web 12 with the first profile 8th get connected. The second profile 13 can have several hollow chambers. Edge webs 14 of the second profile for engagement with the outer shell 3 the door panel 1 ensure a small contact surface to improve thermal insulation. The frame spar 7 can be beneficial as the door panel 1 is completely pre-assembled and is in the preferred variant of 2-6 L-shaped.

3 shows a section of a mounting arrangement 25 comprising the door panel 1 of the 1 and the frame spar 7 of the 2 ,

The frame spar 7 is at least partially in the door panel 1 inserted so that it partially, at least in the first groove-shaped recess 31 is arranged and this partially filled. Thus, the frame spar is located 7 in 3 at least partially between the inner shell 2 and the outer shell 3 ,

The frame spar is preferred 7 through the inner shell 2 and / or through the outer shell 3 in a front view of the door panel 1 concealed, so that there is a visually particularly high-quality and advantageous impression of the mounting arrangement for the viewer.

According to an embodiment of an assembly method according to the invention, individual frame beams can 7 a door leaf 1 in the frame areas 6 the door panel 1 brought and plugged.

A frame spar 7 in this case preferably has a smaller height of preferably less than 2 mm. This height is defined by the distance of a bridge 14 for engagement with the outer shell 3 up to a contact surface 15 of the frame spar 7 on the inner shell 2 , The aforementioned height is at least 0.2 mm less than the distance between the inner shell 2 and the outer shell 3 the door panel 1 , Through the game between the components, so the frame spar and the door panel, the insertion of the frame spar or the frame beams 7 in the door panel 1 simplified.

Optional can previously be in hollow chambers 9 and / or grooves 10 the frame spars 7 Connecting means (not shown) are attached. Preference is given to this so-called corner connector for mitred frame profiles. These are in the hollow chambers 9 used. alternative can also be called T Connectors are used for blunt cut profiles. The structural solution of the present invention thus enables the cutting and the assembly of differently tailored frame profiles.

Then, several of the frame spars 7 connected to a frame. The corner and / or T Nailed or screwed according to the prior art connector to obtain a stable frame. The frame spars 7 However, they can also be mechanically connected to one another, in particular screwed, riveted and / or welded.

The frame can thus through the frame rails 7 in the door panel 1 are pre-assembled and is then prefixed form-fitting to the door panel.

Subsequently, the frame is preferably provided with at least one mechanical connection elements 16 , in particular with one or more screws, on the door panel 1 attached.

In this case, the frame for filling advantageously "by hand" and / or with the help of screws 16 be aligned, depending on how the screws 16 be attracted. The bolting area 26 provides the mechanical fasteners 16 , especially the screws, secure hold. The screw shaft 18 penetrates the hollow chamber 9 of the frame spar 7 and the screw head 17 will be in a groove 10 arranged or sunk. This has the advantage that the screw after mounting a cover 19 is no longer visible, whereby the appearance of the wing edge of the door leaf is improved.

To the optics and the easy accessibility of the connecting element or the connecting elements 16 To achieve, it is also particularly advantageous if the introduction of the connecting element from a parallel direction to a plane of the plate A the plate-shaped door panel 1 he follows.

The same applies to the insertion or insertion of the frame spar 7 in the door panel 1 ,

The frame spar 7 is in 4 . 5 and 6 by means of a connecting element 16 with the door panel 1 connected. However, it is also in the context of the present invention, other mechanical connections, such as jamming of the frame spar 7 between the cups 2 and 3 or another possibility of anchoring conceivable. For this purpose, for example, in the area of the plant surface 15 Be arranged spring leg, which is resilient against the inner shell 2 support. The connection between the frame spar 7 and the door panel 1 is preferably detachable, particularly preferably without material connection, in particular without adhesive.

Other optional advantageous elements which on the frame spar 7 and / or at the door panel 1 are arranged in 5 and 6 shown.

The door according to the invention 23 includes at least the door panel 1 and at least one frame spar 7 but in particular a frame comprising a plurality of frame spars 7 ,

A front door includes next to the door according to the invention 23 also a frame 24 which is in 6 is indicated.

For sealing the door leaf 23 to the frame 24 become seals 20 and seal stop 21 in the mounting arrangement 25 , especially in the border area 6 , used, which are designed so that in interaction with the frame spar 7 and the optional cover profile 19 a flat fold 22 which results in at least 50%, preferably at least 70% of the edge area of the plate-shaped mounting arrangement 25 with the frame spar 7 and the door panel 1 extends. This fold 22 improves the appearance and facilitates cleaning of this area. Also improves the feel.

6 shows the door according to the invention 23 with the corresponding frame 24 , shown here in the form of a frame profile on which the door is fixed, preferably struck, is. Other fittings such as door hinges, locks, closing plates, handles, pushers and / or door closers are not shown, but may optionally be provided in a conventional manner.

The frame and the frame can be made partially or completely as extruded aluminum profiles. Alternatively, the production is also possible from a different material such as steel and / or another manufacturing method. Optional insulating webs of the frame or the frame spar may be made of a plastic material, such as plastic. Polyamides (PA66, PA6, PPA), polyester (PET, PBT), polyolefins (PP) or polyvinyl chloride (PVC) may be produced, so that in each case a substantial thermal separation between individual profiles can be achieved.

As mechanical fasteners u.a. Bolts, nuts, including clamped shims, pins, bolts, rivets and / or circlips.

LIST OF REFERENCE NUMBERS

1

door panel

2

inner shell

3

outer shell

4

damp course

5

union end

6

frame area

7

frame spar

8th

profile

9

hollow

10

groove

11

web

12

web

13

profile

14

mooring facilities

15

contact surface

16

connecting element

17

screw head

18

screw shaft

19

cover profile

20

poetry

21

seal stop

22

Fold or seam surface

23

door

24

frame

25

mounting arrangement

26

Verschraubungsbereich

31

recess

32

groove bottom

33

floor area

34

floor area

35

recess

t

surface normal

A

board plane

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 3269915 A1 [0003, 0005]
• DE 102004057162 [0006]
• DE 20314017 U1 [0060]

Cited non-patent literature

• DIN 53571 [0053]

Claims (28)

Door leaf (23) with a frame comprising at least one frame spar (7), wherein the door wing (23) has a plate-shaped door panel (1), which door panel (1) at least one inner shell (2), an outer shell (3) and arranged therebetween Insulating layer (4), wherein the door panel (1) has an edge-side recess (31) which is arranged between the inner shell (2) and the outer shell (3), wherein the frame spar (3) at least partially in the recess (31) is arranged, characterized in that the frame spar (3) is mechanically fixed in the recess (31) and is positively connected to the door panel (1). Door leaf after Claim 1 , characterized in that the frame spar (7) adhesive-free and preferably releasably connected to the door panel (1). Door leaf after Claim 1 or 2 , characterized in that the fixing of the frame spar (7) in the recess (31) by at least one mechanical connecting element (16). Door leaf after Claim 3 , characterized in that the mechanical connecting element (16) is designed as a screw, pin, bolt and / or rivet. Door leaf according to one of the preceding claims, characterized in that the recess (31) is groove-shaped. Door leaf according to one of the preceding claims, characterized in that the frame spar (7) in a direction parallel to the plate plane (A) of the plate-shaped door panel (1) in the groove-shaped recess (31) is inserted. Door leaf according to one of the preceding claims, characterized in that the connecting element (16) in a direction parallel to the plate plane (A) of the plate-shaped door panel (1) in the door leaf (23) is arranged. Door leaf according to one of the preceding claims, characterized in that an insert part (5) is arranged for anchoring the connecting element in the groove-shaped recess. Door leaf according to one of the preceding claims, characterized in that the arrangement of the connecting element (16) in Einlegteil (5) has a greater Auszugswert than an arrangement of the connecting element (16) in the insulating material of the insulating layer (4) outside the Einlegteils (5). Door leaf after Claim 9 , characterized in that the Auszugswert is at least 20%, preferably at least 50% higher than in an arrangement of the connecting element (16) in the insulating material of the insulating layer (4). Door leaf after Claim 9 or 10 , characterized in that the insulating material of the insulating layer (4) and / or the Einlegteil (5) consists of rigid PU foam, with a pull-out value of at least 400-4000 N, preferably 900-1300 N, based on a connection with a sheet metal , Wood or mounting screw with a diameter of 3.9 to 7.5 mm. Door leaf according to one of the preceding claims, characterized in that the insulating material of the insulating layer (4) made of PU foam or polystyrene foam with a pull-out value of less than 400 N based on a connection with a sheet metal, wood or mounting screw with a Diameter from 3.9 to 7.5 mm. Door leaf according to one of the preceding claims, characterized in that the frame spar (7) consists of composite material, in particular of metal and plastic profiles. Door leaf according to one of the preceding claims, characterized in that the groove-shaped recess (31) has a groove bottom (32) and two side surfaces which extend obliquely, in particular perpendicular to the groove bottom (32), and wherein the frame spar (7) L-shaped is formed comprising a web (14) on a first leg of the L-shaped frame spar (7) with at least one web end for abutment with a first of the two side walls of the groove-shaped recess (31) and a contact surface (15) on a second leg of the L-shaped frame spar (7) for abutment with the second of the two side walls of the groove-shaped recess (31), wherein in the system between the side walls prevails a play of preferably 0.2 to 2 mm. Door leaf according to one of the preceding claims, characterized in that the groove bottom (32) is step-shaped with two substantially mutually parallel bottom surfaces (33, 34). Door leaf according to one of the preceding claims, characterized in that the groove-shaped recess (31) is formed as a first groove-shaped recess and that one of the bottom surfaces (34) forms a groove bottom of a second recess (35), which is part of the first groove-shaped Recess (31), wherein the insert part (5) is arranged within the second recess. Door leaf according to one of the preceding claims, characterized in that the side walls of the recess (31) through the inner shell (2) and the outer shell (3) are formed and wherein the frame spar (7) at least one side relative to the inner or the outer shell (2 , 3) is spaced. Door leaf according to one of the preceding claims, characterized in that the door leaf (23) has a cover profile (19) for at least partially covering the mechanical connecting element (16), which cover profile (19) on the frame spar (7) can be fixed. Door leaf according to one of the preceding claims, characterized in that the door leaf (23) has at least one sealing element, in particular a sealing profile (20) and / or a sealing stop (21), which on the frame spar (7) can be fixed and which together with the frame spar (7) at least partially a flat fold (22) is formed. Door leaf according to one of the preceding claims, characterized in that the inner and / or outer shell (2, 3) extends beyond the frame spar (7) or with this concludes such that they the frame spar (7) in the viewing direction, based on a surface normal (t) of the plate plane (A) of the door panel (1), hidden. Door, in particular front door, comprising a window frame (24) and a door leaf (23) connected to the window frame (24) according to one of the preceding claims. Method for producing a door leaf (23) according to one of the preceding claims, characterized by the following steps a. Providing the frame beams (7) and the door panel (1); b. Assembling, in particular inserting, the frame struts (7) into the door panel (1); and c. Connecting the frame members (7) to a frame; and d. mechanically connecting the frame members (7) to the door panel, in particular by means of at least one mechanical connection means (16). Method according to Claim 22 , characterized in that the joining after step b) and the mechanical bonding after step d) takes place without adhesive. Method according to Claim 22 or 23 , characterized in that the mechanical connection means (16) without passage through the inner and / or outer shell (2, 3) in the door panel (23) is anchored. Method according to one of the preceding claims, characterized in that in a step e) a covering of the mechanical connecting means (16) for connecting the frame members (7) with the door panel (23) takes place with the aid of one or more cover profiles (19). Method according to one of the preceding claims, characterized in that in an additional step, a formation of a flat fold (22) by fixing of sealing means (20, 21) on the frame spar (7). Method according to one of the preceding claims, characterized in that a respective frame spar (7) inserted in step b) in a respective recess in the door panel (1) in a direction parallel to the plate plane of the plate-shaped door panel (1) in the recess (31) becomes. Method according to one of the preceding claims, characterized in that the mechanical connecting element (16) is inserted and fixed in step d) in a direction parallel to the plane of the plate-shaped door panel (1) in the door leaf (23).

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