FR2571422A1 - Panel, in particular for external door, and process for manufacturing such a panel - Google Patents

Abstract

The invention relates to a panel, in particular for an external door liable to be subjected to temperature and moisture conditions inside which will be different from those on the outside. The external temperature and moisture conditions being themselves variable with time to a large extent. It comprises a monobloc member 1, comprising a peripheral frame 2, an internal wall 3 rigidly associated to the frame 2; a foam with closed cells 4 filling the space defined by the frame 2 and the wall 4, constituting a barrier of thermal insulation and of leaktightness with respect to water (in the liquid or vapour phase), contributing to the rigidity of the member 1 and forming an external skin 5. This bearing member 1 is thus substantially insensitive to variations in external temperature and moisture conditions.

Description

Panel in particular for exterior door, and method of making such a panel.

The invention relates to a panel, in particular for an exterior door capable of being subjected to different temperature and humidity conditions inside and outside, the outside temperature and humidity conditions being themselves variable. to a large extent; and the method of producing such a panel.

Numerous variants of the door panel are already known, generally comprising a peripheral frame, an internal face, an external face and a central core. These different variants differ from each other by the nature and composition of the frame, the inner and outer faces and of the core as well as by the way they are arranged together.

Thus, in a first variant, the panel has inwardly uprights and crossbars of folded sheet and outwardly a panel of wood particles, filling plywood forming the inner core.

In a second variant, the panel has two sheet metal plates, inward and outward, the core being made of polyurethane foam.

In a third variant, the panel has two plywood walls inward and outward and a groin of expanded polystyrene.

In a fourth variant, the panel has two walls of fiber panel coated with polyester reinforced with glass fiber inwards and outwards, and a core of polyurethane foam embedding longitudinal stiffeners forming spacers for the walls.

In a fifth variant, the panel comprises a metal box forming the internal and external faces and a foam core.

All these variant embodiments are traditional in their design, in particular in that the internal and external faces of the panel are of the same nature and of the same composition, these panels being. most often symmetrical with respect to a median plane parallel to the internal and external faces.

These panels are intended to constitute the leaf of a door, in particular of an exterior door which is subjected to different temperature and humidity conditions inside and outside, the temperature and outdoor humidity being variable over time and to a large extent depending on the seasons and weather conditions. However, it has been found that these known doors had an unsatisfactory resistance to humidity variations. Assuming, in the best of cases, that the temperature and humidity conditions inside remain constant or vary little, the internal face remains stable. But, it is not the same for the external face and it follows very annoying deformations. These deformations of the beat relative to the interior nude of the frame can commonly reach up to 6 mm and even exceed 10 min. In an attempt to alleviate this problem, a panel has been proposed which includes u1. interior panel and an exterior panel and a layer of insulating material between the two panels, the exterior panel being associated in a floating manner with the interior panel in order to allow a relative displacement of the exterior panel with respect to the interior panel in the plane of the panel However, this alternative embodiment has two drawbacks the first is the need to provide at the periphery of the panel holding means with the possibility of displacement, and the second, essential, is that the interior panel is itself capable of deformation between its two inner and outer faces.

The invention therefore aims to solve this problem of the deformation of the door panels due to humidity and temperature, more precisely the variation in the humidity and temperature.

To this end, the invention provides a panel which comprises a one-piece carrying element comprising a peripheral frame; an inner wall rigidly associated with the frame; and closed-cell foam filling the free space defined by the frame and the wall, constituting a barrier of thermal insulation and watertightness (in the liquid or vapor state), contributing to the rigidity of the element and forming an outer skin.

This carrier element is therefore substantially insensitive to variations in external temperature and humidity conditions.

The frame is made of solid wood and the foam is polyurethane. The inner wall is a plywood of wood, dried between 8 and 12% humidity, preferably at or about 10% humidity, so that the load-bearing element is substantially non-deformable under the conditions of internal temperature and humidity. usual.

Preferably, the panel comprises an external covering, for protecting and masking the foam and the frame, possibly decorative or support for a decorative element. This exterior facing can be the subject of several variant embodiments (metal or wood).

By its characteristics, the bearing element of a panel according to the invention completely escapes the traditional design implemented so far. It follows that this bearing element is substantially insensitive to variations in the conditions of temperature and external humidity, and therefore substantially undeformable.

The external facing essentially has the function of masking the foam and allowing the placement of decorative element. However, this exterior facing does not directly participate in the rigidity of the panel or its self-supporting character.

The other characteristics of the invention will emerge from the description which follows with reference to the accompanying drawings in which:
Figure 1 is an elevational view, from the inside, of a first embodiment of a panel according to the invention with metal facing.

Figure 2 is a sectional view along line 2-2 of Figure 1.

Figures 3a, 3b, 3c are three schematic elevational views respectively of the outside, inside and inside of a second embodiment of the panel according to the invention (wood facing) in a first variant.

Figures 4 and 5 are two schematic sectional views along lines 4-4 and 5-5 of Figures 3a and 3c.

FIGS. 6a and 6b are two schematic elevation views of the exterior and interior, respectively, of the second embodiment of the panel according to the invention (wood facing) in a second variant.

Figures 7 and 8 are two schematic sectional views along lines 7-7 and 8-8 of Figures 6a, 6b.

FIGS. 9a and 9b are two schematic elevation views respectively of the exterior and the interior of the second embodiment of the panel according to the invention (wood facing) in a third variant.

 Figure 10 is a sectional view along line 10-10 of Figure 1.

The invention relates to a panel mainly intended to constitute the leaf of an exterior door of a building capable of being subjected to different temperature and humidity conditions inside and outside, the temperature and temperature conditions. humidity outside is itself very variable.

Such a panel according to the invention comprises a one-piece carrying element 1 comprising a peripheral frame 2, an inner wall 3 rigidly associated with the frame 2; and closed cell foam 4 filling the space defined by the frame 2 and the wall 3, constituting a barrier of thermal insulation and watertightness whether in liquid state or in vapor state, participating in the rigidity of the element 1 and forming an outer skin 5.

This monobloc bearing element 1, thus formed, is substantially insensitive to variations in the conditions of external temperature and humidity.

Preferably, the interior wall 3 is a plywood of wood dried between 8 and 12% humidity and preferably at or around 10% humidity, more generally dried with a humidity level corresponding to the usual humidity level. of the interior ambiance.

It follows that the carrying element 1 is substantially non-deformable under the usual conditions of interior temperature and humidity.

The frame 2 is preferably made of solid wood or PVC and the foam 4 is preferably polyurethane.

The panel also preferably includes an external facing 6 whose function is to protect and hide the foam 4 and the frame 2. This facing 6 is optionally decorative or supports decorative elements. However, the exterior facing 6 does not directly participate in the stiffness or in the bearing character of the element 1.

The inner wall 3 is preferably a five-ply plywood 5 mm thick. The frame 2, made of solid wood, preferably has a thickness of the order of 30 to 50 min.

In the first embodiment (Figures 1 and 2), the outer facing 6 is constituted by a metal plate, rigidly associated with the frame and on the outer face of which can be attached decorative elements. The plate 6 is therefore applied against the outer skin 5 and can have on its edges returns 7 applying to the edges of the frame 2. The association of the plate 6 with the frame 2 is carried out by any appropriate means, in particular gluing, screwing Or other.

In a second preferred embodiment, illustrated in FIGS. 3 to 10, the exterior facing 6 is made of wood and consists of a plurality of wooden elements placed side by side,
In this second embodiment, internal inserts 9 are provided inlaid in the foam 4, the external faces 10 of which are coplanar with the skin 5.

The wooden elements 8 are therefore applied to the external faces 10 of the inserts 9 and the skin 5 of the foam t.

These inserts 9 mainly have a function of supporting the external facing 6 made up of a plurality of elements 8. On the other hand, these inserts 9 do not especially have a function of spacer between the internal wall and the external facing 6. C this is why, preferably, the inserts 9 are separated from the interior wall 3 and separated from the latter by the foam 4.

The inserts 9 generally extend parallel to the direction of the first two parts of the frame 2 and are rigidly associated at their two ends with the two second perpendicular parts thereof.

The inserts 9 are made of solid wood of the same nature as the frame 2.

In the first variant (Figure 3b) the inserts 9 are arranged horizontally, parallel to the top and bottom crosspieces and rigidly associated with the two lateral uprights of the frame 2. In the second and in the third variant (Figures 6b and 9b), the inserts 9 are placed vertically, parallel to the lateral uprights of the frame and rigidly associated with the high and low crosspieces.

In the first two variants (Figures 3a and 6a), the wooden elements 8 have the general shape of a blade.

In the third variant (Figure 9a), the wooden elements 8 have a general trapezoidal shape.

Dans'la first and third variant, the wooden elements 8 are made of solid wood and in the second variant, they are made of plywood.

In the first and third variants, the wooden elements are arranged perpendicular to the inserts 9 while in the second variant they are placed # parallel to these.

In the second variant (Figures 7 and 8), the wooden elements 8 are spaced transversely from one another.

The free space 11 between # two adjacent elements being masked by an insert 9, more precisely its external face 10. In the first and in the third variant, the wooden elements 8 are associated with each other continuously.

However, two wood elements 8 are assembled together without rigid attachment in order to allow a certain relative displacement resulting from dimensional variations, and themselves the consequence of variations in temperature and humidity conditions. To this end (Figure 4), two adjacent wooden elements 8 can be provided with surleursdhauts opposite a tongue 12 cooperating with a groove 13, a free space 14 being formed at the bottom of the groove 13 to allow this relative movement.

In the second and in the third variant, the wooden elements 8 are rigidly associated with the inserts 9 in their middle part and held against the external faces 10 of the inserts 9 with the possibility of sliding towards their external parts. These means allowing a certain sliding consist of a nail 15, the point 16 of which is driven into the insert 9 and passes through a wider hole 17 of the element 8 masked outwards by a sufficiently large head 18.

Thus, in the case of the first variant, the wooden elements 8 have the shape of a blade, are made of solid wood, are placed perpendicular to the inserts 9, themselves arranged horizontally. The wooden elements 8 are associated with each other continuously, completely hiding the inserts 9. The wooden elements 8 are associated so as to allow a certain relative displacement between them, in the horizontal direction, by virtue of a tongue assembly 12 and groove 13. For this purpose, the elements 8 are rigidly fixed in their middle part to the central insert 9.

 In the second variant (Ëiguresoa, 6b, 7 and 8), the wooden elements 8 have the shape of a blade. They are made of plywood and placed parallel to the inserts 9, being spaced transversely from one another to leave free spaces 11 of which the bottoms are formed by the outer faces 10 of said inserts 9.

The wooden elements 8 therefore overlap the inserts 9 and are associated with these by nails as described above.

In the case of the third variant (Figures 9a, 9b and 10), the wooden elements 8 have a trapezoid shape, are made of solid wood, are placed perpendicular to the inserts placed in the vertical direction and are associated with each other so continues with tongues 12 and grooves 13 to allow some relative movement.

The wooden elements 8 are associated with their end portions by nails such as 15.

The invention also relates to a method of producing a panel as just described.

In this process, a frame 2 is rigidly associated with an inner wall 3 and a closed enclosure is formed with the frame 2 and the inner wall 3 and foam is closed cell 4 placed therein.

 To this end, at least one injection hole and at least one vent hole are drilled in frame 2.

In the case of the first embodiment, a metal plate 6 constituting the external facing is applied to the frame 2, in order to form the closed enclosure.

And, this metal plate 6 is rigidly associated with the frame 2.

In the case of the second embodiment, a plastic film is applied to the frame 2 in order to form the closed enclosure. After injection and solidification of the foam 4, the film in question is removed.

Before fitting the film, the inserts 9 are rigidly associated with the frame and, after removal of the film, the outer facing 6 is placed.

The invention can be the subject of numerous other embodiments and variant details.

Claims (35)

1. Panel in particular for an exterior door capable of being subjected to different temperature and humidity conditions inside and outside, the temperature and humidity conditions outside being themselves variable over time in to a large extent, characterized by the fact that it comprises a one-piece carrying element (1) comprising a peripheral frame (2), an inner wall (3) rigidly associated with the frame (2); and closed cell foam (4) filling the space defined by the frame (2) and the wall (3) constituting a barrier of thermal insulation and watertightness (-in the liquid state or vapor), participating in the rigidity of the element (1) and forming an outer skin (5); this carrier element (1) thus being substantially insensitive to variations in external temperature and humidity conditions. 2. Panel according to claim l, characterized in that the inner wall (3) is a plywood of dried wood between 8 and 12% humidity, preferably at or about 10% humidity, so that the bearing element (1) is substantially non-deformable under the conditions of temperature and indoor-usual humidity. 3. Panel according to any one of claims 1 and 2, characterized in that the frame (2) is made of solid wood or PVC and or the foam 54) is  polyurethane. 4. Panel according to any one of claims 1 to 3, characterized in that it co # mport an outer facing (6) for protection and masking of the frame (2) and the foam (4), possibly decorative or decorative element support, this facing not constituting a substantial element of stiffening of the panel. 5. Panel according to any one of claims 1 to 4, characterized in that the inner wall (3) is a five-ply plywood of 5 mm-and the frame (2) has a thickness of the order of 30 to 50 mins. 6. Panel according to any one of claims 1 to 5, characterized in that the outer facing (6) is made of wood and consists of a plurality of elements (8) placed side by side. 7. Panel according to any one of claims 1 to 6, characterized in that it comprises interior inserts (9), encrusted in the foam (4), whose external faces (10) are coplanar with the skin ( 5) and on which the elements (8) of the external facing (6) are applied. 8. Panel according to any one of claims 1 to 7, characterized in that the inserts (9) are spaced from the inner wall (3) and separated from the latter by the foam (4). 9. Panel according to any one of claims 1 to 8, characterized in that the inserts (9) extend parallel to the direction of the first two parts of the frame and are rigidly associated at their two ends with the two second parts of that -this. 10. Panel according to any one of claims 1 to 9, characterized in that the inserts (9) are made of solid wood. 11. Panel according to any one of claims 1 to 10, characterized in that the elements (8) of the outer facing (6) have a blade shape. 12. Panel according to any one of claims 1 to 10, characterized in that the elements (8) of the outer facing (6) have a generally trapezoidal shape. 13. Panel according to any one of claims 1 to 12, characterized in that the elements (8) of the outer facing (6) are made of solid wood. 14. Panel according to any one of claims 1 to 12, characterized in that the elements (8) of the outer facing (6) are made of plywood. 15. Panel according to any one of claims 1 to 14, characterized in that the elements (8) of the outer facing (6) are placed parallel to the inserts (9). 16. Panel according to any one of claims 1 to 15, characterized in that the elements (8) of the outer facing (6) are placed perpendicular to the inserts (9). 17. Panel according to any one of claims 1 to 16, characterized in that the elements (8) of the outer facing (6) are spaced transversely from each other. 18. Panel according to claim 17, characterized in that the free space (11) between two adjacent elements (8) is closed by an insert (9). 19. Panel according to any one of claims 1 to 16, characterized in that the elements (8) of the outer facing (6) are associated with each other continuously. 20. Panel according to claim 19, characterized in that the elements (8) are assembled together without rigid attachment to allow a certain relative displacement resulting from variations in temperature and humidity conditions. 21. Panel according to any one of claims 19 and 20, characterized in that the: - elements (8) are assembled by tongue (12) and groove (13) with a free space (14) groove bottom (13 ). 22. Panel according to any one of claims 1 to 21, characterized in that the elements (8) are rigidly associated with the inserts (9) in their middle part and held against the inserts (9) with the possibility of sliding at less towards their extreme parts. 23. Panel according to claim 22, characterized in that the means perman # t this sliding consist of a nail (15) whose tip (16) is driven into the insert (9) and passes through a hole (17) wider of the element (8) masked by a head (18). 24. Panel according to any one of claims 1 to 11, 13, 16, 19 to 21, characterized in that the elements (8) are in the form of blades, of solid wood, placed perpendicular to the inserts (9), associated with each other continuously with the possibility of relative displacement and fixed to the inserts (9) in their middle part. 25. Panel according to any one of claims 1 to 11, 14, 15, # 7 and 18, 22 and 23, characterized in that the elements (8) have a. in the form of blades, are made of plywood, extend parallel to the inserts (9), are spaced transversely from each other and provide free spaces closed by the inserts (9), rigidly associated in their middle part with the inserts (9) 'and held against the inserts (9) with the possibility of axial sliding at their end parts. 26. Panel according to any one of claims 1 to 10, 12 and 13, 16, 19 to 23, characterized in that the elements- (8) are trapezoidal, solid wood, placed perpendicular to the inserts (9 ), associated with each other continuously with the possibility of ~ a certain relative displacement, associated with the inserts (9) with the possibility of sliding.  27. Panel according to any one of claims 1 to s; characterized by the fact that the external facing (6) is constituted by a metal plate rigidly associated with the frame, on the external face of which decorative elements can be fixed. 28. A method of producing a panel according to any one of claims 1 to 27, characterized in that a frame (2) is rigidly associated with an interior wall (3), it is formed with the frame (2 ) and the inner wall (3) a closed enclosure and injected into it, placed under press foam (4) with closed cells. 29. Method according to claim 28, characterized in that at least one  injection hole and at least one vent hole. 30. Method according to any one of the claims  28 and 29, characterized in that to form a  closed enclosure a plate is applied to the frame (2)  of metal constituting an external facing (6).  31. Method according to claim 30, characterized in that the metal plate is rigidly associated  (6) to the frame (2).  32. Method according to any one of the claims  28 and 29, characterized in that to form a closed enclosure, a plastic film is applied to the frame (2).  33. Method according to any one of claims 28, 29 and 32, characterized in that after injection and solidification of the foam (4), the film is removed.  34. Method according to any one of claims  28, 29, 32 and 33 #, characterized in that before the film is put in place, we associate rigidly # ie with the frame (2)  inserts (9).  35. Method according to any one of the claims  28, 29, 32 34, characterized in that after removal of the film, an outer facing (6) is placed.