Door panels are the heart of every door, as they significantly determine the security, thermal insulation and sound insulation properties of the entire door.
Door panels also influence the mass of an entrance door and therefore its sound insulation and insulating properties. In addition to the primarily technical properties, door panels also contribute significantly to the appearance of the front door and characterise the appearance of your home.
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Front door panels usually consist of composite panels, also known as sandwich panels due to their layered structure, which is similar to a sandwich. The finished door panel therefore consists of several layers, usually made of different materials such as plastic, polystyrene, wood and chipboard as well as aluminium panels. The different combinations of these materials form the filling structure. Styrofoam and wood materials contribute in particular to thermal insulation, while reinforcement with an aluminium panel provides security and burglary protection. The sum of the respective layers results in the panel thickness, i.e. the thickness of the entire door panel.
In the production of door panels, the individual layers are glued together. There are various bonding methods and processes. Continuous, linear production offers particularly high productivity thanks to the constant flow of material. Here, a PUR hotmelt adhesive is applied to the entire surface of the material panels using a roller coater machine and then the next layer is applied and immediately pressed in a roller calender. This step is repeated until the filling structure is complete.
The major advantage of PUR hotmelt adhesives for door panels, apart from the continuous processing without static pressing, is their versatility, which allows a wide variety of materials to be bonded together. PUR adhesives are also particularly weather-resistant. The finished front door is constantly exposed to the weather and temperature fluctuations. It is therefore particularly important that the adhesive can withstand heat, cold and humidity so that the structure of the door panel is guaranteed for many years.
You are free to choose the design of your front door panel. In addition to classic, plain door panels, there are also different structures, some with applied ornaments or with panel cut-outs for glazing. You also have almost endless design options in terms of colours, surface textures and decors. Door panels are often covered with high-quality plastic foils that give the front door a choice of different colours as well as a wood or metal look. These decorative foils are weather- and UV-resistant and are characterised by their colour fastness as well as their protective function for the underlying materials. They are also dirt-repellent and easy to clean, and in special cases even graffiti can be removed.
Bonding decorative film to door panels is also known as flat lamination. In most cases, the aluminium or PVC sheets that form the outside of the door panel are laminated before the sandwich panels are installed. They are then glued to the filling materials. However, it is also possible to foil the entire door panel. In both cases, a wide foil lamination system is used for the flat lamination. The best results can be achieved by applying the adhesive onto the foil. This not only saves adhesive, but also guarantees a uniform adhesive pattern thanks to the precise slot nozzle application. This means that the film can be bonded to the door panel without wrinkling or other surface defects such as shiny spots or orange peel.
When laminating door panels, large film widths are usually used, some of which are difficult to handle. Creasing must be avoided and compliance with the recommended process temperatures at strategically important points is essential to guarantee high-quality flat lamination of door panels. TAKA has a range of PUR adhesives that have been specially developed for panel lamination. They allow the adhesive to be applied at low temperatures to prevent the temperature-sensitive plastic foils from rippling. There are also adhesives for the flat lamination of front doors, which are particularly suitable for the production of demanding surfaces such as high gloss or super matt.
Thanks to our joint development work with the company WPR, which manufactures industrial wrapping systems for the flat lamination of door panels, TAKA can offer you comprehensive advice and assistance in all matters relating to flat lamination. Simply contact us using the contact form and we will be happy to help you.
