Door filling is a material that initially participates in the formation of the skeleton of the door, its internal foundation. The doors have different kinds filling. Let's start with the most “airy-dandelion” hollow ones. They are filled with corrugated cardboard cellular appearance. This type of filling is also called MDF. As a rule, this applies to laminated and veneered economy class doors from a low-quality manufacturer. Door filling plays a significant role in its operational characteristics: wear resistance and practicality. Agree, hollow light door you will never put it as the entrance to your apartment. Conversely, do not install heavy door, for example, in openings for a toilet and bathroom. In a house built back in the USSR, where the walls are made of plaster, 30 mm thick, the entire wall structure can collapse.

We are talking to you about the filling for doors: interior, plumbing, painted, construction, veneered, related to wooden doors. But the filling of high-quality metal entrance doors is usually a mineral slab. Mineral wool, polystyrene foam or polystyrene cannot be used there.
Plastic interior doors can be filled with polyurethane fillers. At the same time, their performance properties increase. Such doors become insulated and suitable for the street.

Real door manufacturers will never stuff paper trash into their doors to make “dummies.” They use natural filling with solid wood inserts made from solid wood. coniferous species tree. This type of filling is more practical for doors used in offices, houses and apartments.

Doors filled with slats, massive river filling

Doors filled with massive slats are classified as solid doors. They have higher noise insulation and are less susceptible to wear resistance. Ask yourself a logical question: which interior doors would you prefer, empty cardboard ones or solid solid ones? Most likely, many buyers will choose the second option.

Specifics for high-traffic areas recommend installing doors with a denser panel massive filling. For example, in social, medical, educational, government agencies, reinforced doors dense filling is simply a necessity. For monolithic internal reinforcement of doors, various fillers are used. This can be solid wood and tubular chipboard. Weight of reinforced standard door leaf is more than 30 kg. And if it's reinforced door block double-leaf already with a frame and a threshold, and even a non-standard size, then four people will have to carry it.

DoorExpo company, how reliable manufacturer doors, monitors the quality of its products. Hollow interior doors will never be manufactured here. All our beauties are filled with solid wood, even construction doors. Ours are all wooden, except for the laminated ones. Be careful to avoid hollow doors. Their service life is short. Of course, this cannot be determined immediately, because expensive doors (even Italian ones) can appearance to be irresistible, but in essence to be “dummy”. What can we say about economy class doors - door hollowness is all too common in this segment.

The honeycomb filler in interior doors is corrugated cardboard pressed into a honeycomb shape. If you look at a cross-section of a door with such a filler, the filler will remind you of a honeycomb. As a rule, the design of a door with such a filler looks like this:

door frame (MDF or solid wood) natural wood)

cladding (from plastic to solid wood)

block for installing a lock

corrugated cardboard filler

What are honeycomb doors made of?

Let's start with the door frame. It is no different from other types of doors - several beams. As for the filler, corrugated cardboard is just that: corrugated cardboard. Doors with such filling are suitable for low-rise buildings. This is due to the fact that they can withstand weights of up to eighty kilograms.

The functions of honeycombs in doors are as follows: 1) to fill empty space; 2) give rigidity to the interior door; 3) eliminate possible deformation of the door. Honeycombs can differ in hardness. There are more tough ones, and there are less tough ones.

In Russia, the most common type of honeycomb is honeycomb with a cell size of 45 millimeters and a compressive strength of 500 grams/cm2. This is the state standard. You should also remember that the size of the cells in the doors may vary depending on the manufacturer - not everyone follows state standards. Remember the main thing - what smaller size cells, the better, the higher the density and rigidity of the honeycomb filler.

Advantages of doors with honeycomb filling

the main advantage is the price. Doors with such filling are inexpensive, but again we must not forget about the cladding. If you buy a veneer door with a honeycomb core, it will be more expensive than a PVC door with the same honeycomb core. For example, our Marco DG door in natural walnut color costs around 10 -11 thousand rubles.

environmental friendliness of the door. Unlike PVC and others synthetic materials– corrugated cardboard is environmentally friendly and safe.

resistance to changes in temperature and humidity conditions, resistance to light impacts.

a door with such a filler will be light. Within seventeen kilograms.

Disadvantages of doors with honeycomb core

The main disadvantage of honeycomb core is its soundproofing properties. If we try to evaluate on a five-point scale, we would give 2-3 points.

Another disadvantage of filler is that it is used to reduce the cost of door production. Hence the relative cheapness.

To improve properties building materials are used various means. Therefore they can be used for different rooms. Honeycomb core is often used for doors. Hydrocardboard pressed into a honeycomb shape. In cross-section, the product is similar to a honeycomb. More details about it are described in the article.

Door design

It is usually presented in the form:

1. Frame.
2. Facings.
3. Bar for the lock.
4. Corrugated cardboard filler.

Properties

The production of honeycomb core is necessary to obtain doors. Thanks to the combination with 2 layers, the sandwich panel will be durable and light. Panels may vary depending on the orientation of the structure. Due to the hexagonal shape, the compressive strength of the honeycomb core is greater compared to foam layers.

Polypropylene filler, unlike paper filler, has many advantages. These panels are resistant to water, acids, alkalis and salts, they have low thermal conductivity. Protection against fire and ultraviolet radiation is ensured by choosing suitable facing materials.

Purpose

Honeycomb core is used in the following areas:

1. Creation interior doors. The material is valued for its excellent quality, minimum costs and excellent properties.
2. Production of thick furniture elements. Due to the increase in the thickness of the material, the weight of the furniture panel almost does not increase, while its price is lower compared to chipboard and MDF.
3. Manufacturing of furniture structures with curved surfaces.
4. Creation of flat panels for furniture and doors. This does not require additional mechanical processing.

Using Abaqus to model honeycomb cores can improve the properties of finished doors. They turn out to be of higher quality and original.

Advantages

Honeycomb core is made not only from pressed cardboard, but also from hardboard. The properties of the material include:

1. Ease. The design will last much longer. The door is easy to install, and the hinges do not sag under the weight of the door leaf. Even after several years, the product will be very easy to open and close.
2. Heat and sound insulation. Insulation protects against cold and noise, which is an important quality for a living space.
3. Strength. The filler has good resistance, so the doors can withstand loads of up to 80 kg.
4. Moisture resistance. Corrugated cardboard, used as a honeycomb filler, has special composition, which increases moisture-proof properties.
5. Affordable price. Honeycomb core is much more cost effective than other materials.
6. Environmental friendliness. All filling components are safe and non-toxic.

The door frame is usually made of pine, and at the level of the lock there is a thickening for its insertion. Reinforcement of the fabric is performed around the fixation of the loops. Doors are divided into paneled and smooth, solid and glazed, veneered, painted and laminated. Honeycomb core came from Italy and is now recognized as one of the most common options for improving the properties of doors.

Paper honeycomb also has its disadvantages:

1. Used to reduce the cost of manufacturing doors.
2. Highly flammable.

Before purchasing, it is important to evaluate the advantages and disadvantages of the material. In this case, aluminum honeycomb core is used, which is considered reliable and lightweight. With it, the door gains similar advantages.

Frame characteristics

The characteristics of door frames made of beams are almost no different from other types of doors. In order for the canvas to acquire an aesthetic appearance, as well as to make it reliable, the perimeter of the frame and door handle made from natural wood. The garter is made from cheaper wood, the qualities of which are almost no different from similar natural materials.

The advantage of the door filler is its density and lightness, which is ensured by the cellular structure of the cardboard. Pressed cardboard is considered natural and environmentally friendly pure material. Doors can be used in different rooms.

Finishing and fittings

The finishing of doors with such a filler can be different materials. MDF and chipboard sheets are used to frame the opening of the canvas. This option is considered affordable. Wood veneer is considered an expensive finish valuable species, which allows designers to experiment.

The doors are made with glazing, which looks very beautiful. The canvases can be smooth or with a panel. Original options For country houses created with vintage ornaments and mirror elements. This range of possibilities is affordable. Thanks to the finishing, interior doors can become a work of art.

Since the design is lightweight, it does not require heavy hinges. For installation, universal components for hidden and open type. Handles and latches can be different, it all depends on the style and features of the doors.

Types of insulation

IN construction stores Many types of insulation from different manufacturers are sold. In addition to honeycomb filler, the following is used:

1. Foamed polystyrene.
2. Plates based on foamed propylene.
3. Minvata.
4. Polyurethane foam.

Each material has its own characteristics. Mineral wool, foamed polystyrene and honeycomb filler are used to insulate economy class doors. And polyurethane foam and foamed propylene plates are necessary for luxury doors and hollow armored doors.

How is insulation performed?

All work can be done independently. Before this, you need to remove the overhead elements from the canvas - handles, lock, peephole. Then they are fixed to the surface from the inside with self-tapping screws. wooden frame. The procedure should be performed carefully so as not to damage the metal sheet.

The insulation is placed between wooden beams and frame base. It must be fixed with glue or fastening by surprise. Using 2 methods simultaneously, you will be able to secure the material efficiently. It is cut there so that there is no gap between the frame and the insulation. All insulation can be cut with a metal ruler or a thin knife.

The procedure for laying insulation is carried out by coating inner surface canvas with adhesive. Need to apply glue thin layer on a sheet or in strips. Then the material must be pressed. After drying, check for gaps. Any gaps that appear are eliminated with polyurethane foam.

Sealed Entrance door also lets in the cold. When insulating the canvas, all metal parts must be covered thermal insulation material, due to which the tightness will increase. This is the basis for doing quality work.

Thus, honeycomb core is used in the construction of many doors. With it the design will be light and high quality. But each person must decide for himself whether he should buy such a canvas.

Interior doors complement the design of our home. They delight the eye with their variety of laminated, veneered and painted surfaces. We don't ask ourselves what is in the middle of the product. It’s a pity, because the internal component – ​​the filling – largely determines the sound and thermal conductivity of the canvas, and also affects its strength, ability to maintain geometry and service life. There are several types of filling: honeycomb, lumber, chipboard, tubular chipboard, etc.

Honeycomb filling of the door leaf

The era of aircraft construction (40-50s) began with the appearance of honeycomb fillers. They were used to lighten and give permanent shape to aircraft structures. The composition began to be actively used for interior doors in the middle of the last century, making them more durable, lighter, and cheaper. Such filling internal space and today one of the most common.

Honeycomb filler consists of cells (honeycombs) made of pressed cardboard - corrugated cardboard, compressed with material enclosed in a frame. With the help of bars, the space near the lock is strengthened, and due to the air spaces in the cells, the filler makes the doors light (maximum 17 kg), facilitates installation and reduces the load on the hinges. To all the advantages cellular content includes moisture repellency and permanent shape support. Such doors made of chipboard and MDF are given a marketable appearance: laminated, veneered or simply painted. Modern filler (impact-proof alloys, opaque materials) is used in leaves with a profile made of anodized aluminum (Al) - these are modern German doors made of aluminum (Al) and steel, in combination with glass.

Bar filling of the door leaf

Bar filler can be partial. The bars inside the door are located at a distance of 5-7 cm from each other, which lightens the door leaf and the load on the hinges.

Solid filler, when the bars fit tightly to each other - high sound insulation and the ability to withstand heavy loads.

Filling the door leaf with chipboard

Chipboard filler is obtained by hot, flat pressing of wood particles plus binder. This method is used to fill low-traffic economy class products.

Extrusion board - this filler is obtained by vertical pressing, the wood particles are perpendicular to the board, which increases strength. This filler is located between panels made of MDF, chipboard, HDF. To give it a marketable appearance, it is covered with veneer or enamel.

Extrusion - tubular filler is the use of slabs with voids (holes in the form of tubes) as an alternative to honeycomb. These are much easier, from here easier installation, less wear on loops, more economical, since little material is spent on the canvas. They are not afraid of large passages of people and can withstand pressure of 20 kg/cm. sq., shockproof, heat and noise resistant. This material best meets quality requirements.

The company's website presents products from various profiles with modern design. Do right choice A sales consultant will help you; professionals will complete an order that meets your wishes, deliver and install it on time. The company has existed for 6 years in the construction market and has established itself as a serious partner.

Technological process for manufacturing honeycomb doors

The door leaf consists of the following parts:

• frame (wood or MDF);
• block for inserting a lock on both sides (30-40 cm);
• cladding (cladding) - fibreboard, chipboard, MDF, etc.;
• filling (paper-honeycomb filler according to GOST 23233-78).

The frame is made of wood or MDF bars. The width of the frame bars must be no less than single - one and a half thickness of the canvas, but not more than 60 mm.
Door frame parts can be made glued in width and length. Gluing of wood along the width should be done on a smooth fugue in accordance with GOST 9330-76, and along the length - on jagged tenons in accordance with GOST 19414-74.

At the locations of hinges and handles and other devices, the longitudinal parts of the frame must be increased in width due to additional installation bars with a width of at least 40 mm, a length of at least 250 mm and secured with staples or other means. When processing a door frame part, thickness tolerance is very important and should be reduced to a minimum.
If a hot press is used to press the door leaf, you need to make channels in the form of holes or slots on the lower and upper bars of the frame to allow water evaporation from the glue to escape. Without channels, the canvas can become deformed from hot, damp vapors.

The canvas is assembled as follows:
We stretch the honeycomb core according to the dimensions of the door leaf frame, install it in the frame and fasten it with staples to the frame. The honeycomb paper filler should be 0.3 - 0.6 mm thicker than the frame frame to achieve better sizing.

Main function of cell- fill the void between the skins and give rigidity to the canvas, eliminate local deflections of the skins on both sides of the canvas, while creating the flatness of the surfaces so necessary for further operations. Honeycombs, depending on the cell size and cardboard density, vary in rigidity. For doors, honeycombs with a cell size of 45 mm and a compressive strength along the thickness in the stretched state of at least 0.5 kg/cm2 (GOST 23233-78) are mainly used. According to the experience of honeycomb core manufacturers, it is preferable to use honeycombs with a cell size of 35 mm or less for doors.

Sheathing - fibreboard, chipboard, MDF, etc.
Sheathing parts are prepared 5 mm wider than the dimensions of the frame frame in the amount of 2 pieces.
The gluing assembly is as follows:
We apply hot-curing resins or PVA glue to the frame of the door leaf with honeycomb core. The most commonly used hot-curing resin is KF, since it is convenient to use and requires more low pressure press and is also a cheap material. The frame is laid on the skin, the second skin is laid on top and placed in the press. The press is set to a pressure that creates a force on the surface of the pressed product that is slightly greater than the compressive strength of the honeycomb used.

There are 2 pressing methods: hot and cold press.

Hot press:
The greatest advantage of this pressing method is speed.
The average temperature is about 90°, so the drying speed is 6 minutes or less. In this case, the channels must be in both the frame and the cells. Each millimeter of sheathing thickness requires approximately 1 minute

Cold press:
Drying speed ranges from 30 minutes to 2.5 hours.

The finished canvas is processed until required sizes on a jointer or circular saw.