ES3036083T3 - Door leaf, door and method for producing the door leaf - Google Patents

Abstract

A door leaf (23) with a frame comprising at least one frame member (7), wherein the door leaf (23) has a plate-shaped door panel (1), said door panel (1) having at least an inner casing (2), an outer casing (3), and an insulating layer (4) disposed between them, wherein the door panel (1) has a lateral recess (31) disposed between the inner casing (2) and the outer casing (3), wherein the frame member (3) is at least partially disposed in the recess (31), and wherein the frame member (3) is mechanically fixed in the recess (31) and is not positively connected to the door panel (1); as well as a door with the door leaf and a method for producing the door leaf.

Description

DESCRIPTION

Door leaf, door and door leaf manufacturing method

The present invention relates to a door leaf according to the preamble of claim 1, as well as to a door and a method for producing the door leaf.

State-of-the-art door leaves are often additionally glued. This applies, among other things, to the attachment of door panels to a frame. The disadvantage is that the adhesive's curing time often takes up a significant portion of the production time. In many designs, gluing must also be carried out horizontally, which, under certain circumstances, can hinder the production process. Therefore, purely mechanical solutions for the connection between the door leaf and the frame are preferable.

A generic door leaf is described in EP 3269915 A1. L-shaped frame profiles, also referred to as sash frame profiles in the aforementioned publication, are first assembled to form a frame. The plate-shaped door panel is then inserted into the frame and screwed through a door panel casing parallel to the surface normal of the door panel plate plane. Finally, one of the door panel casings is covered with the frame beam.

With this design, the main concern was to eliminate the need to glue the frame beam to the panel. Therefore, the sheets can be processed immediately. The long curing time required for glued sheets is not required. This is made possible by the special assembly sequence and panel screwing mentioned above.

The manufacturing method of EP 3269 915 A1, while suitable for a single-sided sash covering design, is not suitable for a double-sided sash covering design, in which the profile or beam of the sash frame is covered by the door panel on both sides. Screwing to the inner casing is not permitted for aesthetic reasons.

The prior art for a variant with a double-sided sash is also described in DE 102004057 162. Here, the individual frame beams are inserted into the finished panel and then joined together to form a frame. The advantage is that the panel can be manufactured by a panel manufacturer, for example, while the door manufacturer subsequently manufactures the frames surrounding the panel and installs the fittings.

One disadvantage of this design is that the casings, referred to in the publication as panels, are manufactured with smaller than usual dimensions, meaning they are manufactured with a special panel thickness, making insertion into the frame beams extremely difficult due to the clamping pressure. Furthermore, the casings must be glued to the beams, which, as described above, should be avoided. This is time-consuming, and the long curing time of the adhesive bond disrupts the assembly process. The door panels, which must be stored temporarily, take up considerable space, as they must cure horizontally.

Other relevant prior art can be found in documents DE 202 04 177 U1, AT 399 019 B and BE 903601 A.

Therefore, it is the object of the present invention to improve the aforementioned constructive solutions and in particular to provide a door leaf and a method for its production with which a double-sided leaf covering construction can be realized without the use of adhesive.

The present invention solves this object by means of a door leaf having the features of claim 1 and by means of a method for its production having the features of claim 12. Furthermore, the invention relates to a door having the features of claim 11.

A door leaf according to the invention comprises a frame with at least one frame beam and a plate-shaped door panel.

The door panel consists of at least an inner shell, an outer shell, and an insulating layer arranged between them. Optionally, additional intermediate shells, insulating layers, expansion compensation layers, inserts for anchoring mechanical fasteners, etc., can be included.

The door panel also has a gap in the edge, which is arranged between the inner casing and the outer casing, with the frame beam being arranged at least partially in the gap.

Compared to glued door variants where there is a material bond between the frame and the door panel, the frame beam of the present invention is mechanically fixed in the gap and snap-fitted to the door panel.

In this door leaf construction, the door panel can cover both sides of the frame beams.

The panel can be completely manufactured first. The panel is attached to the frame purely mechanically, i.e., without adhesives. This translates into advantages in assembly and costs.

The gap is shaped like a slot to create a flat connection between the frame beam and the door panel.

The frame beam is inserted into the groove-shaped recess in a direction parallel to the plane of the plate-shaped door panel plate, so that the frame beam can be covered by the door panel on both sides.

The door leaf has an insert, for example a solid or hollow profile, to anchor the connecting element, the insert being arranged in the recess in the form of a slot.

In the hollow profile configuration, the insert has a first groove or channel, particularly in the area of the insert opposite the base, in the form of a threaded groove or threaded channel. The groove or channel has a longitudinal axis for engagement with a first mechanical connecting element, particularly a screw. The screw thread engages the wall of the groove or channel.

Advantageous embodiments of the invention are described in the dependent claims. The frame beam can advantageously be connected to the door panel without adhesive and, preferably, can be removably connected.

The frame beam is secured in the opening by at least one first mechanical connecting element. This is particularly advantageous for securely securing the frame to the door panel, preventing it from unintentionally shifting within the frame. A suitable mechanical connecting element can be a screw, a pin, a bolt, or a rivet.

The connecting element can be arranged in a direction parallel to the plane of the plate of the plate-shaped door panel on the door leaf, so that no screw heads or the like protrude along the visible sides of the door panel.

In the design as a solid profile, it can be, for example, a solid wood profile or a solid foam profile.

The insert can also be arranged only in a few selected positions in the gap or extend along the entire gap in the form of a slot.

The arrangement of the connecting element in the insert may have a higher pull-out value than an arrangement of the connecting element in the insulating material of the insulating layer, the insert not being assigned to the insulating material of the insulating layer within the scope of the present invention, even if it may have insulating properties.

The aforementioned pull-out value of the insert may be at least 20%, preferably at least 50% higher than when the connecting element is arranged in the insulating material of the insulating layer.

The insulation material of the insulation layer and/or insert can advantageously be rigid PU foam. This material is particularly suitable for anchoring connecting elements.

The insulation material can also be PU foam or polystyrene foam. This material typically has good insulation values, but due to its low hardness, it is not suitable for anchoring connecting elements.

The frame beam can advantageously be made of composite material, in particular metal and plastic profiles.

The slot-shaped recess may advantageously have a slot base and two side surfaces extending obliquely, in particular perpendicularly, to the slot base, the frame beam having an L-shape. The frame beam may have a rib on a first leg of the L-shaped frame beam, with at least one end of the rib for bearing against the first of the two side walls of the slot-shaped recess. The frame beam may also have a bearing surface on a second leg of the L-shaped frame beam for bearing against the second of the two side walls of the slot-shaped recess.

Contact between the side walls is achieved with a gap. This may preferably be 0.2 to 2 mm. Thus, the frame beam may contact one side wall on one side, with clearance only toward the second side wall, or the frame beam may have clearance toward each of the two side walls. The term "contact," as defined herein, may encompass a small separation, expressed by the gap.

The base of the slot can advantageously be stepped, with two substantially parallel base surfaces. The slot-shaped recess can preferably be formed as a first slot-shaped recess. One of the base surfaces can be formed as the slot base of a second recess, which forms part of the first slot-shaped recess, with the insert being arranged in the second recess. The second recess forms part of the first slot-shaped recess. This advantageously allows the statically supporting portion of the frame beam to be positioned on one side of the recess, which forms the interior of the door and houses fittings such as hinges and locks.

The side walls of the recess can be formed by the inner and outer casing, with the frame beam separated from the inner or outer casing on at least one side. This provides sufficient space to counteract the expansion of the panel materials, particularly the outer and inner casings, which can occur, for example, due to solar radiation, and facilitates the insertion and installation of the frame beam into the recess.

The door leaf can advantageously be provided with a cover profile to at least partially cover the mechanical connecting element. This cover profile can be attached to the frame beam and/or the outer or inner casing. This creates a pleasant surface on the edge, both tactile and visual, and the connecting element is better protected from environmental influences.

Advantageously, the door leaf may have at least one sealing element, in particular a sealing profile and/or a sealing stop, which can be fixed to the frame beam and which, together with the frame beam, forms a flat recess at least in some areas.

The inner or outer casing can extend beyond the frame beam or be flush with it. This allows the respective casing to conceal the frame beam in the viewing direction, relative to a surface normal to the plane of the door panel.

In a second embodiment of the invention, the insert can be designed as a hollow profile with at least one hollow chamber. Preferably, the hollow profile can be designed as a metallic hollow profile and, particularly preferably, as an aluminum hollow profile.

Preferably, the insert may have a first wall running parallel to the inner casing and a second, opposite wall partially abutting the inner casing, at least one receiving area for introducing adhesive being arranged between the wall and the inner casing.

The insert can preferably be glued in the area between the second wall and the inner casing.

The insert may have a continuous bottom in contact with at least one of the bottom surfaces of the recess.

The insert may have a second slot or channel, in particular a threaded slot or threaded channel, with a longitudinal axis for engaging a second mechanical connecting element, in particular a screw. The second connecting element may connect another insert to the aforementioned insert, so that a corner connection of a frame composed of multiple inserts can be formed.

The first mechanical connecting element may be provided for mechanically fixing the frame beam in the gap and the second mechanical connecting element may be provided for fixing the insert with another insert to form a frame comprising a plurality of inserts, in particular in a corner connection area of this frame.

The longitudinal axis of the first groove or the first channel for coupling a mechanical connection means may be arranged perpendicular to the longitudinal axis of the second groove or the second channel for coupling a mechanical connection means.

The insert may have a receptacle for a screw head, in particular a countersunk screw head, adjacent to the first slot or the first channel for engaging the first connecting means.

Furthermore, the invention provides a door comprising a frame and a door leaf according to the invention connected to the frame.

A method for producing a door leaf according to the invention is characterized by the following steps:

a. provision of the frame beams and door panel;

b. joining, in particular inserting, the frame beams into the door panel; and

c. connection of the frame beams to form a frame;

d. connection of the frame beams to the door panel, in particular by means of at least one mechanical connection means.

The aforementioned process allows for the manufacture of a door leaf without adhesive. The assembly in step b is performed without fixing, as a pre-positioning procedure, which allows for subsequent centering of the door panel after the frame has been fitted. The connection between the door panel and the frame is made in step d).

Advantageous configurations of the method are the subject of the dependent claims.

Preferably, the mechanical fastener can be anchored to the door panel without penetrating the inner or outer casing. This avoids having to trim the material in the event of accidental misplacement, for example, and reduces scrap during production. Furthermore, this position of the fasteners is undesirable for the customer. Furthermore, the expansion of the casings is not hindered or restricted.

In an additional optional step, the joining means for joining the frame beams to the door panel can be concealed by one or more cover profiles.

Additionally, in an additional step, a flat fold can be formed by applying sealants to the frame beam.

The corresponding frame beam can advantageously be inserted in step b) into a respective recess in the door panel in a direction parallel to the plane of the plate of the plate-shaped door panel.

In step d), the connecting element can advantageously be inserted and fixed into the door leaf in a direction parallel to the plane of the plate of the plate-shaped door panel.

The invention will be explained in more detail below using an exemplary embodiment and the accompanying figures. It is shown in:

Fig. 1 shows a section through the edge region of a door leaf panel according to the invention; Fig. 2 shows a section through a beam of the door leaf frame according to the invention;

Fig. 3, section of a mounting assembly comprising the frame beam of Fig. 2 and the panel of Fig. 1;

Fig. 4, section of the mounting system from Fig. 3 with the frame beam and panel fixed together; Fig. 5, section of the mounting mechanism with additional door leaf profiles;

Fig. 6 shows a section through a door cutout, a cutout of the door leaf, and a cutout of a frame; Fig. 7 shows a section through a door cutout, a cutout of a second embodiment variant of a door leaf according to the invention, and a section through a frame;

Fig. 8, detailed view of a frame beam used in the variant of Fig. 7 with an insert;

Fig. 9, detailed view of the insert of Fig. 8; and

Fig. 10, schematic representation of a corner connection area of two inserts according to Fig. 9 of a door leaf according to the invention.

Fig. 1 shows a cross-section of the edge of a prefabricated door panel 1, designed as a multi-layer panel. The door panel 1 consists of at least an inner shell 2, at least an outer shell 3, and at least one insulating layer 4. Preferably, it can be designed as a sandwich panel or a sandwich plate.

The terms "interior" and "exterior" refer, for example, to the interior space of a building, which the door panel 1 of a door equipped with such a panel separates from the surroundings or an outside area. In this case, the inner housing 2 is the housing of the door panel 1, arranged in the positive y-coordinate direction with respect to the coordinate system of Fig. 1. Accordingly, the outer housing 3 is the housing of the door panel 1, arranged in the negative y-coordinate direction with respect to the coordinate system of Fig. 1.

Door panel 1 has a stepped edge zone 6. This stepped edge zone 6 is preferably located on at least three sides relative to the plane of the door panel 1. On a fourth side (on the lower horizontal part of the installed door), frame zone 6 can be designed differently, for example, if a plinth profile is used for the door leaf. In this case, the edge zone approximately corresponds to the contour of the plinth profile.

The stepped edge region 6 of the door panel 1 has a first groove-shaped recess 31 in the edge, which preferably extends over the entire length of the side region of the door panel 1. The recess 31 is delimited by the inner housing 2 and the outer housing 3 and by a groove base 32, formed by the insulating material of the insulating layer 4.

The groove bottom 32 is stepped with a first base surface 33 and a second base surface 34, which is offset deeper in the insulating layer 4 compared to the first base surface 33, so that within the first groove-shaped recess 31 a second U-shaped recess 35 is arranged, which is delimited on at least two sides by the insulation material of the insulating layer 4 and on a third side by the inner housing 2.

The inner housing 2 and the outer housing 3 may preferably consist of metal plates, preferably aluminum. Other materials, such as plastic, wood, composite materials (e.g., metal and plastic), and the like, may also be used within the scope of the present invention. The size of the inner housing 2 may vary with respect to the size of the outer housing 3. This may affect both the size of the plate surface and the plate thickness. However, preferably, the plate thickness of the inner and outer housings 2 and 3 may also be the same.

Between housings 2 and 3 is at least the aforementioned insulating layer 4, bonded to the inner and outer housings. This insulating layer 4 has a high thermal insulation value. This may preferably be between 0.022 and 0.078 W/(m*K).

The insulating layer can also be flexible to compensate for thermal expansion of the housing. The preferred elongation at break is greater than 150% according to DIN 53571 in its current version (April 2018).

To anchor the panel with a screw connection, it can have high pull-out values of at least 400 N, preferably 900 to 1300 N. The pull-out values refer to the panel material in combination with a connecting element, which is a sheet metal, wood or mounting screw with a diameter of 3.9 to 7.5 mm.

This does not exclude the alternative use of other connecting elements, but serves as a reference value to describe the material properties of the insulation material and/or the insert material.

In this way, the insulating layer can be formed as a single piece from a heat-insulating material. In this case, the insulating layer can be designed, for example, as a dimensionally stable, heat-insulating plastic film, particularly a foamed plastic film, which offers sufficient strength to anchor a mechanical fastener, particularly a screw or rivet.

If these properties cannot be sufficiently provided by a single material, the insulating layer 4 may also be composed of several materials with the required properties.

The insulation material used is preferably a foam, such as PU foam or polystyrene foam, which is characterized by high thermal insulation. This foam can also preferably be combined with one or more fixing segments, in particular with one or more inserts and/or insert profiles 5, to anchor a mechanical connection means, in particular for a bolted connection.

The fixation segment, in particular the insert or

The insert profiles 5 thus form a fixing region, in particular a screw connection region 26. Suitable materials for the inserts or insert profiles include hard plastics or plastics with high tensile strength, in particular PVC, rigid polyurethane foam, fiber-reinforced plastics, in particular carbon-fiber-reinforced plastics, as well as wood or metal. The inserts or profiles can also be equipped with hollow chambers or threaded channels.

Furthermore, at least one fully or partially flexible layer, for example made of elastic plastic such as cellular rubber or a closed-cell foam elastomer, can be included to compensate for expansion (stretching) and/or bending. This layer can preferably be positioned between the insulating layer 4 of the outer casing 3. Such expansions can occur due to temperature differences on both sides of the door leaf and the resulting considerable differences in the thermal expansions of the casings 2 and 3. Thanks to its properties, the flexible layer compensates for the thermal expansion of the outer casing 3 on the outside of the door leaf. For a detailed description of the properties and function of the aforementioned layer, which is often also referred to as a compensation layer, reference is made to document DE 203 14 017 U1.

The individual layers/parts of the door panel are glued together and are preferably completely prefabricated.

A frame beam 7 is shown in Fig. 2. It consists of a metal profile 8, particularly aluminum, and a second plastic profile 13. The two profiles are connected to each other to form a thrust-resistant composite profile.

However, a push-free connection is also possible.

The first profile 8 has at least one, preferably two, hollow chambers 9. Furthermore, a functional groove 10 can preferably be provided in the first profile 8 for the concealed accommodation of connecting elements.

Advantageously, the first profile 8 has a fixing rib 11 at the transition to the second profile 13 for mounting one or more fittings, such as locks or hinges. The fixing rib 11 offers greater extraction capacity for screwed connections and is located in the central area of the door panel 1, i.e., approximately between 35% and 65% of the thickness of the door panel 1 plate.

In its preferred configuration, the second profile 13 serves as a plastic profile for thermal insulation and as a spacer for the outer casing 3. The second profile 13 can be connected to the first profile 8 via the fixing rib 12 by a pressing process, either by snap-fitting or by positive-fitting. The second profile 13 can have multiple hollow chambers. The ribs 14 on the edge of the second profile, which contact the outer casing 3 of the door panel 1, ensure a small contact surface to improve thermal insulation. The frame beam 7 can advantageously be supplied completely pre-assembled, like the door panel 1, and in the preferred variant shown in Fig. 2-6 is L-shaped.

Figure 3 shows a section of a mounting assembly 25 comprising the door panel 1 of Fig. 1 and the frame beam 7 of Fig. 2.

The frame beam 7 is inserted at least partially into the door panel 1, so that it is received at least partially in the first slot-shaped recess 31 and partially fills it. The frame beam 7 in Fig. 3 is therefore located at least partially between the inner casing 2 and the outer casing 3.

Preferably, the frame beam 7 is hidden by the inner casing 2 and/or the outer casing 3 in a front view of the door panel 1, so that a visually particularly advantageous and high-quality impression of the assembly is created for the observer.

According to a variant embodiment of an assembly method also according to the invention, the individual frame beams 7 of a door leaf 1 can be brought to the frame areas 6 of the door panel 1 and inserted.

The frame beam 7 preferably has a lower height, preferably less than 2 mm. This height is defined by the distance from a rib 14 for contact with the outer casing 3 to the contact surface 15 of the frame beam 7 in the inner casing 2. This height is at least 0.2 mm less than the distance between the inner casing 2 and the outer casing 3 of the door panel 1. The clearance between the components, i.e. the frame beam and the door panel, simplifies the insertion of the frame beam(s) 7 into the door panel 1.

Optionally, connection means (not shown) can be pre-installed in the hollow chambers 9 and/or slots 10 of the frame beams 7. These are preferably so-called corner connectors for mitered frame profiles. These are inserted into the hollow chambers 9. Alternatively, so-called T connectors for butt-cut profiles can also be used. The structural solution of the present invention thus allows the cutting and assembly of frame profiles with different cuts.

Several frame beams 7 are then connected to form a frame. The corners and/or T-connectors are nailed or screwed together according to the state of the art to create a stable frame. However, the frame beams 7 can also be easily connected to each other using mechanical methods, particularly screws, rivets, or welding.

In this way, the frame can be pre-assembled on the door panel 1 by means of the frame beams 7 and then pre-fixed to the door panel so that it fits its shape.

The frame is then preferably fixed to the door panel 1 with at least one mechanical connecting element 16, in particular with one or more screws.

The frame can advantageously be aligned with the panel "by hand" or with screws 16, depending on how the screws 16 are tightened. The screwing zone 26 provides a secure hold for the mechanical connecting elements 16, in particular the screws. The screw shank 18 penetrates the hollow chamber 9 of the frame beam 7, and the screw head 17 is arranged or countersunk in a groove 10. This has the advantage that the screw is no longer visible after installation of the cover profile 19, which improves the appearance of the edge of the door leaf.

In order to achieve aesthetics and easy accessibility of the connecting element or connecting elements 16, it is also particularly advantageous if the insertion of the connecting element is carried out from a direction parallel to a plate plane A of the plate-shaped door panel 1.

The same applies to the insertion or insertion direction of frame beam 7 into door panel 1.

In Figs. 4, 5 and 6, the frame beam 7 is connected to the door panel 1 by means of a connecting element 16. However, other mechanical connections are also conceivable within the scope of the present invention, for example, by securing the frame beam 7 between the housings 2 and 3 with clips or another anchoring option. For this purpose, elastic lugs can be arranged, for example, in the area of the contact surface 15, which bear elastically against the inner housing 2. The connection between the frame beam 7 and the door panel 1 is preferably removable, and in particular without bonding materials, in particular without adhesive.

Other optional advantageous elements arranged on the frame beam 7 and/or on the door panel 1 are shown in Figs. 5 and 6.

The door leaf 23 according to the invention comprises at least the door panel 1 and at least one frame beam 7, but in particular a frame comprising several frame beams 7.

In addition to the door leaf 23 according to the invention, an entrance door also comprises a frame 24, which is indicated in Fig. 6.

To seal the door leaf 23 to the frame 24, seals 20 and seal stops 21 are inserted into the mounting assembly 25, particularly in the edge region 6. These seals are designed such that, in interaction with the frame beam 7 and the optional cover profile 19, a flat recess 22 is created, which extends over at least 50%, preferably at least 70%, of the edge region of the plate-shaped mounting assembly 25 with the frame beam 7 and the door panel 1. This recess 22 improves the appearance and makes this area easier to clean. It also improves the feel.

Figure 6 shows the door leaf 23 according to the invention with the corresponding frame 24, shown here in the form of a frame profile to which the door leaf is attached, preferably with hinges. Additional fittings such as hinges, locks, strike plates, handles, push buttons, or door closers are not shown, but can be optionally installed in a conventional manner.

The frame and the frame assembly itself can be made partially or entirely from extruded aluminum profiles. Alternatively, they can be made from a different material, such as steel, and/or using a different manufacturing process. Optional insulating ribs for the frame or frame beam can be made from a plastic material, such as polyamide (PA66, PA6, PPA), polyester (PET, PBT), polyolefins (PP), or even polyvinyl chloride (PVC), ensuring ample thermal separation between the individual profiles.

Mechanical fasteners include screws, nuts (including clamped washers), pins, bolts, rivets, and/or retaining rings, among others.

Fig. 7 shows a section of a second embodiment variant of a door leaf 201 according to the invention and a section of a frame 202.

The door leaf 201 has a frame beam 117, which is designed analogously to the frame beam 7 of the variant in Fig. 1-6.

In addition, the door leaf 201 has a groove similar to that shown in Fig. 1-6. Within the groove is another variant of an insert 101.

Fig. 8 shows the connection between the frame beam 117 and the insert 101 and Fig. 9 shows the insert again in detail.

The insert is shaped like a hollow profile and consists of a hollow chamber 105. The insert 101 has a first wall 102, which is parallel to the inner housing 2 of the door panel and faces the door panel's filling material on its outer side. Facing this wall 102 is a second wall 103, which partially rests on the inner housing 2, particularly at its ends.

At least one receiving area 104 for introducing adhesive is arranged between the wall 103 and the inner housing 2. This receiving area can also be subdivided so that several receiving areas can be arranged.

The insert 101 also has a continuous base 106 that delimits the hollow chamber 105 and that is in contact with the base surface 34 of the recess 31.

Insert 101, particularly in the area opposite base 106 of insert 101, has a threaded slot 107 with longitudinal axis AL1 for inserting a screw. Naturally, a threaded channel can also be provided instead of a slot. Other mechanical connecting elements are also possible.

The longitudinal axis AL1 of the first threaded groove 107 is perpendicular to the longitudinal axis AL2 of the second threaded channel 108.

The insert 101 has a receptacle 109 for a screw head, in particular a countersunk screw head, adjacent to the first slot or the first channel for the installation of the first connection means.

The insert also has a second threaded groove or a second threaded channel 108 with a longitudinal axis AL2, the threaded channel being provided for the installation of a second screw 116.

The first screw 16 serves, analogously to Figs. 1-6, to mechanically fix the frame beam in the recess 31. The second screw 116 makes it possible to fix the insert with a second insert, forming a frame with a plurality of inserts. This is illustrated particularly clearly in Fig. 10. First and second inserts 101 and 101' are shown there. Only the inner casing 2 of the door panel is indicated. The frame beam 117 is not illustrated in Fig. 10, but can be placed on the corresponding insert 101 or 101' in a manner similar to Fig. 7 and connected by means of the screw 16. The insert 101' has a similar structure to that of the insert 101, so the same reference symbols are used for its explanation.

In the case of screw 116, it is inserted parallel to the threaded channel 107 of the insert 101'. It penetrates the surface of the receptacle 109, the threaded channel 108 and the base 106 of the insert 101' and is threaded into the threaded channel 108 of the insert 101. The receptacle 109 may also be partially open to facilitate insertion of the screw 116 into the insert 101'.

By securing inserts 101 and 101' with screw 116, a stable corner connection is created, allowing a frame to be formed with multiple inserts. It works both in a corner connection with a butt joint of inserts 101 and 101' and in a corner connection with a bracket.

The longitudinal axis of the screw 116 is preferably located on the longitudinal axis AL2 of the threaded channel 108 of the insert 101. The head of the screw 116 is then located in the receptacle 109, so that the frame beam 117 can be positioned flush with the insert 101 (as shown in Fig. 7).

List of reference signs

1 Door panel

2 Inner casing

3 Outer casing

4 Insulating layer

5 Insert

6 Frame area

7 Frame beam

8 Profile

9 Hollow chamber

10 Slot

11 Rib

12 Rib

13 Profile

14 Contact rib

15 Contact surface

16 Connecting element

17 Screw head

18 Screw stem

19 Roof profile

20 Board

21 Joint stop

22 Lowering or lowering surface

23 Door leaf

24 Marco

25 Mounting set

26 Screwing area

31 Hollow

32 Slot bottom

33 Base surface

34 Base surface

35 Hollow

101 Insert

102 First wall

103 Second wall

104 Accommodation area

105 Hollow chamber

106 Base

107 Threaded slot

108 Threaded channel

109 Receptacle

116 Second screw

117 Frame beam

201 Door leaf

202 Marco

101' Insert

AL1 Longitudinal axis of the threaded slot

AL2 Longitudinal axis of the threaded channel

t Surface Normal

A Plate plane

Claims (16)

1. Door leaf (23) with a frame comprising at least one frame beam (7), which comprises a first metal profile (8) and a second profile (13) as a plastic profile, the first profile (8) having at least one hollow chamber (9), the door leaf (23) having a plate-shaped door panel (1), the door panel (1) comprising at least an inner housing (2), an outer housing (3) and an insulating layer (4) arranged therebetween, the second profile (13) serving in its design as a plastic profile as a thermal insulator and as a spacer for the outer casing (3); the door panel (1) comprising a peripheral gap (31) which is arranged between the inner casing (2) and the outer casing (3), the frame beam (7) being arranged at least partially in the recess (31), the frame beam (7) being mechanically fixed in the recess (31) and pressure-connected to the door panel (1); characterized by the frame beam (7) is inserted in a direction parallel to the plane (A) of the plate of the plate-shaped door panel (1) into the recess (31) designed in the form of a slot, the frame beam (7) being fixed in the recess (31) by means of at least a first mechanical connecting element (16), having in the slot-shaped recess an insert (5, 101) arranged to anchor the first mechanical connection element (16), the insert (101) being formed as a hollow profile comprising at least one hollow chamber (105), the insert (101) having a first slot or a first channel, such as a threaded slot (107) or a threaded channel, having a longitudinal axis (AL1) for the installation of the first mechanical connection element (16), or the insert (5) being shaped as a solid profile. 2. Door leaf according to claim 1, characterized in that the first mechanical connecting element (16) is designed as a screw. 3. Door leaf according to one of the preceding claims 1 or 2, characterized in that the groove-shaped recess (31) has a groove base (32) and two lateral surfaces extending obliquely, in particular perpendicularly to the groove base (32), the groove base (32) preferably being of stepped design with two base surfaces (33, 34) extending essentially parallel to each other. 4. Door leaf according to one of the preceding claims, characterized in that the door leaf (23) has at least in some areas a cover profile (19) for covering the first mechanical connection element (16), the cover profile (19) being able to be fixed to the frame beam (7). 5. Door leaf according to one of the preceding claims, characterized in that the door leaf (23) has at least one seal, in particular a seal profile (20) and/or a seal stop (21), which can be fixed to the frame beam (7) and which, together with the frame beam (7), forms a flat recess (22) at least in some areas. 6. Door leaf according to one of the preceding claims, characterized in that the inner casing (2) and/or the outer casing (3) extends beyond the frame beam (7) or is aligned with it in such a way that it covers the frame beam (7) in the viewing direction, with respect to a normal (t) of the surface of the plane (A) of the door panel plate (1). 7. Door leaf according to one of the preceding claims, characterized in that the insert (101) preferably has a first wall (102) extending parallel to the inner housing (2) and an opposite second wall (103) which rests in certain areas against the inner housing (2), preferably also having at least one receiving area (104) for the introduction of adhesive arranged between the wall (103) and the inner housing (2). 8. Door leaf according to claim 1, characterized in that the insert (101) has a second groove or a second channel, in particular a threaded groove (107) or a threaded channel (108), which has a longitudinal axis (AL2) for the installation of a second mechanical connecting element (116), in particular for a screw. 9. Door leaf according to claim 1 or 8, characterized in that the longitudinal axis (AL1) of the first groove or the first channel for installing the first mechanical connecting element (16) of a first insert (101) is arranged perpendicular to the longitudinal axis (AL2) of the second groove or the second channel (108) for installing the second mechanical connecting element (116) to a second insert (101'). 10. Door leaf according to one of the preceding claims 1, 8 or 9, characterized in that the insert (101) has, adjacent to the first groove or the first channel for the installation of the first connection element (16), a receptacle for a screw head, in particular a countersunk screw head, of the second connection element (116). 11. Door, in particular an entrance door, comprising a frame (24) and a door leaf (23) connected to the frame (24), according to one of the preceding claims. 12. Method for manufacturing a door leaf (23) according to one of the preceding claims, characterized by the following steps: a. provide the frame beams (7) and the door panel (1); b. joining, in particular inserting, the frame beams (7) into the door panel (1); and c. connect the frame beams (7) to form a frame; and d. mechanically connecting the frame beams (7) to the door panel, in particular by means of at least a first mechanical connecting element (16). 13. Method according to claim 12, characterized in that before assembly according to step b), inserts are inserted into the door panel which are connected to each other, in particular by means of second connecting elements (116), to form a frame. 14. Method according to claim 12 or 13, characterized in that the first mechanical connection means (16) is anchored to the door panel (23) without passing through the inner casing (2) and/or the outer casing (3). 15. Method according to one of the preceding claims 12 to 14, characterized in that in a further step a flat recess (22) is formed by fixing joints (20, 21) to the frame beam (7). 16. Method according to one of the preceding claims 12 to 15, characterized in that in step b) a beam (7) of the corresponding frame is inserted into a corresponding recess in the door panel (1) in a direction parallel to the plate plane of the plate-shaped door panel (1) in the recess (31), the mechanical connecting element (16) being preferably introduced and fixed in step d) in the door leaf (23) in a direction parallel to the plate plane of the plate-shaped door panel (1).