WO2013128038A1 - Improved door panel center and mold for producing same - Google Patents

Description

 IMPROVED AND MOLDED DOOR SOUL

FOR YOUR MANUFACTURE

OBJECT OF THE INVENTION The present invention, as expressed in the statement of this specification, refers to a door core and mold for its manufacture, providing notable advantageous features in the manufacture of this type of door soul that unlike the massifs have their hollow interior. They have a sandwich structure formed by a central core that defines the hollow part together with the perimeter frame, object of the invention and two external plates or covers.

It is an object of the invention to be able to form the hollow central core and the perimeter frame by pressing of wood or DM particles and glue as well as conventional boards, this phase being developed in the manufacturing mold proposed by the invention.

It is an object of the invention to be able to use as tops or external plates of the sandwich structure of the atamborado board, also agglomerate plates or MDF that are glued to the hollow central core with the same tails by another process.

BACKGROUND OF THE INVENTION

Nowadays, atamborados boards or atamboradas doors are manufactured that include a hollow central frame or core formed by stringers and cross them of solid wood to which they are attached by both sides plywood covers joined with adhesives or glues.

There is also a light type of atamboradas doors that include as central core the aforementioned solid wood frame and an internal honeycomb structure or similar as insufficiently resistant reinforcement to at least maintain the parallelism of the sandwich structure tops. On the other hand, with respect to the mold with which the cores or central panels of atamborated boards are manufactured in accordance with the present invention, it is worth mentioning the Invention Patent No. P-200601305 of the same applicant of the present invention, which contemplates that souls of doors can be formed with the paneling or glazing gaps so that material is not wasted since the soul of the door is perfectly finished and finished, only in the absence of final rejection and without requiring any machining.

This Invention Patent cited contemplates that the mold for atamboradas doors is formed by a fixed perimeter frame that follows the contour of the soul of the door, or a multiple of the surface of the door to be able to simultaneously obtain several door souls in the same phase of pressed, then separated by cuts.

In the Invention Patent No. P-200602572 which is also of the same applicant of the present invention, improvements in the aforementioned structure are contemplated, with which an automatism and versatility in the manufacture of different types and models of doors is achieved With the same mold. For this, it has a rectangular frame with different hollows or windows with the outline of the soul of the door to be manufactured, to simultaneously achieve several fully finished units defining a composite mold. The blocks that occupy the position of the paneling or glazing holes are defined by a plurality of transverse elements that can be moved individually, having the same or different amplitude. The useful surface of the first rectangular frame defines an area where a greater quantity of product is received since it descends to a greater extent than the rest, so that in the pressing a notable higher density is obtained than in the rest.

The first and second rectangular frames, as well as the independent intermediate blocks with which the holes for paneling or glazing can be formed, are supported by through vertical rods through an upper horizontal platform that is driven by the lower hydraulic cylinders of the press This operation is performed once the upper hot plate of the press has covered the mold. In the Certificate of Addition No. P-200701308 to the main Invention Patent No. P-200602572 discussed above, improvements are contemplated in the mold for manufacturing door souls that focus on both the fixed part of the mold and the lifting and lowering structure of the first and second frames to vary the travel stroke depending on the thickness of the door's soul.

As for the rectangular frame or walls of the mold in which several units can be manufactured in the same pressing phase, instead of being fixed to manufacture souls of standard doors, it is divided into two parts: a fixed outer perimeter to each independent unit and another mobile interior telescopically movable in this one and capable of occupying two positions: an upper one that remains flush with the perimeter outer part to manufacture standard door souls and another lower position to manufacture door souls of larger dimensions in length and width, when descending to the same extent as the first rectangular frame does to receive greater volume of material to be pressed.

The hydraulic cylinders that assist these first and second frames are extended or collected as desired depending on the order they receive from the automatic computer control unit that includes the installation. The movements of admission (descent) are sequential during the advance of the dispensers that supply the product to be pressed, since in the displacement towards one side of the press the product contained in the hoppers is discharged which in this case, can be DM or wood and glue particles with different densities when making sandwich door souls. When the mobile frame on which the dispenser or dispensers is mounted, leaves the press, pressing is carried out and thus when it returns to the other side, the withdrawal of the manufactured door souls takes place simultaneously, which is carried out once that the upper plate of the press has been lifted and the lower cylinders thereof have been extended to remove the soul from the door with respect to the mold. The dispenser includes a large central hopper with the product to be the central area of the sandwich of the soul of the door of two densities and two other smaller side hoppers that contain the product of the standard layers thereof. At the bottom of the hoppers there are rotating vane rollers that distribute the product towards the sides and also the entire bottom of the hopper is occupied by two transport bands that move towards the center where there are rollers with vanes that are responsible for Fill the mold. In the lower part of this chassis or movable carriage, there are some cleaning rollers of the mold surface to prevent unwanted scale formation. DESCRIPTION OF THE INVENTION

It is important to note that the present invention significantly improves the patents owned by the inventor, No. P200702385 and P200701710, by solving a series of problems that these patents had in their realization and manufacture. In general terms, the core of the atamborada door that the invention proposes, together with the mold for its manufacture, offers a central core that together with the perimeter frame is the sandwich part of a atamborada door that is constituted with the mold. The recesses of one face, preferably trunk-pyramidal, are out of phase with respect to those of the other face to form walls of little thickness, thus achieving the resistance due to and at the same time lightening weight, and to which later it is enough to attach the covers or side plates to form the soul of the door atamborada, being these covers or plates advantageously of the same pressed material of particles of wood agglomerate and tails. To this soul of door atamborada only remains to repel it to form the door, both in their faces seen and in the songs thus imitating a finish in the chosen noble wood

In order to achieve these recesses or recesses when molding the central core, the toothed plate of the bottom of the mold and the one attached to the hot upper plate of the press, they are determined by two plates whose exposed faces incorporate a plurality of trunk-pyramidal or trunk-conical projections , with the aforementioned distribution, to form the recesses in the blanket of particles of wood agglomerate and glues poured into the mold by the corresponding dispenser, when deposited on the bottom plate and lowering the upper hot plate to close the mold.

The vertices of this toothed surface constructed in the mold, are truncated to increase the surface of gluing of the tops or external plates of the sandwich.

For its part, the mold is loaded with the product of a single density that is in a dosing hopper arranged in a carriage that has a reciprocating movement from one side of the mold to the other, leaving the press to allow the upper hot plate to lower of the same to close the mold superiorly. This plate includes another plate of toothed profile similar to the lower one but with its teeth offset to the three-leg and not getting to join both to form the broken surface with the desired thickness.

Under these conditions, before the mold is filled, the lower hydraulic cylinders of the press act, causing the thrust platform to be located to determine the size of the blanket, in addition to performing the final pressing of the board. After this initial step and once the mold is filled, lower the upper toothed plate that has a flat perimeter extension with respect to its toothed area since the mold must be completely closed. The teeth are located only in the central area, although it is wide.

In the pressing they interconnect the upper and lower projections without reaching contact and with them the walls are formed with the expected thickness. In addition to the different thicknesses of souls can be achieved by varying the stroke of the thrust platform, using gauge system.

To facilitate the understanding of the features of the invention and forming an integral part of this specification, some sheets of drawings are attached in whose figures, for illustrative and non-limiting purposes, the following has been represented; BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1.- It is a cross-sectional view in elevation, of an atamborado board formed by a hollow central body together with the perimeter frame and two external boards or plates acquiring a sandwich structure, according to the invention.

Figure 2.- It is a view similar to Figure 1, where only the hollow central body is observed together with the perimeter frame, as it is manufactured in the mold object of the invention.

Figure 3.- Detail of plan view where we can see the hollow central body, the perimeter frame and the demoulding pushers.

Figure 3 - 3D view of the hollow central body.

Figure 4.- It is a view in longitudinal elevation of the mold for simultaneous manufacture of door souls, arranged in a gantry press and with the dosing hopper located on the mold. Figure 5.- It is a view similar to Figure 4, but in this case with the press closed.

Figure 6.- It is a cross-sectional view of that shown in Figure 4, not including the dosing hopper.

Figure 7.- It is a view of the frames of the press Figure 8.- It is a plan view of the base of the press, of the frames and location of the cylinders that raise the thrust platform, the frame and the toothed plate .

Figure 9.- It is a plan view of the mold release system of the mold board once the press is opened, and we can also observe pushers that have the function of starting the board of said toothed mold by means of pneumatic cylinders. Figure 10.- It is a view of the upper plate being represented in it the upper hydraulic cylinders of the lower mold closure and in turn we have a view of the central hole of the door.

Figure 11.- It is an elevational and longitudinal plan view according to the direction of travel of the dosing hopper of the mobile car.

DESCRIPTION OF THE FORM OF EMBODIMENT

Referring to the numbering adopted in the figures and especially in relation to figures 1 to 3, we can see the structure of a atamborada door referenced in general with No. 1 (Figure 1) and constructed according to the invention, or better still, the soul of a door atamborada, since it has a sandwich structure that only lacks both sides and the perimeter edge to imitate a solid noble wood door.

 In Figure 2 we can see the central core (2) and the perimeter frame (4) and this is what constitutes by itself the special novel feature of the invention since it is formed by pressing wood and glue particles, like than conventional chipboard, with particles of certain size and density. As we said before, the zigzag arrangement according to inclined sections with truncated vertices is formed by pressing without simply incorporating in the press hot plates, serrated plates (4 and 5) (figure 4) that interconnect without pressing get together, determining the separation of the thickness of the central core (2) (Figure 2)

 The central core (2) in addition to this hollow atamborada part, (Figure 3), has a perimeter frame (4) (Figure 1 and 2) of the dimensions corresponding to the door.

 In figure 3, in addition to the hollow central core (2) and the perimeter frame (4), we can also observe the demoulding pushes (25).

In the figures from 4 to 6 we can see the gantry press (7). At the top of this, we can see the hydraulic cylinders (9) lowering the upper hot plate (10) of the press which closes the mold superiorly once it has been filled with the product discharged by the dosing hopper (11). We can also see the hydraulic cylinders (6) for opening the mold once the product is pressed.

 In addition to these two types of cylinders, we see the hot plate

(10) the upper part of the press which has an insulating plate (19) attached on top, which will protect the cylinders (6 and 9) from heat, and at the same time it has a serrated plate ( 5), which, when the press is closed, will coincide with the lower toothed plate (4) of the mold but its teeth will be offset to the treadmill and will not come together to form the broken surface of the desired thickness between the teeth.

 In the lower part of the press in addition to the toothed plate (4) mentioned above, there are other elements that form it, among them are the lower hot plates (15), which have the serrated plates (4) attached thereto dimensions, this hot plate is scrollable down to receive the product to be pressed. These hot plates (15) have, like the upper one, an insulating plate (19) that will protect the pushing platform (20) from heat, and in turn this insulating plate has a protective metal plate (30) that will prevent use deteriorate the insulating plate (19). Also noteworthy is the perimeter frame (21), which is the one that closes the mold when the upper hot plate (10) comes down. This perimeter frame, in the longitudinal part, is aligned by fixed supports to the frames (29) and by means of some regulating screws (33) they can push or pull the perimeter frame to adjust it to the telescopic frames (22) and thus ensure the correct functioning of these (figures 6 and 8). The telescopic frame (22) has the mission of raising or lowering together with the thrust platform (20) to form the part of the door with the highest density (fence) (4) (figures 1 and 2). This solid door frame is formed naturally in the same pressing phase in the mold, loading with a greater quantity of product to obtain a higher density than in the atamborada part. The perimeter frame (4) Figure 1 and 2 has a higher density than the rest and allows adjustment machining to the exact measurements of the door and makes the fastening of the fittings with screws optimal.

When the press is open, the telescopic frame (22) is lower than the toothed plate (4) (Figure 4) to allow more product and when the press is closed, the telescopic frame (22) is at the same height as the toothed plate (4) (Figure 5), which is why it will have a higher density. This telescopic frame is attached to the thrust platform (20) by means of fastening screws (31).

 The thrust platform (20) has holes through which the rods (17) pass, which are joined two by two at the bottom of this thrust platform (20), from this union a screw (16) comes out ( Figure 8) who is responsible for regulating the thickness of the blanket.

 In the descent of the mold, to proceed to its filling, two positions can be observed: one of the toothed mold that is handled by the rods (17) and another of the telescopic frame (22) that is operated by the pushing platform (20) with its cylinders (8) that determine the size of the blanket.

 The gauges (32) determine the thickness of the pressed board.

Once the board has been pressed and the press is opened, the core is on the toothed plate (4), it must be demoulded and this will take place through demolding rods (25) that pass through the push platform (20) attached to a frame with pushers (23) and this is driven by pneumatic cylinders (24). (Figure 4 and 9).

 When the board is already demoulded, a car enters for its removal to the stacking area.

 At the same time that the carriage removes the board, the product container hopper (11) for filling the mold is entering.

 Figure 11 shows the geometry of the car with the large hopper (11) containing the product. In this figure we can see the two-way scroll wheels (13), the conveyor belt (27) of the product and endless rollers (28) distributors of said product. There is also a pneumatic cylinder (12) that regulates the gate (34) that has two functions, one regulating the fall of the product to said endless rollers (28) and another a motorized endless belt that facilitates the lowering of the product by dosing it. Cleaning brushes (18) will be responsible for cleaning the surface of the lower mold for the closure of the press.

Claims

1. CUSHION DOOR SOUL, of the type that includes a sandwich structure defined by a hollow central panel or body with a perimeter frame and a honeycomb or similar filling structure, closed on both sides with joined plates or plates with adhesives, characterized in that the hollow central core (2) is constituted by a pressed layer of wood and glue agglomerate, defined by a perimeter frame (4) whose internal emptying is occupied by a broken surface of oblique transverse zigzag walls with profile in "V" of truncated vertices defining upper and lower coplanar parallel bands with each other and with the surfaces of the perimeter frame (4) for application of the bonding adhesive to the external plates (3) of the sandwich. 2. CUSHION DOOR SOUL, according to claim 1, characterized in that the external plates (3) are also made of particleboard of wood or DM and adhesive with the desired thickness.  3. CUSHION DOOR SOUL, according to claim 1, characterized in that the solid door frame naturally forms in the same pressing phase in the mold being loaded with a greater quantity of product. 4. MOLD FOR MANUFACTURE OF DAMPED DOOR SOULS, the type of which has a fixed rectangular frame or perimeter wall in whose interior emptying a telescopic frame (22) is moved, which together with the heating plates (15) complete the surface of the mold and which is driven together with the thrust platform (20) by the hydraulic cylinders (8) by running a downward stroke to admit the product contained in a dosing hopper (11) that is movable horizontally sweeping the surface of the mold and unloading the product until it is filled. Once the mold is filled, it closes with the lowering of the upper hot plate (10) through hydraulic cylinders (9), this upper hot plate is characterized in that it includes rectangular plates (5) with a toothed profile defined by section grooves in "V" and truncated vertices that occupies the central surface of the soul of the door being its free surfaces smooth. Next, the doors are pressed when they are compressed by the platform (20) that will cause both the heating plates (15), with their respective serrated plates (4), and the telescopic frame (22), actuated by the powerful hydraulic cylinders (8) for lifting and pressing.  5. MOLD FOR MANUFACTURE OF DAMPED DOOR SOUL, according to claim 4, characterized in that the plate (4) with toothed profile and the heating plate (15), rest on respective vertical rods (17) located in the angular zones, which cross loosely the lifting platform (20) and they are joined two by two at the bottom of this thrust platform (20) and from this union a screw (16) comes out that is responsible for regulating the thickness of the blanket. This plate with toothed profile (4) together with the telescopic frame (22) totalizes the useful surface of the mold and rests directly on the thrust platform (20). 6. MOLD FOR MANUFACTURING OF DAMPED DOOR SOULS, according to claim 4, characterized in that the gantry press has its upper hot plate (10) provided with serrated plates (5) similar to those linked to the lower hot plate (15) of the press, but whose teeth are offset to the three-ring forming in the final phase of the press, a sheet of broken profile of pressed product of thickness corresponding to the separation between the teeth and that is continued throughout the perimeter flat, defining a frame whose surfaces are flush with the ridges of their teeth to allow the joining and subsequent bonding of the external plates (3) of the sandwich of the soul of the door atamborada (1)  7. MOLD FOR MANUFACTURE OF ATMABORATED DOOR SOULS, according to claim 4, characterized in that the teeth of both upper (5) and lower (4) plates have a broken profile of oblique zigzag walls and truncated vertices.  8. MOLD FOR MANUFACTURE OF DAMPED DOOR SOULS, according to claim 4, characterized in that on the thrust platform (20) there is an insulating plate (1) and a protective metal plate (30).  9. MOLD FOR MANUFACTURE OF DAMPED DOOR SOULS, according to claim 4, characterized in that the thickness of the pressed board will be determined according to the thickness of the gauge (32).  10. MOLD FOR MANUFACTURE OF DAMPED DOOR SOULS, according to claim 4, characterized in that the dosing hopper (11) with the product to be pressed is arranged in a movable carriage (35) from one to the other side of the mold. The dosing hopper (11) has a gate (34) that regulates the product to be poured into the mold. At the bottom of the movable carriage (35) are the two-way scroll wheels (13), the conveyor belt (27) and the endless rollers (28) product distributors and the cleaning and leveling brushes (18) 11. MOLD FOR MANUFACTURE OF DAMPED DOOR SOULS, according to claim 4, characterized in that the telescopic frame (22) is attached to the thrust platform (20) with the clamping screws (31).