Our production is a door leaf of a frame structure made using natural wood, medium density fibreboard (MDF) and restructured veneer (fine-line), adhesive and paints and varnishes, glass, fasteners and other materials and products that meet the requirements of standards and specifications.
For door production the sawn timber of coniferous wood "pine" with a moisture content of 7 ± 1% is used. To achieve the specified moisture content of wood, a drying complex has been built and operates at the enterprise, consisting of an autonomous boiler room, four drying chambers with front loading with a capacity of 50 m 3 each. The drying complex is equipped with automated system control of drying processes. The drying chambers are equipped with reversible fans, humidification systems, wood and air humidity control sensors, and an air conditioning system. The dried sawn timber is unloaded into a cooling room, where it cools down for 48 hours to relieve internal stress.
The resulting material is used to form the frame of the door leaf.
The canvases consist of:
Non-glazed (deaf) canvases are made with only one outer frame. Glazed doors have an internal frame corresponding to the size of the glass to be inserted and a lath filling.
MDF (MDF-medium-density fiberboard) medium density fiberboard is a sheet material produced from wood species in an ecologically favorable conditions by dry hot pressing, with an increased density of 850 kg / m. cub.
In MDF, the developed surface of wood fibers and a shortened pressing cycle are effectively combined with strength due to the participation of binders in interfiber interaction. The production technology of MDF doors excludes the use of epoxy resins and phenol, which are harmful to health.
This type of semi-finished product is highly environmentally friendly, and also has excellent compactness, fiber adhesion, and dimensional stability over a long period of time.
Application of this material in door production allows you to acquire the properties of excellent planarity of the surfaces of the canvas, surface hardness and impact resistance.
Honeycomb is a high-tech material used to form the frame of the structure. Honeycomb fillers got their name due to the geometric resemblance to honeycombs. The main task of the material is to fill the space between the two skins. By placing a honeycomb filler between the skins, the rigidity of the structure is actually increased by a factor of 100 or more - this is the effect of the separation of the bearing layers. Thus, the honeycombs placed between the skins do not particularly burden the structure, for they are light, but they guarantee strength. Honeycomb core is the most promising material today for the manufacture of ultralight and durable structures for various purposes.
Filling the door leaf using cardboard honeycomb:
Door construction with honeycomb filling significantly lightens the weight of the curtain, which reduces the load on the hinges, has good heat and sound insulating properties, and also avoids warping of the curtain during operation.
Natural veneer- these are thin cuts of natural wood, which have the color and texture of wood. The indisputable advantage of such material in door production is that it retains the natural wood pattern, which cannot be conveyed by any modern technological tricks. In addition, natural veneer is durable, it does not flake or crack, because it is glued to the MDF base.
Veneering the surface and assembling the frame of the canvas is carried out by hot pressing. Next, the door leaf is formatted in length and width, followed by gluing the ends with veneer.
To create an individual profile for each model, milling is carried out along the contour specified by the template. The processing process is personal for each type of canvases.
Each door leaf is processed by hand grinding the surface with abrasive materials. To obtain the smoothest possible surface, our specialists have developed a step-by-step system for processing the door leaf with a grinding tool with varying degrees of grain size.
The finishing of the coating is carried out by specialists of the highest category by hand with Swedish-made paints and varnishes "Becker Acroma". This two-component, organic-based alkyd varnish has a high hiding power due to its high solids content and forms a tough yet flexible film on the surface of the product. In addition to the decorative function, the lacquer coating plays a protective role - it prevents the canvas from swelling at too high room humidity and protects the door structure from drying out at low humidity.
And besides, do not forget that varnish also makes the surface of veneered doors more beautiful. appearance... Only after varnishing does the final color of the wood appear ...
On the door production a system for identifying the performers of operations has been introduced, which makes it possible to minimize the number of defective products and to identify a specific performer who violates the technological process. Marking is done on the upper and lower edge of the door leaf. Each product undergoes strict control of the quality control department. Frosted Bronze glass is installed in the door leaves under the glazing, which gives the door its individuality and completeness. Glazing is made using elastic spacers in the amount of six pieces, which eliminates the vibration of the glass and ensures its precise fixation. Thanks to this glazing technology, the glass can be easily removed and reinstalled.
All door leaves are packed in corrugated cardboard along the perimeter and polyethylene packaging, which allows us to protect our products from external influences. All our products must be completed with a product passport, with detailed description warranty obligations and recommendations for storage and operation.
Applicable materials:
Manufacturing technology. The base of the box beam is made of dry lumber by the method of butt splicing. When splicing lumber, wood defects are removed: knots according to the tolerance rate, cracks, blueness, rot, etc. Glued blanks are profiled to a given size on four-sided planing machines. MDF is cut to the specified size on the panel saw center. The use of this machine provides the required geometry of the workpiece. The MDF strip is glued to hot melt glue on an automatic line for veneering molded products. The resulting "rough billet" is processed on four-sided planing machines, after which a natural veneer is glued to the billet on an automatic line for facing molded products. The veneered box beams are delivered to the paint shop. Where is the final finishing of the products made: sanding, priming and topcoat varnish.
The platband is made of profiled MDF blanks wrapped in fine-line veneer and having a paint-and-lacquer coating identical to the door leaf. Packed in polyethylene. The finishing element is made of MDF blanks and veneered with the appropriate veneer. Packed in polyethylene.
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Often choosing from a wide range of door designs a person cannot find a door that is ideally suited for all parameters. As a result, many opt for one of the most functional models. Others decide to manufacture wooden doors, fully meeting the owner's requirements, independently.
Undoubtedly, having the skills of a carpenter is a significant advantage. However, if desired, even a person without such experience, through diligence, improvisation and with the help of some instructions, is able to make the necessary structure.
A popular and inexpensive material suitable for making doors is pine lumber. The use of spruce is undesirable, since the structure of the tree is rather unstable and a large number of knots and chips are formed during processing.
Making beautiful and even pine wood doors means, first of all, right choice and technology for preparing boards. It is necessary to choose lumber of an even structure, without obvious chips and flaws. You also need to pay attention to the color of the boards. The presence of some blue on the surface of the boards is a direct evidence of gross violations in storage technology. The use of such boards is highly undesirable, since decay processes will soon begin in them.
For absolute confidence in the quality of the material used, and subsequently the entire door structure, after the purchase, the boards must be additionally dried. This must be done even if their appearance is perfect. For this, each of the boards is laid on a spacer that separates the bars so that they do not come into contact with each other in a warm room with low humidity.
The manufacture of wooden doors using such manipulations is necessary to remove excess moisture, which is necessarily inside the wood fibers. If you skip this stage, mold will grow in the material, which will subsequently destroy the door made from such boards.
The place for drying wood must meet the following parameters:
Under these conditions, the drying stage takes about 1.5-2 months. However, this process can be greatly accelerated by using special cameras. In such rooms, the air temperature is blown up to about 50 ° C, but this value cannot be exceeded.
Production of wooden doors in violation of technology and exceeding the permissible temperature regime during drying will entail the release of resinous substances from the tree, the main function of which is to hold the wood fibers together.
The drying chamber can be equipped in any suitable place in terms of parameters, be it a garage, warehouse or barn. In the process of such drying, lumber is laid in the same way as when drying without heating the air.
To manufacture a high-quality structure that effectively absorbs noise and protects from the cold, you must have the following tools:
As the technology of manufacturing wooden doors prescribes, one of the sides of the canvas must be made completely flat and pasted over with fiberboard, followed by laying insulation.
Based internal dimensions door frame the dimensions of the future door are calculated. In addition, it is important to determine the dimensions of the gaps at the top and bottom. When the measurements are made, it is necessary to cut a rectangle out of a fiberboard sheet that repeats the shape and dimensions of the future door. During the manufacturing process, special attention must be paid to the corners. They must be exactly 90 ° in size.
For a standard box with dimensions of 200 * 90cm, 2 boards must be planed to a thickness of 50 mm and a width of 110 mm. Since gaps are necessary for the free movement of the door, the canvas should be planed to dimensions 192 * 82 cm. For the entrance structure, panels are often used in the amount of 5 pieces. This allows the use of solid pieces of lumber.
Next, you need to cut 2 boards of 192 cm in length and 4 pieces of 72 cm. In addition, it is necessary to take into account studs with dimensions of 50 mm on each side. In the production of wooden doors, it is best to use a strictly symmetrical arrangement of panels. However, if it is necessary to create doors with asymmetric shapes, the parts will be fixed in the required place. This structure will not affect the functionality of the product. But do not forget about the 50 mm grooves.
When checking the assembly of parts, in the case of complete coincidence of the elements and the absence of gaps in the grooves, the assembly of the structure is performed with gluing. If it is necessary to further strengthen the structure at the joints, you can drive in chopiki 10 mm wide. After the glue has dried, it is necessary to level the structure to absolute smoothness.
In the production of wooden doors for fixing the panels, it is necessary to choose suitable material, half thinner than the main one.
These elements are cut from solid wood. The panel should fit snugly into the groove without leaving any gaps. One of the sides must be absolutely smooth. The other, if desired, can be decorated with carvings or in any other way. Panels, in order to avoid subsequent deformation of the fiberboard sheet, during installation should be located at the same level with the main surface.
After checking the accuracy of the ratio of all parameters, the panels are fixed with self-tapping screws, which are placed at an angle from the side of the subsequent lining of the fiberboard sheet. To give aesthetics, the finished product is covered with paints and varnishes or stain.
The next step in how to make doors with your own hands from wood is to install hinges. One of the most popular are semi-hinged products. With their help, the door is installed by pushing the door hinges onto the axis from above in the open position.
Initially, the marking of the loops is made at the end of the canvas and the box. The hinges themselves are attached to the canvas using self-tapping screws of suitable size. In case of distortions, it is necessary to correct the position of the hinges. Otherwise, the structure will be susceptible to self-opening or closing.
In most cases, the production of wooden doors also implies their insulation and sound-absorbing properties. To achieve this effect, it is possible to use the outer upholstery of the product. This is done by gluing the fiberboard cloth with a layer of foam rubber, while retreating from each edge by 10 mm. Subsequently, decorative outer material will be nailed onto these free strips. However, this option is more suitable for entrance doors.
The easiest way to insulate the interior linen is to fill the voids under the fiberboard sheet with a layer of cotton wool or foam rubber.
Interior doors are mandatory element in the interior, which helps in isolating rooms, distributing odors and noises. There are a lot of high-quality doors, so those who are familiar with the manufacturing technology are especially lucky interior doors do it yourself, as this will make it possible to significantly save your money.
How to make a door with your own hands?
Before proceeding with the description of the manufacturing process, it is worth considering possible options doors. Plywood products are easy to make, but glass and wood are more difficult. This will require special equipment, as well as work experience. The main types of canvases for dividing rooms today are:
Doors can be covered with coatings such as:
The simplest of them are painting and toning.
For painting, you will need one, and sometimes several layers of paint. Moreover, the quality of work directly depends on the types of paint used and the equipment used.
As for toning, in this case, a transparent or translucent varnish is used for the coating. This method will help to perfectly convey the texture of the wooden base, as seen in the photo. But for soft wood, this type of coating is undesirable, as it can leave small dents and scratches on the surface.
The lamination process consists of applying a plastic or paper film by means of over-molding.
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Veneering consists in applying a 1 mm thick wood film to the door leaf.
To start the production of paneled interior doors, you will need not only special knowledge, but also the corresponding experience. But there is such a type of product, for the manufacture of which you will need:
As for the materials, you will need to purchase:
The smallest costs will be needed when renovating the canvases that are in your premises. For this:
The veneered interior door, the manufacturer of which is the Vladimir Doors Factory (VFD), has a well-deserved reputation for elite products, which owes, first of all, to materials and production technology.
Veneered doors are made from natural high quality wood, MDF (Medium Density Wood Fiber), restructured wood veneer and finishing materials- glue, varnish, paints. All materials are rigorously and carefully selected and tested to meet quality and environmental standards.
The door can consist of a blank (solid, non-glazed) leaf or contain decorative elements and glass inserts, but, in general, is a frame structure.
Glazed door leaves consist of:
External frame made of coniferous timber;
The elements filling it are strips of special cardboard, combined with each other in the form of a structure resembling a honeycomb;
Inserts made of bars for inserting the lock;
Internal frame required for the subsequent installation of the glass filling of the glazed door;
Veneer wrapped MDF cladding.
Blind door leaves have a similar structure, with the exception of the inner frame for glazing.
The raw material used to create the frame is pine wood, which has a strictly defined moisture level: no more than 7 ± 1%.
To achieve the specified moisture content, the manufacturer uses a special technological cycle in which the wood passes through a system of four front-loading drying chambers, each of which can hold up to 50 cubic meters. m. of raw materials. The chambers are equipped with reversible fans, humidification, purification and air conditioning systems. The process is automated; the accuracy of the set indicators is achieved thanks to the system of sensor-controllers.
At the end of the drying process, the wood is moved to the cooling room, where it is kept for the next 48 hours. This stage ensures the elimination of internal stresses in the lumber, due to which the products made from it are distinguished by reliability and an extremely long service life.
MDF (Medium Density Fiberboard), used for lining the base frame, is made from harder, hardwood. The plate is produced in a highly environmentally friendly way - by hot dry pressing, with the addition of special binders that meet safety standards. This not only relieves the material of the presence of harmful substances and components that are usually contained in MDF - phenol and epoxy resins - but also guarantees it an increased density (850 kg / m3)
Produced in this way, MDF retains its density, strength, strength and geometry unchanged for a very long time.
The honeycomb elements filling the interior of the door frame between the skins give the structure the required degree of rigidity, one hundred or more times higher than the rigidity that other fillings guarantee. It is a high-tech material that gives ultra-strength and, at the same time, ultra-lightweight construction.
Doors with such a filler are not only extremely durable and lightweight (and this reduces the load on the hinges), but also have excellent heat and sound insulation qualities.
The next structural element is natural veneer. It is a thinly cut layer of wood that retains its rich natural texture and color, which cannot be imitated by any technique or trick. Bonded securely to the wood fiber backing, this highly eco-friendly and durable material does not exfoliate, does not dry out and does not crack.
The veneer application, as well as the assembly of the door frame, takes place in the already mentioned method - hot pressing. Then the door leaf is formed in accordance with the specified dimensions and the ends are veneered.
The finished door leaf is milled along the contour specified by the template, depending on the desired type of door leaf. Each of the types has its own, special way of milling. Then it is sanded by hand.
To make the latter as effective as possible, VFD specialists have developed a technology for stage-by-stage surface treatment, in which tools with different grain sizes are used in a certain sequence.
Finishing involves the application of paints and varnishes. They are applied strictly by hand, and by the masters of the highest category, real professionals. A Swedish two-component acrylic compound based on organic components "Becker Acroma" is used as a coating.
The varnish forms on the surface of the door leaf a thin but hard film with a high covering characteristic. It protects the tree from moisture changes, preventing the wood from swelling or, conversely, drying out. In addition, a layer of varnish in in full brings out the richness of wood color and texture, giving the door a finished look.
Glazed doors are supplied with frosted glass "Bronze", installed with six flexible spacers that securely fix the glass and exclude its smallest vibrations. At the same time, the process of extracting a double-glazed unit, if necessary, is very simple and not difficult.
The manufacturer has introduced a system for identifying performers, which makes it possible to detect "scammers" and eliminate them from production operations. Thus, the maximum possible control over all manufacturing technologies has been achieved. The performers' markings are located at the top or bottom - at the end of the door leaf.
Doors are packed in corrugated cardboard, wrapped on top with plastic wrap. Each door has a passport containing a description of the model, a section on warranty obligations, recommendations for use.
No matter how good the door is, for its installation and successful long-term use, such elements as a frame and platbands are needed. Their production technology also has its own characteristics that allow you to achieve excellent quality characteristics products.
The basis for the door frame is dry lumber (moisture indicator - no more than 8 ± 1%); , ten millimeter MDF and natural veneer.
The raw materials are joined by butt splicing. In order for the alignment to be successful, any defects that exceed the tolerance range are removed. The lumber gets rid of knots, cracks, rot, etc. the workpieces are glued together, and then brought to the established dimensions on four-sided planing machines.
MDF blades are cut into blanks the right size ideally matching the specified parameters. This precision has become possible thanks to the use of a special panel saw machine.
Further, with the help of hot melt glue, MDF is fixed to the prepared sawn timber. This takes place in a special workshop on automated line for facing molded products. The finished rough product is again processed with a four-sided planer, after which it is again fed to the cladding line, but this time for wrapping with veneer.
The veneered timber is sent to the paint shop, where it undergoes finishing - grinding, priming, varnishing.
Platbands and additional elements are made of profiled wood-fiber board, veneered and varnished, similar to the paintwork on the door leaf. To prevent damage, the products are packed in several layers of polyethylene.
In the production of the door leaf, the method of hot pressing is used. A distinctive feature of this method is its high productivity. At the expense of high temperature there is a rapid curing of the glue between the parts of the door leaf. One of distinctive features modern production, is the use of honeycomb filler - the most promising material for the manufacture of ultra-light and durable structures. Placing a honeycomb filler between the skins sharply increases the rigidity of the structure by more than 100 times.
Honeycomb core is one of the most economical of the existing modern construction materials... Significant strength at low weight, environmental friendliness, good heat and sound insulation, the ability to withstand shock loads, high manufacturability of processing are the main factors that ensure the high quality of products.
Honeycombs, depending on the size of the cell, the density of the cardboard, differ in their physical and mechanical properties. For doors, honeycombs are mainly used with a cell of 45 mm, 35 mm and less, and a compressive strength in a stretched state of at least 0.5 kg / cm 2 (GOST 23233-78).
The innovative honeycomb filling technology is used today in wooden structures such as doors, furniture boards, interior elements of premises, shipping pallets, as well as in aircraft construction and the manufacture of sports equipment.
Special attention during manufacturing door leaves the method of hot pressing with the use of honeycomb is given to such technological parameters as temperature, time, pressure. Strict adherence to them allows you to get quality products.
Door leaf interior door consists of the following parts:
For the manufacture of the frame, chipboard (particle board GOST 10632-89), MDF (medium density fiberboard GOST 27680-88), or their combination, depending on the wishes of the customer, are used. Frame parts are made glued in width and length. The wood is glued in width on a smooth joint in accordance with GOST 9330-76, and along the length - on a toothed spike in accordance with GOST 19414-74.
In the places where hinges, handles and other devices are located, the longitudinal bars of the frame are increased in width due to the additional installation of the bars. In a chipboard frame - under the lock and under the hinges. When machining a door leaf frame part, the thickness tolerance is very important and should be kept to a minimum. In the lower and upper bars of the frame, channels are made in the form of holes or grooves for the escape of water vapor from the glue, in order to avoid deformation of the canvas from hot vapors and moisture.
The honeycomb is stretched according to the dimensions of the frame of the door half-tone, installed in the frame and fastened with brackets to the frame. The thickness of the filler is selected in accordance with the thickness of the frame in such a way that no swelling or dips occur on the surface of the skin during pressing.
The main function of the honeycomb filler is to fill the void between the skins and to stiffen the fabric, to prevent deformation of the skins on both sides of the fabric, and thus to obtain a uniformly flat surface.
For the manufacture of skins, TSN-40 is used, HDF laminated with decorative foil. Parts are procured with an allowance for the size of the frame for subsequent formatting to the final size. The application of hot-curing resin or PVA glue, depending on the model being made, on the frame of the door leaf, with a fixed honeycomb filler, is carried out on special glue-applying equipment. The most commonly used hot-curing resin KF, since it is convenient to work with, requires more low pressure press, and is also a cheap material. The frame is laid on one skin, the second skin is placed on top and laid in the press. The press is adjusted to a pressure that creates a force on the surface of the pressed product slightly greater than the compressive strength of the honeycomb used.
The workpieces, after maturing and complete cooling, are processed to the required size on a panel-cutting center.
The beam of the door frame, the casing and the additional element are also made of chipboard, MDF, or a combination of them, again, depending on the type of batch produced, the order being executed. On special equipment, the workpieces are processed to the required geometric shapes and sizes and they are wrapped (wrapped) with decorative films. The molding process is essentially identical to the door leaf lamination process. The only difference is that in the first case the parts have a complex geometric shape, and in the second they are absolutely flat. And, accordingly, different equipment is used for these purposes.
All operations of the technological process are performed on high-tech machines of foreign and domestic production.
In the production of all types of products, several developments have been applied that relate to individual operations and materials used and are the intellectual property of the enterprise.
Before giving each individual individuality and originality, our designers develop original design for each model. In this case, the buyer can directly participate in the creation of the desired pattern or ornament. We have the ability to translate any of your fantasy into reality.
For these purposes, at the glass production site, two types of art glass processing technologies are used.
