Door leaf comprising at least one stone cover plate preferably for an interior door, and method for producing the same

Abstract

The invention relates to a door leaf, preferably for an interior door, and to a method for producing the same. The aim of the invention is to provide a door leaf for a double-wing door or revolving door, which is relatively light-weight and stable and which can be opened using normal force. The outer layer should consist of a layer that is break-proof, scratch-resistant and not susceptible to shocks and should be securely linked with the subject layer without complications. The use of water should be possible during the production of the door without damaging the door leaf. According to the invention, cover plates are glued onto the entire surface of both sides of an inner layer that has a suitable size for a double-wing door or revolving door. At least one of the one-piece cover plates consists of natural stone or artificial stone. During production of the door leaf the inner layer is foamed from high-resistance plastic foam in a mold and is removed from the mold after setting and then glued together with the cover plates. The cover plates are cut down to minimum thicknesses and/or ground down (calibrated). Alternatively, the inner layer is foamed from high-resistance plastic foam in a mold. The cover plates are first inserted in the mold at a distance to each other and then foamed to the inner layer. After setting, the door leaf is removed from the mold and the cover plates are cut down to minimum thicknesses and/or ground down (calibrated).

1 - 7 . (canceled)  
   
   
       8 . A procedure to manufacture a door leaf, comprising an inner layer that is first foamed of hard plastic and is bonded with or foamed onto at least one cover plate of natural or synthetic stone and wherein said cover plate is cut ground to a minimum thickness.  
   
   
       9 . The procedure as in  claim 8 , wherein the hard plastic inner layer is foamed in a mold and removed from the mold after hardening, and wherein the first cover plate of natural or synthetic stone is subsequently bonded to the inner layer and is then cut or ground to a minimum thickness.  
   
   
       10 . The procedure as in  claim 8 , wherein the inner layer of hard plastic foam is injected directly between two cover plates that were previously placed into a mold separated from each other and bonded to them, and wherein the first cover plate is made of natural or synthetic stone and is cut or ground to a minimum thickness after the inner layer has hardened and been removed from the mold.  
   
   
       11 . The procedure as in  claim 8 , wherein a fiberglass mat or a plastic or melanin epoxy plate is positioned between at least the first cover plate made of natural or synthetic stone and the inner layer.  
   
   
       12 . The procedure as in  claim 11 , wherein the fiberglass mat or a plastic or melanin epoxy plate is bonded to the surface of the first cover plate facing the inner layer, and wherein the first cover plate is subsequently bonded with or foamed onto the inner layer via the fiberglass mat or a plastic or melanin epoxy plate.  
   
   
       13 . The procedure as in  claim 8 , wherein at least one security element selected from the group consisting of plates, armoring, boxed profiles, locks, sensors, and cables or edge-protected profiles, are embedded in or attached to the foam.  
   
   
       14 . The procedure as in  claim 8 , wherein a second cover plate is also made of natural or synthetic stone that is opposite the first cover plate on the other side of the inner layer, and is processed in the same manner as the first cover plate.  
   
   
       15 . The procedure as in  claim 8 , wherein the cover plates made of natural or synthetic stone are cut or ground down to a thickness of 2 to 3 mm using water.  
   
   
       16 . The procedure as in  claim 8 , wherein the cover plates made of natural or synthetic stone have a final thickness of 8 to 20 mm after being bonded with the inner layer.  
   
   
       17 . A door leaf with an inner layer of hard plastic foam and two covering layers shaped as cover plates that are bonded on both sides flat to the inner layer or are foamed onto the inner layer, and wherein at least one cover plate is made of natural or synthetic stone and is monolithic, wherein the cover plates made of natural or synthetic stone have a initial thickness of 8 to 20 mm after being bonded to the inner layer, and are processed down to a final thickness of 2 to 3 mm after bonding.  
   
   
       18 . The door leaf as in  claim 17 , wherein both cover plates are made of natural or artificial stone, are made in one piece, and are bonded flat to the inner layer or are foamed onto the inner layer.  
   
   
       19 . The door leaf as in  claim 17 , wherein the inner layer is of polyurethane, and wherein the door leaf is configured for an interior door.  
   
   
       20 . The door leaf as in  claim 17 , wherein at least one security element selected from the group consisting of plates, armoring, boxed profiles, locks, sensors, and cables or edge-protected profiles, are embedded in or attached to the foam.  
   
   
       21 . The door leaf as in  claim 17 , wherein a fiberglass mat or a plastic or melanin epoxy plate is positioned between the inner layer and the cover plate.