US 6,067,699 AGranted

Method for assembling a multi-panel door

AssigneeJELD-WEN, Inc.

InventorCharles R. Jackson

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Abstract

A method and apparatus for assembling a multi-panel door. The method includes the steps of fashioning a plurality of rails; fashioning a plurality of panels; fashioning a plurality of mullions; fashioning a plurality of stiles; and preassembling selected rails, selected panels, and selected mullions into sub-assemblies of the door. The sub-assemblies are positioned intermediate a first stile and a second stile in a pre-assembly orientation with the first stile and second stile generally coplanar with the sub-assemblies. The sub-assemblies, the first stile, and the second stile are compressively urged together in two substantially perpendicular axes to create a squared assembly with respect to the two axes. The sub-assemblies are intermediate the first stile and the second stile and are affixed to the first stile along at least a portion of the first stile, and are affixed to the second stile along at least a portion of the second stile.

Claims19

Dependent claims

A method of in-line manufacturing of a plurality of doors;

the method comprising the steps of:
(a) fashioning a plurality of rails;
(b) fashioning a plurality of panels;
(c) fashioning a plurality of mullions;
(d) fashioning a plurality of stiles;
(e) conveying selected rails of said plurality of rails, selected panels of said plurality of panels, and selected mullions of said plurality of mullions to a plurality of different locations, and pre-assembling the selected rails, selected panels and selected mullions into a plurality of sub-assemblies, with one sub-assembly being assembled at each of said plurality of different locations;
each respective sub-assembly of said plurality of sub-assemblies having at least one respective selected rail, at least one respective selected panel, and at least one respective selected mullion;
(f) positioning said plurality of sub-assemblies intermediate a first stile of said plurality of stiles and a second stile of said plurality of stiles in a pre-assembly orientation;
said plurality of sub-assemblies, said first stile, and said second stile being generally coplanar in said pre-assembly orientation;
and
(g) while in said pre-assembly orientation, compressively urging together said plurality of sub-assemblies, said first stile, and said second stile in two substantially perpendicular axes;
said compressive urging substantially seating and joining said plurality of sub-assemblies, said first stile, and said second stile to one another thereby creating a substantially squared door with respect to said two axes;
said plurality of sub-assemblies being affixed to said first stile along at least a portion of said first stile;
said plurality of sub-assemblies being affixed to said second stile along at least a portion of said second stile;
said plurality of sub-assemblies being attached to one another intermediate said first stile and said second stile.

12 more elements

A method of in-line manufacturing of a plurality of doors, the method comprising the steps of:

(a) conveying a first rail-set of a plurality of rails, a first mullion-set including at least one mullion of a plurality of mullions, and a first panel-set of a plurality of panels to a first location;
(b) assembling the first rail-set, the first mullion-set and the first panel-set into a first sub-assembly at the first location;
(c) conveying a second rail-set including at least one rail of a plurality of rails, a second mullion-set of a plurality of mullions, and a second panel-set of a plurality of panels to a second location, different from the first location;
(d) assembling the second rail-set, the second mullion-set and the second panel-set into a second sub-assembly at the second location;
(e) conveying a third rail-set including at least one rail of a plurality of rails, a third mullion-set of a plurality of mullions, and a third panel-set of a plurality of panels to a third location, different from the first and the second location;
(f) assembling the third rail-set, the third mullion-set and the third panel-set into a third sub-assembly at the third location;
(g) assembling first and second stiles of a stile-set with the first sub-assembly, the second sub-assembly, and the third sub-assembly, thereby creating a fourth sub-assembly;
and
(h) compressing the fourth sub-assembly in two substantially perpendicular axes, thereby substantially squaring and planarizing the fourth sub-assembly, with respect to the two axes, and thereby creating a door of the plurality of doors.

6 more elements

A method of in-line manufacturing of a plurality of doors, each door including a plurality of rails, a plurality of mullions, a plurality of panels, and a plurality of stiles, the method comprising the steps of:

(a) providing a first rail-set of a plurality of rails, a first mullion-set including at least one mullion, and a first panel-set of a plurality of panels;
(b) conveying the first rail-set, the first mullion-set and the first panel-set to a first location, and assembling at the first location the first rail-set, the first mullion-set and the first panel-set into a first sub-assembly which is substantially symmetrical with respect to a first plane, the first sub-assembly including a first top rail and a second top rail of the first rail-set, a first top panel and a second top panel of the first panel-set, and a first top mullion of the first mullion-set, the first top rail and the second top rail interference fittingly engaging the first top panel and the second top panel intermediate the first top rail and the second top rail, the first top rail and the second top rail interference fittingly engaging the first top mullion intermediate the first top rail and the second top rail, the first top panel and the second top panel interference fittingly engaging the first top mullion intermediate the first top panel and the second top panel;
(c) providing a second rail-set including at least one rail, a second mullion-set including at least one mullion, and a second panel-set of a plurality of panels;
(d) conveying the second rail-set, the second mullion-set and the second panel-set to a second location, different from the first location, and assembling at the second location the second rail-set, the second mullion-set and the second panel-set into a second sub-assembly which is substantially symmetrical with respect to a second plane, the second sub-assembly including a first center rail of the second rail-set, a first center panel and a second center panel of the second panel-set, and a first center mullion of the second mullion-set, the first center rail interference fittingly engaging the first center panel and the second center panel on a first side of the first center rail, the first center rail interference fittingly engaging the first center mullion on the first side of the first center rail, the first center panel and the second center panel interference fittingly engaging the first center mullion intermediate the first center panel and the second center panel;
(e) fashioning a third rail-set including at least one rail, a third mullion-set including at least one mullion, and a third panel-set of a plurality of panels;
(f) conveying the third rail-set, the third mullion-set and the third panel-set to a third location, different from the first and the second location, and assembling at the third location the third rail-set, the third mullion-set and the third panel-set into a third sub-assembly which is substantially symmetrical with respect to a third plane, the third sub-assembly including a first bottom rail of the third rail-set, a first bottom panel and a second bottom panel of the third panel-set, and a first bottom mullion of the third mullion-set, the first bottom rail interference fittingly engaging the first bottom panel and the second bottom panel on a first side of the first bottom rail, the first bottom rail interference fittingly engaging the first bottom mullion on the first side of the first bottom rail, the first bottom panel and the second bottom panel interference fittingly engaging the first bottom mullion intermediate the first bottom panel and the second bottom panel;
(g) providing a stile-set of a plurality of stiles;
(h) assembling a first stile of the stile set and a second stile of the stile set with the first sub-assembly, the second sub-assembly, and the third sub-assembly, thereby creating a fourth sub-assembly, the first plane, the second plane, the third plane, the first stile, and the second stile being substantially coplanar when assembled in the fourth sub-assembly, the first stile being affixed with a first side of the first sub-assembly, being affixed with a first side of the second sub-assembly, and being affixed with a first side of the third sub-assembly, the second stile being affixed with a second side of the first sub-assembly, being affixed with a second side of the second sub-assembly, and being affixed with a second side of the third sub-assembly, the second top rail interference fittingly engaging the first center panel, the second center panel and the first center mullion, the first center rail interference fittingly engaging the first bottom panel, the second bottom panel and the first bottom mullion;
and
(i) compressing the fourth sub-assembly in two substantially perpendicular axes thereby squaring and planarizing the fourth sub-assembly, with respect to the two axes, and thereby creating a door of the plurality of doors.

7 more elements

A method for in-line assembly of a multi-panel door, comprising the steps of:

(a) conveying a first top rail and a second top rail, a first top panel and a second top panel, and a first top mullion to a first location, and at the first location interference fitting the first top rail and the second top rail with the first top panel and the second top panel, interference fitting the first top rail and the second top rail with the first top mullion, and interference fitting the first top panel and the second top panel with the first top mullion, thereby forming a first sub-assembly;
(b) conveying a first center rail, a first center panel and a second center panel, and a first center mullion to a second location that is different from the first location, and at the second location interference fitting the first center rail with the first center panel and the second center panel, interference fitting the first center rail with the first center mullion, and interference fitting the first center panel and the second center panel with the first center mullion, thereby forming a second sub-assembly;
(c) conveying a first bottom rail, a first bottom panel and a second bottom panel, and a first bottom mullion to a third location that is different from the first location and the second location, and at the third location interference fitting the first bottom rail with the first bottom panel and the second bottom panel, interference fitting the first bottom rail with the first bottom mullion, and interference fitting the first bottom panel and then second bottom panel with the first bottom mullion, thereby forming a third sub-assembly;
and then
(d) assembling the first sub-assembly to the second sub-assembly, assembling the second sub-assembly to the third sub-assembly, assembling a first stile to the first, second and third sub-assemblies, and assembling a second stile to the first, second and third sub-assemblies.

2 more elements

Dependencies are inferred from the claim text.

Facts

Application: 08/918,158Filed 25 Aug 1997 · continuation
Priority: 19 Apr 1995
Granted: 30 May 2000
Term ends: Not estimatedThe source records don’t support an estimate.

Classification9 codes

B27M 3/0093
Manufacture or reconditioning of specific semi-finished or finished articles: of raised panels, i.e. panels having a profiled surface
B23P 21/004
Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g.…:…
E06B 3/74
Consisting of frame and panels , e.g. of raised panel type: with wooden panels or frame
Y10T 29/49829
Progressively advancing of work assembly station or assembled portion of work: advancing work to successive stations [i.e., assembly line]