Thick cardboard is used with the method of laying on the principle of honeycombs, which is why it got its name. Honeycomb filler comes in different qualities; fine-mesh honeycomb and large-mesh. There is also just crumpled cardboard, with which unscrupulous manufacturers fill the voids in order to reduce the cost of their products as much as possible.

honeycomb filler good quality, especially if it is fine-meshed, it provides the door with good rigidity and little heat and sound insulation. Doors with honeycomb filling are resistant to external influences, withstand changes in humidity and temperature. These doors are lighter than conventional doors and are more suitable as decorative element not restraining.

2. Rack (bar filling).

This type of door filling refers to full-bodied or (DU) reinforced doors. And they can also serve as entrances to the premises (DN), external doors.

Advantages: Good resistance to mechanical damage, good soundproofing properties.

Disadvantages: high cost and significant weight of the door, inability to use in rooms with variable or constantly high humidity, good flammability.

There is a full bar filling and a small-hollow bar filling (partial bar filling), it is also called (rack filling every other time), inside the canvas the bars are located at a distance of 5-7 cm relative to each other. With partial filling, the door has sufficient strength, acquires lighter weight and lower cost. But at the same time it loses heat and sound insulation qualities.

3. Extrusion filling (Tubular chipboard).

The most progressive and most commonly used today, filling. There is solid and tubular chipboard. Such filling, even tubular, retains the strength, heat and sound insulation properties of the bar filling. At the same time, it is deprived of their shortcomings, high cost, large weight of the door, sensitivity to humidity and flammability.

To improve properties building materials various means are used. Therefore, they can be used for different rooms. Often used for doors honeycomb filler. honeycomb pressed hydrocarton. In the context of the product like a honeycomb. More about it is described in the article.

Door construction

It is usually presented in the form:

1. frame.
2. Facings.
3. Bar for the castle.
4. Corrugated board filler.

Properties

The manufacture of honeycomb core is necessary to obtain doors. Combining with 2 layers, the sandwich panel will be strong and light. The panels may differ 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, has many advantages. These panels are resistant to water, acids, alkalis and salts, they have low thermal conductivity. Fire and UV protection is ensured by the selection of suitable cladding materials.

Purpose

Honeycomb filler is used in the following areas:

1. Creation of 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, MDF.
3. Production of furniture structures with curved surfaces.
4. Creation of flat panels of furniture and doors. This does not require additional mechanical processing.

The use of Abaqus in modeling honeycomb cores can improve the properties finished doors. They are of better quality and original.

Advantages

Honeycomb filler is made not only from pressed board, but also from hardboard. Material properties 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 canvas. Even after a few 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 up to 80 kg.
4. Moisture resistance. Corrugated cardboard, used as a honeycomb filler, has a special composition that increases the moisture-proof properties.
5. Affordable price. Honeycomb filler is much more cost-effective than other materials.
6. Environmental friendliness. All filling components are safe and non-toxic.

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

Paper honeycomb has its downsides:

1. It is used to reduce the cost of manufacturing doors.
2. Easily ignited.

Before buying, it is important to evaluate the advantages and disadvantages of the material. This uses aluminum honeycomb core, which is considered reliable and lightweight. With it, the door acquires similar advantages.

Frame characteristic

The frame of doors made of beams in terms of characteristics is almost the same as 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 of cheaper wood, the qualities of which are almost the same as similar natural material.

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

Finishing and fittings

Finishing doors with such a filler can serve different materials. The strapping of the opening of the canvases is carried out by MDF and chipboard sheets. This option is considered affordable. Valuable wood veneer is considered an expensive finish, which allows designers to experiment.

Doors are made with glazing, which looks very nice. Cloths are even and with a panel. original variants For country houses create with vintage ornaments and mirror elements. This range of features is available at a cost. Interior doors due to decoration can become a work of art.

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

Types of heaters

IN construction stores Many types of heaters from various manufacturers are sold. In addition to honeycomb filler, it is used:

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

Each material has its own characteristics. Mineral wool, expanded polystyrene and honeycomb filler are used in the insulation of economy class doors. And polyurethane foam and foamed propylene plates are necessary for elite doors and armored door voids.

How is insulation performed?

All work can be done independently. Before that, overhead elements must be removed from the canvas - handles, a lock, a peephole. Then to the surface from the inside is fixed with self-tapping screws. wooden frame. Perform the procedure 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 at the same time, it will turn out to fix the material qualitatively. It is cut there so that there is no gap between the frame and the insulation. All heaters can be cut with a metal ruler or a thin knife.

The procedure for laying insulation is carried out with lubrication inner surface fabrics with adhesive. Apply glue in a thin layer over the sheet or in strips. Then the material must be pressed. After drying, the presence of gaps is checked. The appeared backlashes are eliminated with mounting foam.

Sealed Entrance door also keeps the cold out. During the insulation of the canvas, all metal parts must be closed heat-insulating material, thereby increasing the tightness. This is the foundation for quality work.

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

The outer canvas is designed to protect the premises from moisture, temperature changes, extraneous noise. Its filler provides thermal and sound insulation. The material inside the door affects the functionality during operation. Which filler is better for the input metal door- a question that worries buyers when choosing a product.

The choice of sash depends on the functionality. Main requirements for manufacturers:

• safety;
• environmental friendliness;
• thermal insulation;
• moisture resistance;
• durability.

The outer door must ensure the safety of the inhabitants of the premises. on landings, conservation temperature regime in the apartment - the main characteristics on which the choice of product depends. The ingress of moisture leads to deformation of the canvas, the mechanism, so the material must be water resistant.

Types of fillers for the entrance metal door

Exterior door panels vary appearance and filling. Before buying a product, it is recommended to familiarize yourself in advance with the features, disadvantages of the materials used by manufacturers.

Mineral wool

The filling consists of fibers of an inorganic product with a non-combustible hydrophobic substance from basalt. This type is distinguished by sound and heat insulation, which ensures the preservation of a stable temperature regime in the living room, and a decrease in the level of extraneous noise. Mineral wool is an environmentally friendly product with a high density and heat conductivity.

Durability, strength, fire resistance, affordable price- positive properties of raw materials.

Main parameters:

• heat conductivity - 0.05-0.06 W / m 2;
• density - 15-150 kg / m;
• thickness - 90-100 mm;
• service life - 5-10 years.

Attention! The disadvantage of mineral wool is the need to install an internal frame in order to avoid deformation, sagging of the canvas.

Corrugated cardboard

A cellular fabric made of dense raw materials has a rigid shape. A special coating, which is used in the manufacture of corrugated cardboard, provides water resistance. Positive properties thick paper- lightness, heat preservation, isolation from external noise, low price.

Fragility during operation, leakage due to high humidity living quarters - the negative side of honeycomb corrugated cardboard.

slag wool

The filling is made of inorganic fibers having a hydrophobic substance from blast-furnace slag. Slag wool is intended for temporary use. Disadvantages - deformation of the iron sash when moisture enters, increased levels of humidity and dampness in the living room, low temperature outside, as well as subsidence of fibers over time. Violation of the integrity of the slag wool composition leads to the formation of space inside the door, which requires additional installation fixing frame.

Foamed polyurethane

Filling from synthetic raw materials is securely attached to the metal, completely fills the space of the canvas, ensuring reliability.

The main characteristics of PPU:

• heat conductivity - 0.018-0.034 W / m 2;
• density - 30-160 kg / m;
• thickness - 50-60 mm;
• service life - more than 50 years.

Moisture resistance, reliability, integrity, a high level of sound insulation, durability are the features of an entrance metal door with polyurethane filler.

Important! The disadvantage of a synthetic product is rapid flammability, which leads to the release of toxic substances.

Styrofoam

Tubular plastic mass retains heat during interior absorbs extraneous sounds. Thanks to the harmless, environmentally friendly material, the product is durable.

Foam characteristics:

• heat conductivity - 0.04 W / m 2;
• density - 20-35 kg / m;
• thickness - 80-90 mm;
• service life - 15-20 years.

The disadvantages of expanded polystyrene are flammability, in which there is the release of acrid smoke and toxic substances, as well as low density, the use of fasteners to fix the foam inside the sash. The presence of empty space is the reason for the violation of tightness, deformation of the canvas during use.

Foam propylene

The filler made of thermoplastic polymer pipe prevents the penetration of external noise, moisture ingress, preserves comfortable temperature inside the apartment, guarantees reliability due to its light texture. Foam propylene is a stable material with mechanical, chemical impact on the input steel door. The disadvantages of the polymer are rapid flammability, the release of toxic substances during combustion.

Styrofoam

Molten polystyrene filler has positive properties:

• strength;
• high density;
• reliability.

Expanded polystyrene in the doors does not guarantee sound and heat insulation due to the ability of the material not to let in moisture and air, which leads to the formation of condensate inside the outer leaf. Synthetic product can ignite, causing the release of toxic substances. When asked which is better... mineral wool or Styrofoam, the answer is an inorganic product. High level insulation, non-flammability, durability - the advantages of mineral wool.

Which filler is best

When choosing a material to fill the door space, one should take into account the level and heat, water resistance, fire resistance. Corrugated cardboard has a low temperature retention rate. Expanded polystyrene - weak cupping of extraneous sounds. Synthetic materials are highly flammable. The filler that meets all the needs of the buyer is mineral wool.

Honeycomb filler in interior doors is corrugated cardboard pressed in the form of honeycombs. If you look at a door with such a filler in the section, then 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)

cladding (from plastic to solid wood)

block for locking

corrugated board filler

What are honeycomb doors made of?

Let's start with the door frame. It does not differ from other types of doors - in several bars. As for the filler, corrugated cardboard is corrugated cardboard. Doors with such a filler are suitable for low-rise buildings. Due to the fact that they can withstand weight up to eighty kilograms.

The functions of honeycombs in the doors are as follows: 1) to fill the empty space; 2) give interior door stiffness; 3) exclude possible deformation of the door. Honeycombs can vary in stiffness. Some are tougher and some are less tough.

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 differ depending on the manufacturer - not everyone follows state standards. Remember the main thing - the smaller the cell size, the better, the higher the density and rigidity of the honeycomb filler.

Benefits of honeycomb doors

the main advantage is the price. Doors with such a filler are inexpensive, but again, we must not forget about the cladding. If you buy a veneered 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 tr.

door environmental friendliness. Unlike PVC and other synthetic materials, corrugated cardboard is environmentally friendly and safe.

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

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

Disadvantages of honeycomb doors

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

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

Technological process of manufacturing honeycomb doors

The door leaf consists of the following parts:

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

The frame is made of wood bars or MDF. The width of the frame bars must be at least one and a half thickness of the web, but not more than 60 mm.
Door frame parts are allowed to be glued in width and length. Gluing wood in width should be done on a smooth fugue in accordance with GOST 9330-76, and in length - on toothed spikes in accordance with GOST 19414-74.

At the locations of hinges, handles and other devices, the longitudinal parts of the frame must be increased in width by additional installation of bars with a width of at least 40 mm, a length of at least 250 mm and fixed with brackets or in another way. When processing a frame part door leaf thickness tolerance is very important and should be reduced to a minimum.
If a hot press is used to press the door leaf, it is necessary to make channels in the form of holes or slots on the lower and upper bars of the frame to allow water vapor to escape from the glue. Without channels, the canvas can be deformed from hot wet vapors.

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

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

Sheathing - fiberboard, 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 on the frame of the door leaf with honeycomb core. The most used hot-curing resin KF, as it is easy to use, requires more low pressure press, and is also a cheap material. A frame is laid on the skin, a second skin is laid on top and placed in a press. The press is adjusted to a pressure that creates a force on the surface of the pressed product that is slightly greater than the compressive strength of the honeycombs used.

There are 2 ways of pressing: hot and cold pressing.

Hot press:
Biggest Benefit this method of pressing - speed.
The average temperature is about 90°, so the drying time is 6 minutes or less. In this case, the channels must be both in the frame and in the cells. Approximately 1 minute is required for each millimeter of skin thickness.

Cold press:
The drying time is from 30 minutes to 2.5 hours.

The finished canvas is processed to the right sizes on a jointer or on a circular saw.