GB1573837A

GB1573837A - Door structure

Info

Publication number: GB1573837A
Application number: GB4964477A
Authority: GB
Original assignee: TRIGEX LTEE
Current assignee: TRIGEX LTEE
Priority date: 1977-11-29
Filing date: 1977-11-29
Publication date: 1980-08-28

Description

(54) DOOR STRUCTURE (71) We, TRIGEX LTEE, a company existing under the laws of Canada, of 4475 Laurier Blvd., Douville, St-Hyacinthe Que, Canada, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- This invention relates to a door structure and, more particularly, to an improved door construction having inner and outer metal facing panels separated by insulating material It is essential on such door structure having inner and outer metal panels that there be no direct contact between the panels so as to avoid any thermal conduction from one to the other side of the door. Such construction is particularly useful when the temperature gradient on both sides of a door is of importance.

There are two well-known types of constructions which will prevent thermal conduction between the two metal skins of a door.

A first type includes a frame consisting of vertical stiles and horizontal rails, both made of wood on which the metal skins are adhesively secured along their edges. This construction is subject to warpage. In a more recent type of construction, all the edges of the panels are interconnected to one another by means of a moulding strip which extends along all four edges of the rectangular door.

However, these moulding strips must be connected to one another at the corners of the door with a 450 chamfer and one problem associated with this construction is that, under cold conditions, the moulding strips (which are usually made of a plastics material) are subject to contraction thereby exposing the insulating material at the corners of the door.

According to the present invention there is provided a door structure having a rectangular-shaped body comprising: a pair of parallel inner and outer metal facing panels, each panel having inwardly bent portions extending along each vertical side edge thereof; the bent portions of one panel being spaced from the oppositely facing bent portions of the other panel; an upper rail member and a lower rail member respectively extending at the upper and lower edge of said body, said rail members being fixedly secured to said panels; a pair of flexible strips engagedly interconnecting said oppositely spaced bent portions of said - panels, the length of said strips being greater than the distance separating said rail members; said strips, rail members and panels defining therebetween an enclosed space; and a thermal insulation material filling said space.

In the door structure of the present invention the length of the flexible strips are greater than the distance separating the upper and lower rail members so that contraction of the strips will not leave a gap to expose the insulating material of the door. Furthermore, the flexible strip is particularly constructed so that warpage of the metal skins which are interconnected at their opposite vertical edges by the strip, may be taken up by the strip itself without deformation of the overall structure of the door.

In one form of the invention, the strip has a T-shaped configuration, with a head portion lying fiat with the side edge of the door, and a stern portion provided with flange portions to define channels to receive the bent edge portions on the panels.

A support member may be provided in the lower face of the lower rail member and is arranged to receive a series of weather strips; the support member is further arranged to be vertically adjusted to fill the gap between the lower edge of a door and the sill element.

The lower extremity of the flexible strips further includes side weather strips to prevent air circulation through the lower side corners of the door.

An embodiment of the present invention will now be described, by way of an example, with reference to the accompanying drawing, in which: Figure 1 is an elevational view of a door structure made in accordance with the present invention; Figure 2 is a longitudinal sectional view, shown broken in parts, taken along line 22 of Fig. 1, illustrating the door mounted in a door frame structure; Figure 3 is a cross-sectional view, shown broken in parts, taken along line 3-3 of Fig.

1, illustrating the door in a door frame struc ture: Figure 4 is a bottom perspective view show ing one lower side comer portion of the door of the present invention; Figure 5 is an end view of the door portion illustrated in Fig. 4, showing parts broken away; Figure 6 is an elevational front view of the door portion illustrated in Fig. 4, showing parts broken away; and Figure 7 is a plan view of the door portion illustrated in Fig. 4, showing parts broken away.

Referring to Figs. 1-3, there is shown a door structure having a rectangular-shaped body 10 that includes two parallel inner and outer metal facing panels 12 and 14. Each panel 12, 14 has inwardly bent portions, 16, 18 (see Figure 3) extending along each verti cal side edge thereof. Each bent portion 16, 18 includes a first portion 16a, 1 8a which is perpendicular to the plane of its main panel portion and a second recess portion 16b, 18b which terminates with an inwardly turned extremity 16c, 18c. Extremities 16c, 18c at each vertical side of the body 10 are spaced from one another so as to avoid thermal con duction from one metal panel 12, 14 to the other.

Referring more particularly to Fig. 5 panels 12 and 14 have upper and lower straight edges 20 and 22, 24 and 26 respec tively. An upper rail 28 and a lower rail 30, both preferably made of wood, respectively, extend at the upper and lower edges of the panels 12 and 14 and are fixedly secured, for example, by means of an adhesive, to the inner marginal edges of the metallic panels 12 and 14. As explained hereinafter, the rail members 20 and 30 do not extend the entire width of the panels 12 and 14 and terminate short of the bent extremities 16 and 18 of both panels.

To assemble panels 12 and 14. a flexible moulded strip 32 is slid between the bent portions 16c, 18c of the panel in order to interconnect them (see Figure 3). Each moulded strip 32 has a T-shaped configura tion in cross-section with a head portion 34 and a stem portion 36. The free end of the stem portion 36 further includes two out wardly projecting flange portions 38 and 40 which define with the adjacent face of the stem portion and the opposite face of the head portion, a channel 42, 44 in which are received the bent portions 16b and 16c, 18b and 18c of the panels. One example of a material used for the flexible moulded strip 32 is a plastics material known under the trademark Geon.

The recess formed by portions 16b and 18b of the bent edges of the panels is shaped to receive the head portion 34 of the strip 32 so that the outer face of the strip 32 will be in the same plane as that of the outer face of portions 16a and 18a of the bent edges of the panels. For improved engagement of the bent portions in their respective channels 42 and 44, the inner faces of the head portion and of the stem portion may be provided with small lengthwise ribs 43 and 45.

Moulded strips 32 extend for the entire height of the panels; hence, they abut the opposite extremities of rails 28, 30. This is an important feature of the present invention in that contraction of the plastics strip 32 under cold temperature conditions will not result in leaving a gap between the rails 28, 30 and the strips 32.

The rail members 28 and 30, the moulded strips 32 and the panels 12 and 14 define therebetween an enclosed space. This space is filled with a thermal insulation material 46, such as formed-in-situ polyurethane foam. An opening (not shown) is provided in the lower rail 30 to allow foam injection during assembly.

The door further includes blocks 48, 49, 50 and 52 which are adhesively secured to the inner marginal faces of the panels 12, 14 and serve to secure a handle 54 and hinges 56 (three having been shown). These blocks, which are preferably made all of wood, include on the outside face thereof a groove 58 (see Fig. 3) to receive the stem portion 36 and its flange portions 16c and 18c. The width of groove 58 is preferably made smaller than the overall width of the flange portions 16c and 18c to provide a tight engagement on the flange portions in the groove.

Referring to Figs. 4 to 7, the lower rail member 30 has a concave lower surface in which is adjustably received a support member 60. This support member 60 extends lengthwise of the lower rail and includes a central channel 62 and two side channels 64 and 66. A pair of weather strips 68 and 70 have their upper ends slidably engaged in the channels 64 and 66, respectively. The support member 60 is adjustably secured to the rail member 30 by means of L-shaped elements 72 mounted at each extremity of the rail member 30. These elements 72 include a vertically extending portion 72a abutting the edge of the rail and a horizontally extending portion 72b which is received in the channel 62. Vertical portion 72a is provided with a slot 74 through which a screw 76 extends to engage a socket 78 fixedly received in the edge of rail member 30. As can be seen in Fig. 6, the height of support member 60 may be adjusted by slackening the screw 76.

Further weather strip means are provided on each corner of the door beneath the moulding strips. These weather strips, generally denoted 80, extend perpendicularly to the weather strips 68 and 70 and serve to prevent air circulation along the sides of the door. In the embodiment described, these weather strips consist of a yoke-like member having two vertically extending strips 82 and 84 which are respectively received between the head portion 34 of the moulded strip and the recess portions 16b, 18b of the bent edge portions of the panels. Height adjustment of the weather strip 80 is also done by slackening screw 76 and releasing the pressure exerted by the head portion 34 of the moulded strip on the two vertical strips 82 and 84. A brushlike member 86 is supported in a channel 87 provided in the lower part of member 80.

Referring to Figs. 2 and 3, door 10 is shown mounted for use in a conventional door frame having side members 88 and 90, a header 92 and sill plate 94. The sill plate 94 is usually made of metal and includes a portion 96 provided with series of transversely spaced openings 98 for water flow.

Air entering through openings 98 is prevented from reaching the inside of a room due to the weather strip 70 and side brushes 86. The other members 88, 90 and 92 of the door frame may consist of claddings made of plastics material. Referring to Figs. 2 and 3 these door frame members are each provided with extension means which allow the addition of further members 88a, 92a, 94a, 96a to suit various sizes of door frames.

WHAT WE CLAIM IS:- 1. A door structure having a rectangularshaped body comprising: a pair of parallel inner and outer metal facing panels, each panel having inwardly bent portions extending along each vertical side edge thereof; the bent portions of one panel being spaced from the oppositely facing bent portions of the other panel; an upper rail member and a lower rail members respectively extending at the upper and lower edge of said body, said rail members being fixedly secured to said panels; a pair of flexible strips engagedly interconnecting said oppositely spaced bent portions of said panels, the length of said strips being greater than the distance separating said rail members; said strips, rail members and panels defining therebetween an enclosed space; and a thermal insulation material filling said space.

2. A door structure as claimed in claim 1, in which said interconnected bent portions define a recess along each vertical side of said body; each said strip having a generally Tshaped configuration with a head portion and a stem portion, said head portion being received in said recess.

3. A door structure as claimed in claim 2, in which each said bent portion includes a first portion extending perpendicular to the plane of said panels and a recessed second portion defining in part said recess; said head portion of said strip having an outer surface substantially aligned with said first portions to thereby define generally planar vertical side edges to said body.

4. A door structure as claimed in claim 3, in which each said strip includes flange portions outwardly extending at the free end of said stem portion of said T-shaped configuration; said flange portions defining with said stem portion and said head portion opposite channels to engagedly receive therein said second portions of said bent portions.

5. A door structure as claimed in claim 4, further comprising lengthwise ribs on the inner face of said head portion and of said stem portion for providing tight engagement of said bent portions in said channels.

6. A door structure as claimed in any preceding claim, further comprising blocks located in said space adjacent said vertical bent portions for securing handles and hinges thereto; said blocks being adhesively secured to said panels and each including a groove on one side thereof for receiving therein said interconnected strip and bent portions.

7. A door structure as claimed in claim 6, in which each said groove is slightly smaller in width than the overall width of said flange portions for providing a tight engagement of said flange portions in said groove.

8. A door structure as claimed in any preceding claim, in which said lower rail member is provided with a longitudinal recess in the lower face thereof; a support member adjustably received in said recess; and first weather strip means having one end slidably received in said support member and the other end extending below the lower edge of said panels for contacting a door sill element.

9. A door structure as claimed in claim g, further comprising releasable attachment means for adjusting the height of said support member in said recess and, consequently, for adjusting the lower end of said weather strip means to said door sill element.

10. A door structure as claimed in claim 9, wherein said releasable attachment means include a pair of L-shaped elements mounted at opposite ends of said lower rail member; said L-shaped elements each including a vertical portion having a slot therein and a horizontal portion extending in a further channel provided in said support member; said releasable attachment means further including fastening means extending through said slot and being fixedly received in each said end of said lower rail.

11. A door structure as claimed in any of claims 8 to 10, further comprising second weather strip means mounted adjacent the lower extremity of each said strips; each said second weather strip means including a first

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **. on each corner of the door beneath the moulding strips. These weather strips, generally denoted 80, extend perpendicularly to the weather strips 68 and 70 and serve to prevent air circulation along the sides of the door. In the embodiment described, these weather strips consist of a yoke-like member having two vertically extending strips 82 and 84 which are respectively received between the head portion 34 of the moulded strip and the recess portions 16b, 18b of the bent edge portions of the panels. Height adjustment of the weather strip 80 is also done by slackening screw 76 and releasing the pressure exerted by the head portion 34 of the moulded strip on the two vertical strips 82 and 84. A brushlike member 86 is supported in a channel 87 provided in the lower part of member 80. Referring to Figs. 2 and 3, door 10 is shown mounted for use in a conventional door frame having side members 88 and 90, a header 92 and sill plate 94. The sill plate 94 is usually made of metal and includes a portion 96 provided with series of transversely spaced openings 98 for water flow. Air entering through openings 98 is prevented from reaching the inside of a room due to the weather strip 70 and side brushes 86. The other members 88, 90 and 92 of the door frame may consist of claddings made of plastics material. Referring to Figs. 2 and 3 these door frame members are each provided with extension means which allow the addition of further members 88a, 92a, 94a, 96a to suit various sizes of door frames. WHAT WE CLAIM IS:-

1. A door structure having a rectangularshaped body comprising: a pair of parallel inner and outer metal facing panels, each panel having inwardly bent portions extending along each vertical side edge thereof; the bent portions of one panel being spaced from the oppositely facing bent portions of the other panel; an upper rail member and a lower rail members respectively extending at the upper and lower edge of said body, said rail members being fixedly secured to said panels; a pair of flexible strips engagedly interconnecting said oppositely spaced bent portions of said panels, the length of said strips being greater than the distance separating said rail members; said strips, rail members and panels defining therebetween an enclosed space; and a thermal insulation material filling said space.

upward portion secured between said bent portions of said panels and said strip, and a lower sealing portion extending in a plane perpendicular to the plane of said first weather strip means and having its lower extremity adapted to contact said door sill element.

12. A door structure comprising: a rectangular-shaped body having two pairs of opposite side edges; a pair of parallel inner and outer metal facing panels, each panel having inwardly bent portions extending along a first pair of said side edges, the bent portions of one panel being spaced from the oppositely facing bent portions of the other panel; a pair of elongated members respectively extending at the other of said pairs of said side edges of said body, said members being fixedly secured to said panels; a pair of flexible strips engagedly interconnecting said oppositely spaced bent portions of said panels, the length of said moulding strips being greater than the distance separating said members; said moulding strips, members and panels defining therebetween an enclosed space; and an insulation material filling said space.

13. A door structure, substantially as hereinbefore described with reference to the accompanying drawings.