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Title:
METHOD FOR PROVIDING AN EDGE STRIP ALONG AT LEAST PART OF A DOOR AND A DOOR PROVIDED WITH AN EDGE STRIP
Document Type and Number:
WIPO Patent Application WO/2017/203043
Kind Code:
A1
Abstract:
The invention relates to a method for providing an edge strip along at least one edge face of a door, wherein a mold cavity is formed alongside said edge face, such that said edge face forms a side of the mold cavity, introducing a curable composition into said mold cavity, against the edge face and allowing the composition to cure inside the mold cavity, thereby attaching itself to said edge face and removing the door with the cured composition, wherein the cured composition forms a edge strip along said edge face.

Inventors:
BOLS, Rony (2320 Hoogstraten, 2320, BE)
DE WAAL, Oskar (2320 Hoogstraten, 2320, BE)
Application Number:
EP2017/062794
Publication Date:
November 30, 2017
Filing Date:
May 26, 2017
Export Citation:
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Assignee:
GROUP ERIBEL NV (Industrieweg 32, 2320 Hoogstraten, 2320, BE)
International Classes:
E06B3/82; E06B3/88; E06B7/23; E06B3/70
Foreign References:
GB2278140A1994-11-23
GB2276902A1994-10-12
AT9351U22007-08-15
Attorney, Agent or Firm:
JANSEN, C., M. (V.O, Carnegieplein 5, 2517 KJ Den Haag, 2517 KJ, NL)
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Claims:
Claims

1. Method for providing an edge strip along at least one edge face of a door, wherein a mold cavity is formed alongside said edge face, such that said edge face forms a side of the mold cavity, introducing a curable composition into said mold cavity, against the edge face and allowing the composition to cure inside the mold cavity, thereby attaching itself to said edge face and removing the door with the cured composition, wherein the cured composition forms an edge strip along said edge face.

2. Method according to claim 1, wherein a foaming or non foaming curable composition is used, such as PUR or silicon.

3. Method according to claim 1 or 2, wherein the mold cavity is formed by at least a bottom face extending in a length direction of the mold cavity, parallel to a length direction of the edge face and a side face extending upward from the bottom face, having a length direction

substantially parallel to the length direction of the bottom face, wherein an edge portion of a front or rear face of the door adjacent the edge face is placed against or preferably on the bottom face forming a side of the mold cavity opposite the side face, wherein the length direction of the bottom face is preferably substantially horizontal.

4. Method according to claim 3, wherein a closure is provided over the mold cavity, preferably by placing a closure on top of the other of the front and rear sides of the door and against or on the side face.

5. Method according to claim 4, wherein the closure is formed by or comprises a flexible strip which can be deformed elastically by an injector moved in the length direction of the bottom face during introduction of the curable composition into the mold cavity.

6. Method according to any one of the previous claims, wherein the side face extends at an angle relative to the bottom face, forming an angled face of the cured composition.

7. Method according to any one of the previous claims, wherein at least one artefact is mounted at least partly in and/or on the edge face of the door prior to allowing the composition to cure, preferably prior to forming the mold cavity along said edge face.

8. Method according to claim 7, wherein the at least one artefact is formed by or comprises a heat swellable material such as a heat swelling strip which is provided on said edge face or in a groove in said edge face, which is subsequently covered by the curable composition.

9. Method according to claim 7, wherein the artefact is a hinge leaf or attachment element of a paumelle, which is preferably introduced into said edge face, more preferably at an angle relative to said edge face or mounted against the edge face by at least said curable composition.

10. Method according to any one of the previous claims, wherein the artefact is or comprises a receptacle for receiving at least part of a hinge blade or attachment element of a paumelle or a lock or lock plate, sensor and/or PCB .

11. Method according to any one of the previous claims, wherein an edge strip is provided alongside at least three edge faces of the door.

12. Door formed using a method according to any one of the previous claims.

13. Door having an edge strip formed against an edge face of the door, preferably made using a method according to any one of the previous claims, wherein said edge strip has been made of a plastic or rubber material, especially a curable material, wherein an artefact is positioned at least partly on and/or in said edge face, covered at least partly by said edge strip.

14. Door according to claim 13, wherein the artefact is a hinge blade or a fastening element of a paumelle, extending outward from under said edge strip.

15. Door according to claim 14, wherein the hinge blade or fastening element has a longitudinal direction extending at an angle to said edge face, such that a connector for a further blade or part of the paumelle extends outside the edge face and the opposite end of the hinge blade or fastening element is embedded in the edge face, covered by said edge strip.

16. Door according to any one of claims 12 - 15, wherein the door has a frame and at least a front and rear covering plate, wherein the covering plates are mounted to opposite sides of the frame and the edge strip is formed against an edge face formed by at least the edge face of a frame part and edge faces of the front and rear covering plates.

17. Door according to any one of claims 12 - 16, wherein the door has a front surface and a rear surface, said front and rear surface extending substantially parallel to each other, and wherein the edge strip has an outer strip surface which extends at an angle different from 90 degrees relative to the front and rear surfaces.

18. Door according to any one of claims 12 - 17, wherein the edge strip has a substantially non rectangular cross sectional shape.

19. Door according to claim 18, wherein the edge strip has in cross section perpendicular to a longitudinal direction of the strip a body and two end portions extending from said body, such that the body and end portions substantially form a U-shape, the end portions lying in a front and rear face of the door, the body extending over an edge face of the door.

20. Door according to claim 18 or 19, wherein the cross section of the strip is generally trapezoid or parallelepiped shaped.

21. Mold system for forming an edge strip on at least one edge face of a door, comprising at least a door support table providing for or carrying a bottom face and a side face for a mold cavity, said side face extending upward from a support plane of the table and/or from the bottom face for the mold cavity and an injector for introducing a curable composition into a mold cavity formed by at least the bottom face, the side face and an edge face of a door supported on a rear or front face on said support table.

22. Mold system according to claim 21, wherein furthermore a closure strip is provided for closing off an open upper side of the mold cavity, preferably flexibly.

Description:
Title: Method for providing an edge strip along at least part of a door and a door provided with an edge strip The invention relates to a method for providing an edge strip along at least part of an edge of a door.

Doors in buildings are generally used for separating and closing off spaces such as rooms, corridors, halls and the like, for example for preventing illegal or undesired entry, preventing draft, sound reduction, passing of materials or the like. They are known to be used having blind edges which fit inside a door frame, leaving a slit like opening between the edges of the door and the door frame. This can lead to for example sound and air leaks, drafts, contamination and the like.

It is common to use sealing strips mounted in the door frame for closing off the gaps between the door and the door frame. These strips are however difficult to clean and maintain and are prone to damage.

It is furthermore known to provide edge strips, also referred to as edge slats or edgings to edge faces of a door. Such edge strips can have at least one of several functions, such as for example but not limited to reducing guarding the edge of the door from damage when open, for example protection from damage upon impact of carts, beds or the like.

US7886501 discloses a door with an edge strip mounted over an edge face of the door by a tongue and groove system. The edge strip has a generally U-shaped cross section with inwardly bent ends which fit into grooves in the opposite front and rear sides of the door. US6665997 discloses an edge construction for a door, wherein an edge strip is locked against an edge face of the door frame by providing grooves in sides of said edge strip into which locking edges of the from and rear cover panels of the door engage, locking the strip in position. US4386482 discloses a door having an edge strip made of a plastic resilient material, having a generally T-shaped cross section. A leg of the profile is forced into an annular groove in an edge face of the door.

It is furthermore known to manufacture a door having a wooden frame, on both sides covered by a cover plate, which along a longitudinal edge face is provided with a PUR edge strip, injection molded against the edge face in a mold dedicated to the door. In this door the edge face is provided with two parallel grooves, into which the PUR two component composite is injected in said mold cavity.

This known door has the disadvantage that dedicated mold cavities have to be provided for different types of doors, for example differing in thickness, in height and/or width and/or in edge face profile. Moreover different mold cavities have to be dedicated for turning doors and sliding doors. Moreover in this system the two component composite is injected into the mold cavity under relatively high pressure in order to fully fill the mold cavity, which requires a tight fit of the mold cavity to the sides of the door alongside the edge face. In general such method allows little freedom in design variations of a door or for attachments in or to the doors at or near the edge face.

A further disadvantage of this method of injection molding is that the flow path for the composite material is relatively long, especially for longitudinal edges of the door, which means that the minimum wall thickness is relatively large in order to allow complete filling of the mold cavity. Moreover this method requires a relatively high viscosity for the composite material, which limits the choice of material that can be used.

The present disclosure aims at providing a method for molding at least one edge strip onto an edge face of a door, which is an alternative to the known methods. An aim of the present disclosure is to provide for a method for manufacturing doors having an edge strip or molding an edge strip to a door which at least in part alleviates at least one of the

disadvantages of the prior art. In an aspect a method of this disclosure can be defined by using a mold cavity which is formed alongside an edge face of a door, such that said edge face forms a side of the mold cavity. A curable composition is

introduced into said mold cavity, against the edge face, preferably at low pressure, where after the composition to cure inside the mold cavity, thereby attaching itself to said edge face. The door is then removed from the mold cavity with the cured composition, wherein the cured composition forms an edge strip along said edge face. Contrary to the method known in the art the molding of the edge strip is not effectuated by injection molding in a closed mold, dedicated to one specific type of door, but using a mold filled at low pressure or gravity, allowing the composite material to flow into and through the mold, filling it to a desired degree.

In furtherance a method can be further defined in embodiments by the mold cavity being formed by at least a bottom face extending in a length direction of the mold cavity, parallel to a length direction of the edge face and a side face extending upward from the bottom face, having a length direction substantially parallel to the length direction of the bottom face. An edge portion of a front or rear face of the door adjacent the edge face is placed against or preferably on the bottom face forming a side of the mold cavity opposite the side face. The length direction of the bottom face is preferably substantially horizontal. The weight of the door thus presses the edge of a front or rear face of the door adjacent the relevant edge face of the door against and preferably onto the bottom face of the mold cavity to be formed, sealing enough to prevent the composite material to flow under said front or rear face.

In embodiments a closure can be provided over the mold cavity, preferably by placing a closure on top of the other of the front and rear sides of the door and against or on the side face. Thus the height of the mold cavity will be defined by the closure resting on the door and thus can easily be varied by the thickness of the relevant door. In embodiments the closure is formed by or comprise a flexible strip which can be deformed elastically by an injector moved in the length direction of the bottom face during introduction of the curable composition into the mold cavity.

In embodiments a mold cavity can be used having an open upper side. The level to which the curable composite material is allowed to fill the mold cavity will thereby be defined by the thickness of the door and the expansion of the curable composition during curing.

The side face of the mold cavity may extend substantially perpendicular to the bottom face or at an angle, for example an angle between 80 and 90 degrees. The angle of the side face may be adjustable. The side face of the mold cavity can in embodiments extend parallel to the edge face of the door, for forming an edge strip with substantially parallel opposite faces, or can extend at an angle relative to said edge face, for providing an edge strip having non parallel opposite faces. Also other shapes for the edge strip can be obtained, like curved, undulating or other e.g.

goniometric shapes in cross section.

In embodiments at least one artefact can be mounted at least partly in and/or on the edge face of the door prior to allowing the

composition to cure, preferably prior to forming the mold cavity along said edge face. Such artefact can for example be a leaf of a hinge, or can be a receptacle for receiving a further artefact, such as for example a leaf of a hinge. In embodiments an artefact such as a leaf of a hinge can be held against the edge face of the door, and will then be fixed to the door by the curable composition curing over and/or through said artefact. To that end for example openings can be provided in such hinge leaf through which the composition can flow. Preferably the curable composition will flow at least between part of artefact and the edge face directly adjacent to it, as well as over the artefact at the opposite side, enclosing the relevant part of the artefact such as a hinge leaf. In embodiments the artefact can be or include other features, for example a closure plate, sensor, lock or the like.

In embodiments an intumescent material can be provided between the edge face and the edge strip and/or in the edge strip, which will swell when exposed to excessive heat, and will push at least part of the edge strip outward from the edge face, for example in case of a fire, increasing fire retarding properties of the door.

The present disclosure is further directed to a door having an edge strip molded against an edge face thereof using a curable composite material, especially a door made using a method as disclosed.

In embodiments an artefact is positioned at least partly on and/or in said edge face, covered at least partly by said edge strip. Such artefact can for example be a hinge leaf or attachment element of a paumelle, a receptacle for such hinge leaf or for an attachment element of a paumelle. Alternatively or additionally a strip of an intumescent material can be provided in the edge strip and/or between the edge strip and the edge face.

In embodiments the edge strip can have substantially the same thickness over its width, for example a thickness of between 4 and 20 mm, preferably at least about 6 to 7 mm. In embodiments the edge strip can have substantially a rectangle or parallelogram as cross section. In embodiments the cross section can be substantially a trapezium.

In embodiments the edge strip can be provided over a stepped edge face. In embodiments the edge strip can have a body and two end portions extending from said body, such that the body and end portions substantially form a U-shape. The end portions are positioned in a front and rear face of the door, the body extending over an edge face of the door.

In a further aspect the disclosure is directed to a mold system for forming an edge strip on at least one edge face of a door, comprising at least a door support table providing for or carrying a bottom face and a side face for a mold cavity. Said side face extends upward from a support plane of the table and/or from the bottom face for the mold cavity. An injector is provided for introducing a curable composition into a mold cavity formed by at least the bottom face, the side face and an edge face of a door supported on a rear or front face on said support table. The injector is preferably a low pressure or gravity flow based injector. The injector can for example be a movable injector which can during injection be moved in a longitudinal direction of the mold cavity. Additionally or alternatively the injector can have multiple injection points spaced apart in said longitudinal direction, for

simultaneously or serially introducing the curable composition into the mold cavity.

Methods, doors and mold systems of the present disclosure will be further described, by way of example only, with reference to the drawings, which are only shown in elucidation and should not be understood as limiting the disclosure in any way. In the drawings:

Fig. 1A and B schematically shows in top view and side view a molding system for molding an edge strip to an edge face of a door;

Fig. 1C schematically shows in side view part of a system of the disclosure with part of a door showing;

Fig. 2 shows schematically part of a molding system, where doors having different thicknesses are schematically shown;

Fig. 3 shows schematically part of a molding system, wherein a cover element is provided over a mold cavity;

Fig. 4 shows in perspective view schematically a part of a door with an edge strip and an artefact, here part of a hinge, mounted on the door;

Fig. 5 and 5A schematically a front side of a door, and a cross sectional view of said door along the line B - B in fig. 5;

Fig. 6 and 6A schematically a rear side of a door, and a cross sectional view of said door along the line A - A in fig. 6; Fig. 7 schematically shows an alternative embodiment, in a cross section corresponding to fig. 5A, with an alternatively shaped edge strip having a substantially U-shaped cross section;

Fig. 8 schematically shows a further alternative embodiment, in a cross section corresponding to fig. 5A, with an alternatively shaped edge strip, enclosing a heat swellable or intumescent material based strip;

Fig. 9 schematically shows a further alternative embodiment, in a cross section corresponding to fig. 5A, with an alternatively shaped edge strip, having a substantially parallelogram shaped cross section;

Fig. 10 schematically shows an alternative embodiment, in a cross section corresponding to fig. 6A, with an alternatively shaped edge strip and an artefact, here shown as a leaf of a hinge, mounted to the door by the edge strip;

Fig. 11 schematically shows an alternative embodiment, in a cross section corresponding to fig. 6A, with an alternatively shaped edge strip and an artefact, here shown as a receptacle for a leaf of a hinge, mounted to the door and/or covered by the edge strip;

Fig. 12 schematically shows a part of a door, in perspective view, in cross section, similar to that of fig. 10, mounted in a door frame; and

Fig. 13 in cross sectional top view a part of a door and doorframe of fig. 12.

In this description different embodiments of methods, doors and parts thereof, as well as molding systems suitable for such production are disclosed and described by way of example only. In these embodiments the same or similar elements have the same or similar reference signs.

Combinations of elements of the embodiments shown are also considered to have been disclosed herein.

In this description in general doors will be discussed and disclosed to be used in buildings, such as but not limited to utility buildings, homes and the like. Such doors can be hinged doors as well as sliding doors. The doors can be of any suitable construction, such as for example but not limited to solid core doors or doors having a frame with front and rear cover, for example hollow or filled with a filler material. The frame can in a conventional manner be made of wood, for example pine. The cover plates can be made of any suitable material, such as but not limited to wood, plastic, board, plasticized board. The cover plates can be made of the same or different materials at the front and rear side of the door. A door of the present disclosure can also be a solid door, for example made of wood and/or resin, as is for example schematically shown in fig. 12 and 13, or of any other suitable material, such as but not limited to metal or combinations of such materials.

In the drawings doors are shown in general as hinging door, supported in a door frame by suitable hinges, such as leaf hinges, paumelles or any other such means known in the art. However a door of the present disclosure can also be a sliding door, supported in a suitable frame.

As artefacts mounted to and/or in a door in the drawings hinges are shown, especially leaf hinges or leafs of a hinge or paumelle, and strips of swelling materials or intumescent material. However also other artefacts suitable for use in a door can be mounted in, behind and/or by a curable composite material as disclosed, such as for example but not limited to lock part, closure elements, sensors such as magnetic or electrical sensors, contact sensors, mountings for closure springs or any such elements or devices.

In this description reference is made to curable composite materials for use in the forming of edge strips to doors. Such curable materials are well known in the art, and can for example be based on or formed by PUR (polyurethane), which may be a non foaming or

substantially non foaming PUR, having sufficient elasticity to withstand impact from for example carts, beds, wheelchairs or the like bumping against such edge strip. However also other such curable composite materials could be used, including but not limited to composites which are curable by chemical reaction directly between components thereof of for example by influence of external factors, such as but not limited to heating or radiation, such as radiation by light. In general preferably materials are used which cure by cross linking polymer chains, facilitated by energy and/or catalysts at chemical active sites, which may be unsaturated sites or epoxy sites, for example, linking into a rigid, three-dimensional structure. The cured material can have a foamy structure or a substantially massif, elastically structure. The material may be plastic or rubber suitable to be formed in an open or closed mold, wherein the basic material or materials can be introduced into a mold substantially at ambient pressure, for example by gravitational flow. Alternative to PUR for example silicon rubber could be used. Composite material should in this disclosure be understood as meaning at least a material or combination of materials having at least one component reactive with at least one other component or with energy introduced externally for curing the material or at least for initiating such curing.

In this reference low pressure should be understood as pressures sufficient to allow a composite material to flow into a mold and sufficiently fill said mold before the material is cured. The composite material can be pumped to an injector or otherwise fed, for example for gravity flow into the mold. Pressures necessary will depend largely on the viscosity of the composite material when being fed and may be below 2 bar absolute, for example below 1.5 bar, such as below 1.2 bar. Pressures can be used between about 1 and 1.2 bar, such as gravity induced pressure. Obviously other pressures can be used, especially higher pressures, as long as the material is not pressed between the bottom face of the mold cavity and the surface of the door resting on or against the said bottom surface of the mold cavity. A sealing material can be provided at the table or bottom surface, such as a rubber, PU or silicone seal, to seal off any gap between said surfaces. In embodiments the bottom surface and side surfaces of the mold cavity can be made of or covered by a plastic or rubber material, such as but not limited silicone based material, for easy release of the edge strip and for proper sealing of the cavity against the door. Additionally or alternatively a release agent could be used for easy release of the edge strip from mold surfaces.

In this description reference to top, bottom, up, down, front and rear will be used in their common meaning, unless specifically defined otherwise. In reference to a door 4 this will be considered with reference to a door in a use position, supported vertically in a door frame, wherein the door 4 has a front face 10 and an opposite rear face 11, defining a thickness 12 of the door 4 between said front and rear faces 10, 11. For the sake of convenience for a hinging door 4 the front face 11 of the door 4 shall in this disclosure be referred to as a face at the side of the door 4 at which the hinging pin 35 of the hinge or hinges 33 is positioned (fig. 4, 6, 10 - 13). This means that for a person standing in front of the door the front face will hinge toward him or her when opening the door. The door will have two side edge faces 15, 16, an upper edge face 17 and a bottom edge face 18, as indicated in fig. 1A for a door lying down, in fig. 1A for example shown as lying on its rear face 11.

Fig. 1A and B schematically show a system 1 for forming an edge strip 2 along at least one edge face 15 - 18 of a door 4, as shown for example in fig. 4— 13. In this embodiment, which is shown by way of example only, the system 1 comprises a door support table 5 providing for or carrying a bottom face 6 and a side face 7 for a mold cavity 8. The support table 5 has a substantially flat, substantially horizontal top 20 forming a support plane on which a door 4 can be supported, lying flat on a front or rear face 10, 11 thereof. The top 20 can be a closed top or can be formed having openings or for example be formed by a series of support beams extending parallel to each other, for example parallel to or perpendicular to a longitudinal direction L of the side face 7, for example for reducing friction between the door 4 and the table 5 when sliding a door 4 into or out of position. To that end also rollers, belts or chains can be provided in said table 5, or other suitable such means. Along a side 21 of the table 5 the bottom face 6 for a mold 8 is provided, by an edge portion of the top 20 and/or by a strip of suitable material provided on and/or in said top 20, for example a metal strip, as schematically shown in fig. 1C. The bottom face 6 is preferably flat, but may also have a contour or profile desirable for an edge strip to be formed.

The side face 7 extends upward from the support plane 20 of the table 5 and/or from the bottom face 6 for the mold cavity 8. The bottom face 6 and side face 7 may be integrally formed as a profile having a

substantially L-shaped cross section, for example a metal profile. The side face 7 extends at an angle a relative to the bottom face 6, which angle can for example be 90 degrees for forming an edge strip 2 having a side face 22 extending substantially perpendicular to the front and rear faces 10, 11 of the door 4. Alternatively the angle may be different from 90 degrees for forming an edge strip 2 having a side face 22 extending at an angle relative to the front and rear faces 10, 11 of the door 4. The angle can for example be between 80 and 100 degrees, for example between 80 and 90 degrees, such as for example between 85 and 89 degrees. In embodiments the angle can be about 87 degrees. In embodiments the angle a can be adjustable.

The bottom face 6 and the side face 7 have parallel longitudinal directions L.

In fig. 1C in side view part of the system is shown, showing an edge portion 21 of the table 5 with a strip 3 forming a bottom face 6 and side face 7, said strip supported by the table 5. The top 20 of the table in this embodiment is even with an upper surface of the bottom face 6. This means that a door 4 can rest flat on the top 20 and on the bottom face 6. This means that the distance D between the relevant edge face 15 - 18 of the door 4 and the side face 7 opposite it does not have to be fixed, allowing different thicknesses of edge strips 2 to be formed. Obviously means can be provided for defining the distance D, for example by appropriate stops on the table or a rail at the opposite edge face of the door for the door to be positioned against.

As can be seen in fig. 1 - 3, a door 4 can be placed on the support 20 of the table, having a relevant edge face 15 - 18 of the door facing the side face 7. In fig. 1 by way of example the relevant edge face is shown as a side edge face 15. The edge face 15 can be substantially flat, or can be profiled. The edge face can extend substantially perpendicular to the front and rear faces 10, 11 or can extend at an angle β to said faces, for example an angle between 80 and 100 degrees, for example between 80 and 90 degrees, such as for example between 85 and 89 degrees. In embodiments the angle can be about 87 degrees. The door 4 is placed with an edge portion 23 of the relevant one of the front or rear faces 10, 11 on the bottom face 6, spaced apart from the side face 7 over a distance D which corresponds with a thickness T of the edge strip 2 at said face 10, 11. Thus the relevant edge face 15 of the door 4 forms a side of the mold cavity 8, further defined by the free part of the bottom face 6 and the side face 7. Stops 24A and 24B may be provided at either longitudinal end of the mold cavity 8, for closing off said ends. These stops 24A, 24B may both be movable, or one can be in a fixed position, the other one movable in longitudinal direction towards and away from the fixed stop, for adjusting a length of the cavity 8 to the length of the door, which is in use the height H of the door measured in the direction between the top and bottom edge faces 17, 18, or the width W of the door, measured in a direction perpendicular to the height H, between edge faces 15, 16.

As can be seen in e.g. fig. 2 and 3 the mold cavity 8 is in general an open trough or channel between the side face 7 and the door 4, of which the relevant depth K is defined by the thickness 12 of the door 4. Different doors 4 can be accommodated, having different thicknesses 12, as schematically shown in fig. 2 by thicknesses 12', 12" and 12"', by way of example only. As can be seen in fig. 1 - 3, the edge face 7 has a vertical height H 7 which is preferably higher than the largest thickness 12 of doors 4 to be processes in said system 1, and for example has a height H 7 of more than 4 cm, preferably more than 6 cm and for example 8 cm or more. In embodiments the side face 7 can be adjustable in height or can be exchangeable for side faces having different heights.

An injector 25 is provided for introducing a curable composition into the mold cavity 8 formed by at least the bottom face 6, the side face 7 and an edge face 15 - 18 of a door 4 supported on a rear or front face 10, 11 on said support table 5. The injector 25 is designed to allow filling the mold cavity at relatively low pressure, such as by gravitational flow. The pressure has to be sufficient to allow the composite material to flow into the mold cavity and fill it to a desired level, just up to or below the upper edge 26 of the relevant edge face 15 - 18 of the door 4. In embodiments a composite material can be used which expands during curing, in which case the level of filling the mold cavity will preferably be chosen such that after curing the mold cavity is filled up to at least said upper edge 26. In embodiments a composite material is used which does at least substantially not foam during molding and/or curing, such that a substantially massif edge strip is formed. In other embodiments a material is used which at least after curing has a foamed structure.

By using a mold cavity and injector at relatively low pressure, such as gravity flow pressure no additional seals are necessary for closing off the cavity 8 against the door 4, especially between the bottom face 6 and the relevant edge face 16 - 18. If desired the door 4 can during filling and/or curing be pressed down onto the bottom face 6, should the weight of the door 4 be insufficient. Surprisingly it has been found that filling the cavity 8 at such low pressures will still lead to a thorough connecting between the door 4 and the edge strip 2 after curing, even when the edge face 16 - 18 is substantially flat and smooth. The composite material is preferably sufficiently flowable to fill the cavity quickly enough to prevent undesired curing before a desired filling level is reached. The injector 25 has at least one injector opening 27 for allowing the curable composite to flow into the cavity 8, preferably through an open top side of the cavity 8. In

embodiments the injector 25 or at least the or each injector opening 27 can be moved along the mold cavity 8 in the longitudinal direction L, during introducing the curable composite. Alternatively or additionally several injection openings 27 can be provided along the length of the cavity 8, as indicated in fig. 1A, for introducing material into the cavity at different positions simultaneously or sequentially. The composite material can be premixed or can be mixed in the cavity. Surprisingly it has been found that using a method according to the description will allow the use of materials having a relatively high viscosity, especially by using an injector which is movable along the cavity during filling and/or having multiple injection openings along the length of the cavity. Moreover it has been found that relatively thin edge strips or at least edge strips having relatively thin portions can be made, for example having a thickness of less than 7 mm, such as for example less than 5 mm. In examples edge strips can be formed having a minimum thickness of for example about 3 to 4 mm or less. Even over a full height of a door, such as for edge strips having a length L of over 2 meters.

In this description relatively low pressure can comprise pressures below 2 bar absolute, for example below 1.5 bar, such as below 1.2 bar.

Pressures can be used between about 1 and 1.2 bar, such as gravity induced pressure.

In this description materials can be used having any suitable viscosity. For example materials can be used having a relatively high viscosity, for example a viscosity of above 1000 mPa/s, such as for example a viscosity of above 3000 mPa/s. Materials can be used having a viscosity of 5000 mPa/s or more, for example 7000 mPa or more. However also less viscous materials can be used. Having a higher viscosity may have the advantage that sealing between the door 4 and the bottom face 6 of the mold cavity 8 and/or the stops 24 has to be less tight. Having a higher viscosity may further have the advantage that during curing less crimp will occur, resulting in a better fitting edge strip. For example the surfaces 22, 22A of the edge strip 2 may be flatter and/or more even to the front and/or rears surfaces 10, 11 of the door 4.

After forming an edge strip along an edge face of a door, the door can be rotated over for example 90 or 180 degrees for forming a further edge strip along a further edge face of the door. The length of the cavity can in such cases easily be adjusted to the next edge face, by replacing at least one stop 24A, 24B.

When using an open cavity, as shown in fig. 2, an edge strip 2 formed can have one side face 22A, especially a face 22A next to one of the front or rear faces 10, 11 of the door, which may be slightly irregular and may require finishing, for example by machining, if for example a smoother face is required.

In fig. 3 an alternative embodiment is shown in which a closure 28 is provided over the top of the cavity 8. The closure 28 can for example be a strip 29 which can be pressed onto an edge portion 30 of the face 10, 11 of the door 4 facing upward, which strip 29 is further held against the side face 7. A suitable device 31 can be used, for example a pneumatic or hydraulic cylinder assembly, for moving the closure 28. Preferably the closure 28 is movable such that it can accommodate different thicknesses 12 of doors 4. The closure 28 can be rigid or can be flexible. In fig. 3 by way of example an injector 25 is shown which extends into the mold cavity 8 from an end, especially through a stop 24, above the bottom face 6 and below the closure 28. The injector 25 may be retractable in the length direction during filling of the cavity. Alternatively different injector openings 27 could be provided along the length direction of the mold cavity. Alternatively the injector 25 can have the inlet opening or openings 27 extending over the top of the side face 7, wherein the cover 28 may be flexible such that it can be pushed aside elastically for allowing the injector 25, 27 to pass into and along the cavity 8.

Fig. 4 - 6 shows an embodiment of a door 4 with an edge strip 2, which can have been manufactured using a system of fig. 1— 3. In this embodiment an artefact 32 is mounted to the door 4. In this example the artefact 32 is a hinge 33, more specifically a leaf hinge or paumelle.

Obviously several such hinges 33 can be distributed along a longitudinal edge face 15 of the door 4, in a known orientation for supporting the door 4 hinged in a door frame. In this embodiment a regular hinge 33 is used, by way of example, having two hinge leaves 34 hingedly connected through a hinge pin 35 extending through knuckels 36 provided by the leaves 34. In this embodiment a first one of the leaves 34 is mounted into the edge face 15 of the door in an angled position relative to the edge face 15, i.e. not perpendicular to the front face 10 of the door 4. To this end an indentation 37 is provided in the edge face 15, extending from an edge 26 of the door 4 between the front face 10 and the edge face 15, sloping into the edge face 15. This allows the knot 38 formed by the knuckels 36 and hinge pin 35 to extend partly next to the edge strip 2, the leaf 34 in the indentation 37 being covered by the edge strip 2. Whereas the other of the leaves 34 can extend substantially parallel to an outer face or side face 22 of the strip 2 opposite said edge face 15.

As can be seen in fig. 5 and, especially, the cross section B - B thereof, the edge strip 2 can have a generally rectangular cross section, defined by the thickness 12 of the door and the thickness T of the strip as defined by the width D of the cavity 8. The thickness can for example be between 4 and 15 mm, such as for example about 7 mm. This dimensions are clearly given by way of example only. In fig. 6 a front and cross sectional view (section A— A) are shown of part of the door 4 comprising a hinge 33. As can be seen in the cross section A - A screws 39 can be used for screwing the hinge 33 into the door 4 prior to providing the edge strip. The screws 39 are shown here extending substantially perpendicularly to the leaf 34.

However, they could also be screwed in a different direction, for example substantially parallel to the front and rear faces 10, 11. In this embodiment the hinge 33 can be a standard hinge, having leaves 34 parallel to each other and close to each other when closed. By angling the leaf 34 mounted to the door 4 pivot pin 35 can nevertheless be positioned substantially in the plane of the edge or side face 22 of the edge strip 2.

Preferably the door 4 is provided with the edge strip 2 in a system of the disclosure, as for example shown in fig. 1— 3, wherein the front face 10 and the knots 38 extend above said face 10 and thus above the upper side of the cavity 8, free from the side face 7. This means that after forming the edge strip 2 no machining is necessary for mounting the hinges to the door 4. Moreover the hinge leaf 34 is properly covered by the edge strip 2, without gaps or crevices, which increases cleanability and hygiene. The more so since also the screws are covered.

Surprisingly it has been found that forming the edge strip 2 against an edge face 15 - 18 directly, especially using a method as disclosed, screws or similar means for mounting may not be necessary. The edge strip 2 can be sufficient for properly fixing the hinges 33 to the door 4.

Fig. 7 shows an alternative embodiment of a door 4, or at least part thereof, in cross section, similar to that of fig. 5, showing an alternative edge strip 2. In this embodiment the edge strip has a substantially U-shaped cross section, formed by at least a body portion 2A and two end portions 2B extending from said body 2A. The end portions 2B lie in a front and rear face 10, 11 of the door, the body 2A extending over a relevant edge face 15 - 18 of the door 4. In the embodiment of fig. 7 the edge face 15 - 18 has been made stepped, for example by machining edges 10A, 11A thereof or by using cover plates IOC, 11C which are slightly shorter than the frame 41 (fig. 9). The edges 10A, 11A thus provided for spaces in which the end portions 2B can be extended. An edge strip 2 of fig. 7 requires less material than a solid edge strip having a thickness T over the full cross section similar to the length L2A of the end portions 2B. Surprisingly it has been found that such edge strip can very suitably be made in a mold cavity as disclosed, especially also using low pressure feeding of the composite material, even though one of the end portions 2B will be formed in an undercut portion of such mold cavity 8. Without wanting to be bound to any theory, it appears that since less material is needed, curing, which may be exothermic, may provide less heat in the material, preventing overheating of the material(s) of the door. Especially this may prevent undesired forming of moisture or gas in the cavity 8. This may further reduce the production time. At the corners of the door 4 where edge faces 15 - 18 meet, the edge strips 2 meeting may have a different cross section, for example rectangular, and full.

Fig. 8 shows a cross section of part of a door, similar to fig. 7, in which however between the substantially U-shaped edge strip 2 and the edge face (e.g. 15) a strip 40 is enclosed, made of or at least using a intumescent material. This strip 40 will, when heated above a certain temperature, swell up, pushing the edge strip or at least part thereof outward from the edge face, closing off any slit between the door 4 and a frame 41 in which it is mounted. This is for example suitable for fire retarding, smoke transfer prevention or the like when a fire would happen at one side of the door 4. During forming the edge strip the temperature can easily be kept well below the intumescent temperature.

Fig. 9 shows in cross section part of a door 4 with an edge strip 2 which has a non-rectangular shape. In this embodiment the edge face 15 - 18 formed by a side of a frame slat 42 of the frame of the door has been angled, for example at an angle of about 87 degrees, where after an edge strip 2 has been formed against it, which has a substantially parallelepiped shape. Alternatively the edge face 15 - 18 could be straight, i.e.

perpendicular to the front and rear faces 10, 11, the edge strip 2 having a trapezium shaped cross section in order to obtain a slanted outer surface 22. Which can be advantageous for proper closing of the door 4. Obviously many other shapes of the edge strip would be possible, for example by providing a profiled side face 7 and/or bottom face 6 and/or closure 28, if provided for, of the mold cavity 8.

Fig. 10 shows in cross section an alternative embodiment of part of a door 4, in which a hinge 33 is provided having again two leaves 34 and knuckels 36 with a hinge pin 35. In this embodiment the hinge 33 however has at least one leaf 34 which is non-flat. More specifically the one leaf 34 connected to the door is substantially straight, whereas the other leaf 34 is bent or curved, such that an attachment part 34A of said leaf 34 is parallel with the edge face 15 of the door when the door is closed, in which position the said part 34A is spaced apart from the other leaf 34 over a distance slightly larger than the thickness T of the edge strip 2. The one leaf 34 mounted against the edge face 15 is provided with a series of openings, preferably an array of rows and columns of such openings 44, such that composite material M prior to curing can flow through said openings 44 against the edge face 15. In the embodiment shown the leaf 34 is provided with notches or such distance elements 44A keeping the face of the leaf facing the edge face 15 slightly apart from the edge face 15. The composite material can thus flow in between them which will adhere the leaf 34 even more solidly to the edge face 15 after curing of the material. Alternatively or additionally the leaf 34 can be connected to the door in a different manner, for example by screws or staples.

By using a hinge 33 as disclosed, the hinge leaf 34 can be connected to the edge face 15 in an easy manner, whereas the knot 38 stays away from the side face 7 when the door 4 is placed on the table 5 for forming the edge strip 2 along the edge face 15, i.e. the knot 38 does not extend beyond the plane P defined by the side face 22 of the edge strip 2.

Fig. 11 shows again a cross section of a part of a door 4, similar to fig. 10, wherein a hinge 33 is shown similar to that of fig. 10. This hinge 33 is however shown separate from the door 4. In this embodiment between the edge strip 2 and the edge face 15 of the door an artefact 32 is enclosed, in the shape of a pocket or receptacle 45 for receiving at least part of a hinge blade 34 or attachment element of a paumelle. In this embodiment the receptacle 45 is formed by a block 46 comprising a slit 47 extending into said block 46 from a front 10 of the door 4, in which a hinge blade 34 fits snugly. The hinge blade 34 can be fixed inside the block 46, preferably after forming the edge strip 2 on the edge face 15. This has the advantage that during forming of the edge strip 2 the hinge 33 can be separate from the door 4, leaving a substantially flat and smooth front face 10 of the door 4, which will allow the door 4 to be placed on either face 10, 11. Moreover this will allow the edge strip 2 to be machined, such as sanded after curing, in order to finish the side 22A of the edge strip 2 formed at an open side of the mold cavity 8, if no closure is used. Moreover this will more easily allow a cover or closure 28 to be used since the knots 38 of hinges 33 will not interfere.

Further more it will allow separate transport of the door 4 and the hinges 33. The hinge leaf 34 can for example be press fit, glued, bonded in the block 46 by a resin or mounted in any other suitable manner. For example a locking mechanism can be provided inside the block 46, for example a spring biased element which can lock in one or more suitable openings in the leaf 34 when forced into said block 46, such that it cannot be removed or move inside the block any more. Combinations are obviously also possible.

Furthermore a screw or bold could be provided through the door or the edge strip, locking the leaf inside the block.

Fig. 12 and 13 show in perspective view and partial cross section part of a door with a hinge 33 and edge strip 2, similar to that of fig. 11. In this embodiment the hinge 33 is shown connected with a leaf 34 to a door frame 50, which in this embodiment, by way of example only, is shown as a metal door frame 50. In this embodiment a mounting part 34A of the relevant leaf 34 is connected to at least one knuckle 36 by an angled connecting part 34B, and is designed such that in the closed position as shown in fig. 12 and 13 the knot 38 is substantially positioned next to the edge strip 2. The edge strip 2 in this embodiment has an end face or surface 22 extending at an angle γ, for example of about 3 to 5 degrees relative to the end face 15 of the door, such that closest to the knot 38 a slit 51 between said surface 22 and the door frame 50 is smaller than at the opposite end. The knot 38 is positioned just next to an imaginary plane P defined by said surface 22. When manufactured in a system 1 as described said plane coincides with the end surface 7 of the mold, when the door is placed on the table 5 by its rear face 11. This means that the knot 38 does not interfere with said end face 7, irrespective of the thickness 12 of the door 4.

In the embodiment of fig 12 and 13 the bent leaf 34 has the mounting part 34A extending through a slit 52 in the door frame 50, such that it can be bolted to the door frame by bolts or screws extending through the door frame 50, or in any other suitable manner. This can provide for a substantially smooth outer surface of the door frame facing the door 4, which is easy to clean and maintain. The other leaf 34 can be a standard leaf or for example a leaf according to fig. 10, and can be mounted to the door in any suitable way, such as by screws, by the edge strip and/or in a provision as disclosed in or similar to that of fig. 11.

The present invention is by no means limited to the embodiments as disclosed in this description. Many alternatives are possible, including but not limited to any combination of elements and features of the disclosed embodiments. For example other type of hinges can be used, such as paumelles having leaves or other attachment means, such as but not limited bolts. Injector 25 can have multiple injector openings, as schematically shown in fig. 1A by thin lines 25A. In embodiments fixed stops can be provide defining fixed size mold cavities, in which for each edge face a different mold cavity can be used. However preferably flexible such cavities are used. In stead of or additional to hinges other artefacts can be provided in a door, including but not limited to locks, bolts, sensors, PCB's and the like. For example a lock can be inserted in an edge face 16 opposite that receiving hinges 33, which can extend into the mold cavity when forming the edge strip 2, and can for example abut the side face 7 of the mold cavity, protecting the lock from composite material flowing into it. The low pressure insertion of the material will make this easily possible without the necessity of additional closures. The edge strip 2 can then be formed against a housing part of the lock, again preventing crevices or the like and thus making maintenance and cleaning easy. The table for supporting the door during feeding and curing of the material can have a different position. For example substantially vertical, having a bottom face 6 and a side face 7 provided on opposite sides 10, 11 of the door 4 and the relevant edge face 15 - 18 against which an edge strip is to be formed facing upward. Also the table 5 can be at a slight angle for having the door slide into position supported by gravity. These and similar amendments are considered to have been covered by the disclosure.