Automated door assembly and methods, press used therewith, and adhesive therefor

Abstract

A door pressing system for pressing interior passage doors, exterior entry doors, bi-fold doors, and/or closet doors features a multi-door pressing station including first and second presses, a loading device, and a discharging device. The pressing station is configured to alternatively move the first and second presses into operative alignment with the loading and discharging devices. The press in operative alignment delivers a pressed assembled door to the discharging device and receives an assembled door layup to be pressed from the loading device. The other press that is out of operatively alignment presses an assembled door received therein. Additional methods and systems are also provided.

1 . A system for making doors comprising:
 a first pressing station comprising
 a first press including a first set of platens, and 
 a second press including a second set of platens, each set of platens respectively having at least one platen movable relative to the other platen of the set of platens between an open state and a closed state; 
   the first pressing station configured to alternatingly move the first and second presses between (i) a loading/unloading position, in which one of the first and second presses is in the open state to receive at least a first assembled door in a layup state to discharge at least a second of assembled door that has been pressed, and (ii) a pressing position, in which the other of the first and second presses is in the closed state for pressing a third of assembled door   a first accumulator configured to hold the assembled doors that have been pressed in the first pressing station while an applied adhesive develops bond strength;   a second pressing station comprising
 a third press including a third set of platens, and 
 a fourth press including a fourth set of platens, each set of platens respectively having at least one platen movable relative to the other platen of the set of platens between an open state and a closed state, 
 the second pressing station configured to alternatingly move the third and fourth presses between (i) a loading/unloading position, in which one of the third and fourth presses is in the open state to receive at least a fourth of assembled door and to discharge at least a fifth of assembled door that has been pressed, and (ii) a pressing position, in which the other of the third and fourth presses is in the closed state for pressing a sixth of assembled door; 
   a second accumulator configured to hold the assembled doors that have been pressed in the second pressing station while the applied adhesive develops bond strength; and   a conveyor configured to carry doors away from the first and second accumulators.   
     
     
         2 . The system of  claim 1 , wherein the first and second presses are movable vertically between the loading/unloading position and the pressing position, and the third and fourth presses are movable vertically between the loading/unloading position and the pressing position. 
     
     
         3 . The system of  claim 1 , further comprising hydraulics for moving the first, second, third, and fourth presses vertically between the loading/unloading position and the pressing position. 
     
     
         4 . The system of  claim 1 , wherein the first pressing station is configured to alternatively move the first and second presses after each individual assembled door is delivered thereto, and wherein the second pressing station is configured to alternatively move the third and fourth presses after each individual assembled door is delivered thereto. 
     
     
         5 . The system of  claim 1 , wherein a conveyor configured to deliver the first, second, third, or fourth press by the conveyor. 
     
     
         6 . (canceled) 
     
     
         7 . The system of  claim 1 , wherein each of the first and second accumulators comprises a star conveyor. 
     
     
         8 . The system of  claim 1 , further comprising:
 a first frame assembly station configured to apply adhesive to door frame components and to frame the door frame components and applied adhesive into door frames;   a first door assembly station configured to secure door skins on opposites surfaces of the door frames assembled in the first frame assembly station to provide assembled doors to be delivered to the first or second press;   a second frame assembly station configured to apply adhesive to door frame components and to frame the door frame components and applied adhesive into door frames; and   a second door assembly station configured to secure door skins on opposites surfaces of the door frames assembled in the second frame assembly station to provide assembled doors to be delivered to the third or fourth press.   
     
     
         9 . The system of  claim 8 , wherein the first and second presses are movable vertically between the loading/unloading position and the pressing position, and the third and fourth presses are movable vertically between the loading/unloading position and the pressing position. 
     
     
         10 . The system of  claim 8 , further comprising hydraulics for moving the first and second presses vertically between the loading/unloading position and the pressing position, and for moving the third and fourth presses vertically between the loading/unloading position and the pressing position. 
     
     
         11 . The system of  claim 8 , wherein the first pressing station is configured to alternatively move the first and second presses after each individual assembled door is delivered thereto, and wherein the second pressing station is configured to alternatively move the third and fourth presses after each individual assembled door is delivered thereto. 
     
     
         12 . The system of  claim 8 , wherein the first and second frame assembly stations, and the first and second door assembly station comprise conveyors. 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . The method of  claim 21 , further comprising:
 applying adhesive to door frame components and framing the door frame components and applied adhesive into door frames;   securing first and second door skins on opposites surfaces of the door frames to provide the assembled doors in the layup state.   
     
     
         17 . A system for making door frames, comprising:
 a core attachment station for connecting an expandable core to a top rail and a bottom rail;   a robotic system comprising first and second grippers configured to grip the top rail and the bottom rail, respectively, and to draw the top and bottom rails apart from one another so as to expand the connected expandable core; and   a framing station configured to connect first and second stiles to the top and bottom rails and thereby form a door frame.   
     
     
         18 . The system of  claim 17 , wherein the robotic system is configured to connect the first and second stiles to the top and bottom rails to form the door frame. 
     
     
         19 . The system of  claim 17 , wherein the door frame has four corners, and wherein the framing station comprises a jig system configured to support and hold the door frame at the four corners. 
     
     
         20 . The system of  claim 19 , wherein the jig system comprises clamps each comprising at least one respective nozzle for applying adhesive to associated edges of the stiles and rails where the stiles and rails abut one another. 
     
     
         21 . A method of making doors, comprising:
 providing the system for making doors of  claim 1 ;   successively delivering assembled doors in a layup state to the first and second pressing stations;   discharging the pressed first assembled door from the first press of the first pressing station and loading the second assembled door in the layup state into the first press of the first pressing station, and simultaneously pressing the third assembled door in the second press of the second pressing station;   moving the second press into the loading/unloading position and the first press into the pressing position;   discharging the pressed fourth assembled door from the third press of the second pressing station and loading a fifth assembled door in the layup state into the third press of the second pressing station, and simultaneously pressing a sixth assembled door in the fourth press of the second pressing station; and   moving the fourth press the loading/unloading position and the third press into the pressing position.   
     
     
         22 . The method of  claim 21 , further comprising the step of holding the pressed fourth assembled door in the second accumulator and holding the pressed first assembled door in the first accumulator. 
     
     
         23 . The method of  claim 22 , further comprising the step of transporting the assembled doors away from the first and second accumulators via a conveyor. 
     
     
         24 . The system of  claim 8 , wherein the first frame assembly station comprises
 a first core attachment station for connecting a first expandable core to a first top rail and a first bottom rail;   a first robotic system comprising first and second grippers configured to grip the first top rail and the first bottom rail, respectively, and to draw the first top and bottom rails apart from one another so as to expand the connected first expandable core; and   a first framing station configured to connect first and second stiles to the top and bottom rails and thereby form a first door frame.