Method and systems for the automated manufacture of composite doors

Abstract

Disclosed are automated processes and systems for the assembly of composite doors, and doors made using such processes and systems. The automated process may comprise a continuous series of steps allowing individual doors to be made in tandem, rather than in batch. The process may allow for the automation of individual steps such that the need for coordinating separate assembly steps may be substantially reduced.

1 . A system for the automated assembly of a composite door comprising: (a) a station for automated assembly of a frame for the door; (b) a device for automated application of an adhesive to at least one surface of the frame; (c) a station for automated positioning of the assembled frame to which adhesive has been applied on top of a first door skin; and (d) a device for positioning a second door skin on the upper surface of the frame. 
     
     
         2 . The system of  claim 1 , wherein the individual doors are made substantially in tandem rather than in batch, such that the assembly of an individual door is substantially independent of the assembly of any other door. 
     
     
         3 . The system of  claim 1 , further comprising a station comprising a press for pressing the first door skin and the second door skin to the frame to facilitate adhesion of the door skins to the frame. 
     
     
         4 . The system of  claim 1 , further comprising a robotic pick and place system for aligning the frame parts relative to each other. 
     
     
         5 . The system of  claim 4 , further comprising a device for automatically applying adhesive to at least one frame part at each corner of the frame. 
     
     
         6 . The system of  claim 4 , further comprising an adjustable clamp for clamping the frame together. 
     
     
         7 . The system of  claim 1 , wherein the adhesive applied to the surface of the frame causes a setting time of less than 5 minutes. 
     
     
         8 . The system of  claim 1 , wherein the adhesive applied to the surface of the frame causes a set time of about 10 to 90 seconds. 
     
     
         9 . The system of  claim 1 , wherein the adhesive applied to the surface of the frame comprises a reactive hot-melt PUR adhesive. 
     
     
         10 . The system of  claim 1 , further comprising a robotic pick and place system for positioning the frame on the first door skin. 
     
     
         11 . The system of  claim 1 , further comprising a robotic pick and place system for positioning at least one lock block on the upper surface of the first door skin. 
     
     
         12 . The system of  claim 1 , wherein the time to complete the assembly process for an individual door is 12 seconds or less. 
     
     
         13 . The system of  claim 1 , further comprising a device for applying an interior core material to the assembled frame. 
     
     
         14 . The system of  claim 13 , wherein the core material comprises a polyurethane foam. 
     
     
         15 . The system of  claim 14 , wherein the core comprises 20% or more polyurethane foam. 
     
     
         16 . The process of  claim 14 , wherein the core comprises 75% or more polyurethane foam. 
     
     
         17 . The system of  claim 13 , wherein the core material comprises an expandable mesh. 
     
     
         18 . The system of  claim 17 , wherein the core material comprises a cellulosic mesh comprising a honeycomb structure.