AU2003257921A1

AU2003257921A1 - Improvements In And Relating To Doors

Info

Publication number: AU2003257921A1
Application number: AU2003257921A
Authority: AU
Inventors: Trevor James Bills
Original assignee: Dominator International Ltd
Current assignee: Dominator International Ltd
Priority date: 2002-11-06
Filing date: 2003-10-30
Publication date: 2004-05-27
Also published as: AU2009238266A1; AU2009238345A1; NZ522454A

Description

TITLE OF THE INVENTION Improvements in and Relating to Doors BACKGROUND TO THE INVENTION This invention relates to improvements in doors and more particularly door panels.

The door panel of the present invention can be used for a variety of purposes. However, its main use is seen to be in the construction of hinged sectional doors of the type which are now widely used for garage door openings. Thus, throughout this specification the panel will be referred to in its primary in-use situation of a sectional door.

Sectional doors have generally been considered to provide a superior construction for garage doors openings. However, they have usually been considered to be a more expensive option. Also, with larger garage door openings (which are nowadays becoming more common), problems with strength, yet in a light-weight construction, can arise. Furthermore, it is desirable to ensure that the sectional door is as weatherproof as possible.

From an aesthetic point of view, it is desirable to be able to use natural timber finishes and also enable the panels to be custom made. Once again, these desirable attributes can raise the question of cost, both in use of materials and manufacturing processes.

SUMMARY OF THE INVENTION An object of the present invention is to provide a sectional garage doors and which at least goes some way to achieving some or all of the aforementioned desirable attributes or at least provides the public with a useful choice.

Broadly according to one aspect of the invention there is provided a door panel including a frame constructed primarily of metal components and a facing panel comprising a backing panel attachable to the frame and finishing elements (which form the outward facing surface of the panel) attached to the backing panel BRIEF DESCRIPTION OF THE DRAWINGS In the following more detailed description of a preferred embodiment of the invention reference will be made to the accompanying drawings in which:- Figure 1 is a front perspective view of a door panel according to the present invention, Figure 2 is a rear elevation view of the door panel of Figure 1, Figure 3 is an end elevation view of the door panel of Figures 1 and 2, Figure 4 is a partial perspective end view of the frame section of the door panel as viewed from the external panel side of the frame, Figure 5 is a more detailed end elevation view of the lower end of the door panel, Figure 6 is another partial perspective end view of the door frame but when viewed from the internal side of the frame, Figure 7 is a partial cross-sectioned end elevation view of the frame section shown in conjunction with the top rail of an adjacent frame section showing the orientation of the bottom rail of one panel with the top rail of a lower panel in a sectional garage door construction, Figure 8 is a partial perspective view from the inside of the door frame in the region of a muntin and as illustrated in Figure 7, with the top rail of a lower frame of a door panel, Figure 9 is a view similar to Figure 7 but from the external side of the frame, Figure 10 is a partial perspective front view of an alternative door panel according to the present invention, the door panel having a raised panel design, and Figure 11 is an exploded view of the facing panel of Figure DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION Referring to Figures 1 and 2, the door panel 10 is seen to comprise a facing panel 11 and a frame 12. In the illustrated form the face panel 11 comprises a backing panel 14 and a facing, which as shown, is a series of strips/boards 13 affixed to the backing panel 14. The backing panel 14 can be of plywood, hardboard or similar construction. The strips/boards 13 are adhered to the backing panel 14 by a suitable adhesive such as waterproof wood glue.

The frame 12 includes a top rail 15 with a spaced apart and bottom parallel rail 17. The top and bottom rails 15/17 are joined together by end caps 16. One or a plurality of muntins 18 are positioned between the top and bottom rails 15/17 along the length of the panel between the end cap 16.

In the illustration form, only one muntin 18 is shown. For longer door panels up to five muntins may be present.

Frame 12 is, in the preferred form, of the invention fabricated from metal componentry. As can be seen in Figure the bottom rail 17 is constructed (as is the top rail 15) so as to have a step 24 in the profile. The stepped profile of rail 17 therefore inter-engages with the stepped profile of rail 15 of an adjacent lower panel 10 in a sectional hinged door. This inter-relationship of the rails 15 and 17 can for example be seen in Figure 7.

Each of rails 15 and 17 have upstanding legs 25 and 26.

Each leg has a terminal edge formed by a portion of the leg being bent back upon itself as shown at 27. Where the legs and 26 merge into the stepped portion 24 the profile provides a "bulbous" form 28 (see for example, Figure End cap 16 is of channel form. The base 29 of the end cap 16 is profiled at each end so as to conform with the profile of the stepped portion 24 of the rails 15 and 17 (see for example Figures 4 and One leg 30 of the end cap 16 has a pair of punched out tabs 31, these tabs engage with the terminal end of leg 26 of each of rails 15 and 17.

As can be seen in Figure 4, the bent back portion 27 are pressed flat (32) where the end caps 16 are positioned over the rail 15/17 (see for example, Figure 4).

Referring to Figure 6, the other leg 33 of the end cap 16 is of wider dimension. Once again, this leg 33 engages over the leg (this time leg 25) of the rails 15 and 17. A series of openings 34 can be formed in leg 33 for the mounting of hinges so that one panel 10 can be hingedly coupled to a next adjacent panel 10 in accordance with normal sectional door construction.

As indicated in Figure 7, the legs 30 and 33 of the end cap 16 are riveted by rivets 35 to the legs 25 and 26 of the rails 15/17.

In a like manner, a muntin 18 spans between and is coupled at its ends respectively to the top rail 15 and bottom rail 17. Muntin 18 is also of channel shape with the side legs 37 thereof cut short at each end so that the floor 38 of the channel overlaps the rails 15 and 17 (see Figure 8) and riveted in place by rivets indication at 36 (see Figure 7) Once again, openings 39 can be provided in muntins 18 for mounting of hinges for joining adjacent panels.

As can be seen in Figure 8, the bulb 28 of the rail 15/17 is pressed flat where the muntins 18 are mounted. In Figure 8 the muntin 18 attached to the top rail 15 of the next lower panel 10 has been omitted in the interest of clarity.

As shown in Figure 9, a bridging member 40 is mounted between rails 15 and 17 on the opposite side of frame 12 to which the muntin 18 is mounted. This bridging member 40 is also coupled to rails 15 and 17 by rivets 36 (see Figure 7) There is thus provided a lightweight yet rigid frame 12.

Panel 11 is adhered to framework by an adhesive suitable for this end purpose.

A plywood/hardwood or other suitable panel (not shown) can be glued to the frame 12. This further panel is adhered/fastened to the opposite side of the frame to that which panel 11 is attached. This further panel will once again preferably be glued to the metal frame 12 by use of a suitable adhesive. This further or "backing" panel is optional.

An alternative panel construction 11 is shown in Figure and 11. This is a so-called raised panel design and once again, the components of the panel are adhered to a backing sheet 14. As shown, the components comprise top and bottom rails or mouldings 18 and end rail/mouldings 19. These end rail/mouldings 19 inter-connect with the rails 18 by tongues 20 and grooves 21.

The tongue 20 is preferably, as shown, part of rail 18, as this provides a clearance so that the rails 18 fit over a peripheral edge 22a of a moulded panel 22. Similarly, a rebate is formed in the end members 19 to fit over the peripheral edge 22a of panel 22.

Across the length of the backing 14 there will be a plurality of panels 22. These are separated by intermediate members 23, which once again are rebated so as to fit over the peripheral edge 22a of the or adjacent panels 22.

The arrangement shown in Figures 10 and 11 is a preferred construction using spindle moulded panels. These are made from wood throughout the panel with the steel frame adhered or mechanically fastened e.g. by screws, to the wood backing panel 14. Exterior grade glue will be used to seal all contact surfaces. The ends of the vertical elements/styles 19 and 23 are moulded out to the reverse of the rails 18 so that final assembly forms mitred internal corners. It will be appreciated by those skilled in the art that the moulding shapes may vary for different door styles.

Known raised panel designs use grooves, horizontal rails, and vertical styles to retain the infill centre panels.

With the design of the present invention, however, all external components are placed onto a backing sheet 14.

The use of more expensive facing materials is thus reduced with the backing (generally of plywood) construction providing better strength and waterproofness. The additional advantages of the panels shown in Figure 1 are also present.

With regard to panel 11, the construction provides for no tongue and groove forms, which can create capillaries for water absorption. There is also no shiplap, which once again in known constructions, can create capillaries for water absorption. Furthermore, there is no overlap of timber to other panels and this overcomes known problems of breakout of timber.

By having direct contact with the plywood/hardwood backing, good strength characteristics are achieved, while waterproofing with the use of a cross-linking adhesive is also an advantage. Because the veneer can be of say 4mm to there is a saving on expensive facing materials, thereby making a saving of natural resources. There is also less wasted material due to the cutting methods, which can be employed to create the panel 11.

By adhering panel 11 to frame 12 there is provided according to a preferred form of the invention, an adhesive line which provides further waterproofing of internal structure. As the glue is flexible, it allows relative movement, thereby flexibility of the door, which is a desirable attribute. This can lead to noise reduction during operation of the door.

By having frame 12 of a metal construction, preferably steel, good strength characteristics are exhibited. A galvanised steel construction does not warp, shrink or dry out, as can be the case with a timber frame. The use of steel also leads to a reduction in natural resources by saving on timber. A further advantage is that less maintenance is required.

The steel frame also enables roll-forming of the rails and brake press manufacture of the end caps and muntins. This is seen as providing advantages in manufacture.

While the addition of a backing panel to the frame 12 i.e.

a panel on the side of the frame opposite to that having panel 11, increases the aesthetic appeal of the construction, the backing panel also contributes to door strength, sound insulation and heat insulation. The advantages achieved by adhering the additional panel to the frame 12 correspond with those previously referred to above in respect of adhesion of panel 11 to frame 12.

Accordingly, the present invention provides a panel construction which is particularly suited for use in the manufacture of hinged sectional doors, such as the type commonly used with garage openings. Not only does the construction provide for manufacturing efficiencies and economical production, it also provides advantages to the end user as will be apparent from the foregoing disclosure.

11 It will be appreciated by those skilled in the art as described herein is by way of example and modifications are possible which fall within the scope of the invention.

Claims

2. A door panel as claimed in claim 1 wherein the frame includes top and bottom rials coupled together and held in a spaced array by end caps.
3. A door panel as claimed in claim 2 further including at least one muntin extending between the top and bottom rails.
4. A door panel as claimed in claim 2 or 3 wherein an outward facing edge profile formed by one or both of the top and bottom rails includes a longitudinally extending step. A door panel as claimed in claim 2, 3 or 4 wherein the top and bottom rials are of a generally U shaped cross section.
6. A door panel as claimed in claim 5 wherein the distal end of each leg of the U shape is folded back upon itself.
7. A door panel as claimed in claim 5 or 6 wherein each end cap is of a substantially U shape cross section, each end of the end being engaged respectively with the top and bottom rails, a position of each leg of the U shape end cap being removed to enable the floor of the U shape to engage with the top or bottom rail as the case may be.
8. A door panel as claimed in claim 6 wherein each leg of the top or bottom rail merges into the bottom of the U shape via a bulbous projection.
9. A door panel as claimed in any one of the preceding claims wherein the backing panel is adhered to the frame. A door panel as claimed in claim 9 wherein backing panel is of plywood, hardboard or similar construction.
11. A door panel as claimed in claim 9 or 10 wherein the finishing elements are adhered to the backing panel.
12. A door panel as claimed in any one of the preceding claims wherein a further panel is attached to the reverse side of the frame.
13. A door panel as claimed in claim 9, 10, 11 or 12 wherein the finishing elements comprise top and bottom elements and transverse elements extending therebetween.
14. A door panel as claimed in claim 13 wherein the transverse elements inter-connect with the top and bottom elements by a tongue and groove construction. A door panel as claimed in claim 14 wherein a tongue is formed as part of each of the top and bottom elements.
16. A door panel as claimed in claim 13, 14 or 15 further including a panel element located within an area bounded by the top and bottom element and spaced apart transverse elements.
17. A door panel as claimed in claim 16 wherein there is a plurality of panel elements.
18. A door panel as claimed in claim 16 or 17 wherein that part of each transverse element which is adjacent a panel element is rebated and an edge of the panel element is located in the rebate.
19. A door panel substantially as herein described with reference to the accompanying drawings. DATED this 21 ST Day of October 2003 DOMINATOR INTERNATIONAL LIMITED Patent Attorneys for the Applicant/Nominated Person DON HOPKINS ASSOCIATES