Automated door assembly system and method

Patent metadata

Field	Value
Publication number	US-9555609-B2
Application number	US-201514675065-A
Country	US
Kind code	B2
Filing date	Mar 31, 2015
Priority date	Sep 16, 2003
Publication date	Jan 31, 2017
Grant date	Jan 31, 2017

Abstract

The present invention is directed to a method of making a door having first and second door facings and an internal doorframe. An interior side of a first facing is coated with quick acting adhesive. A frame is placed on the coated interior side about the periphery of the first facing. The frame is then coated with quick acting adhesive. An interior side of a second facing is placed on the coated frame. The facings and frame assembly are then compressed to form a door. The present invention also provides for an automated system of making the door.

First claim

I claim as follows:

1. A process for making doors, comprising the steps of:
a) removing a first door skin from a first plurality of stacked door skins having respective first exterior surfaces disposed face up and respective first interior surfaces disposed face down;
b) flipping the first door skin;
c) applying adhesive on at least a portion of the face-up first interior surface of the first door skin;
d) positioning a door frame onto the adhesive applied face-up first interior surface;
e) applying adhesive on at least a portion of an upwardly facing surface of the door frame;
f) removing a second door skin from a second plurality of stacked door skins having respective second exterior surfaces disposed face up and respective second interior surfaces disposed face down;
g) positioning the face-down interior surface of the second door skin in contact with the adhesive applied upwardly facing surface of the door frame to form a door assembly; and
h) compressing the door assembly.

2. The process of claim 1 , wherein steps a) to h) are performed at different stations.

3. The process of claim 1 , wherein steps c) or e) is accomplished by a spray coater or a roll coater.

4. The process of claim 1 , wherein the adhesive sets in step h).

5. The process of claim 1 , wherein steps a) and f) are accomplished by a first vacuum gantry and a second vacuum gantry, respectively.

6. The process of claim 1 , further comprising the steps of
i) trimming an edge of the door assembly; and
j) applying a coating to the exposed edges of the frame.

7. The process of claim 1 , wherein step c) is accomplished by coating the face-up first interior surface of the first door skin with a spray coater having multiple spray nozzles that apply a uniform coat of quick acting adhesive to the interior surface of the first door skin.

8. The process of claim 1 , wherein the first plurality of stacked door skins are stacked on a first pallet and the second plurality of stacked door skins are stacked on a second pallet.

9. The process of claim 8 , wherein said process further comprises the steps of repeating said step a) until the first pallet is empty and automatically sensing when the first pallet of is empty and removing the empty first pallet.

10. A process for making doors, comprising the steps of:
a) removing a first door skin from a first plurality of stacked door skins having respective first exterior surfaces disposed face up and respective first interior surfaces disposed face down;
b) flipping the first door skin;
c) applying adhesive on at least a portion of the face-up first interior surface of the first door skin;
d) positioning a door frame and a core component onto the adhesive applied face-up first interior surface;
e) applying adhesive on at least a portion of upwardly facing surfaces of the door frame and of the core component;
f) removing a second door skin from a second plurality of stacked door skins having respective second exterior surfaces disposed face up and respective second interior surfaces disposed face down;
g) positioning the face-down interior surface of the second door skin in contact with the adhesive applied upwardly facing surfaces of the door frame and of the core component to form a door assembly; and
h) compressing the door assembly.

11. The process of claim 10 , wherein steps a) to h) are performed at different stations.

12. The process of claim 10 , wherein steps c) or e) is accomplished by a spray coater or a roll coater.

13. The process of claim 10 , wherein the adhesive sets in step h).

14. The process of claim 10 , wherein steps a) and f) are accomplished by a first vacuum gantry and a second vacuum gantry, respectively.

15. The process of claim 10 , further comprising the steps of
i) trimming an edge of the door assembly; and
j) applying a coating to the exposed edges of the frame.

16. The process of claim 10 , wherein step c) is accomplished by coating the face-up first interior surface of the first door skin with a spray coater having multiple spray nozzles that apply a uniform coat of quick acting adhesive to the interior surface of the first door skin.

17. The process of claim 10 , wherein the first plurality of stacked door skins are stacked on a first pallet and the second plurality of stacked door skins are stacked on a second pallet.

18. The process of claim 17 , wherein said process further comprises the steps of repeating said step a) until the first pallet is empty and automatically sensing when the first pallet is empty and removing the empty first pallet.

Assignees

• Masonite Corp

Inventors

• Tyler Kenneth Charles

Classifications

• E06B2003/7049

  Specific panel characteristics · CPC title

• B32B37/18 Primary

  involving the assembly of discrete sheets or panels only · CPC title

• Y10T156/1744

  Means bringing discrete articles into assembled relationship · CPC title

• Y10T156/1089

  of discrete laminae to single face of additional lamina · CPC title

• B62D65/06 Primary

  the sub-units or components being doors, windows, openable roofs, lids, bonnets, or weather strips or seals therefor {(assembling sealing arrangements with vehicle parts, e.g. doors, windows B60J10/45)} · CPC title