GB2261460A - Door construction - Google Patents

Abstract

A door comprising a plurality of timber frame members held together by metal skins. The door can be assembled very quickly to provide a secure and solid structure, without the need for screws, nails or other fixing members. One edge of each of the skins 12, 13 comprises a flange (Fig 4) which overlaps one side frame; the other edge comprises a curved flange 15 which extends around a portion of the other side member 10 and projects into a groove 14 therein. The space between the skins can be filled with a foamed plastic which also acts as an adhesive between the skins, side members and horizontal top and bottom members. <IMAGE>

Description

DOORS AND THE LIKE The invention relates to doors and like planar members.

The invention provides a door or like planar member comprising a plurality of members of timber or like material arranged to form a frame, and a pair of metal skins between which the frame is sandwiched, the metal skins retaining, or assisting in retaining, the frame members in position, by means of connections which include at least one hook-like connection between metal and timber or the like and at least one metal retaining flange extending over one of the frame members.

There may be a pair of first frame members, e.g. side members, and spacer means between the first frame members, the first frame members being held against the spacer means by hook-like connections between the metal skins and the first frame members.

Each hook-like connection may comprise a curved flange extending around a portion of a first frame member and projecting into a groove or slot in the first frame member.

The curved flange may be provided by a rolling process.

The spacer means may comprise other frame members, for example top and bottom frame members.

The other frame members may be held against the first frame members by metal retaining flanges of the skins.

Each first frame member may have a shoulder formed thereon to receive one end of one of the other frame members.

The space between the skins may be filled with insulating material, for example foamed plastics material.

Gaps may be provided between the frame members at certain locations, the insulating material being allowed to flow into these gaps to act as adhesive between the frame members.

By way of example, specific embodiments of the invention will now be described, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of one corner of an embodiment of the door according to the invention; Figure 2 is a top view of the corner of the door shown in Figure 1; Figure 3 is a horizontal cross-sectional view through part of an alternative embodiment of the door according to the invention; and Figure 4 is a vertical cross-section through part of the door shown in Figure 3.

The door, part of which is shown in Figures 1 and 2, comprises a rectangular door having two side members spaced apart by top and bottom members. One of the upright side members, comprising a timber stile, is shown at 10.

The opposite side member (not shown) is identical. The top member, comprising a timber rail, is shown at 11. The bottom frame member is identical.

The door is faced by two metal skins 12 and 13.

Each side of each side member has a slot 14 therein and the side members are prevented from moving away from the top and bottom members by bending the edges of the metal skins to form a curved flange 15 which extends around part of the side members and into the slot 14.

The top and bottom members are prevented from collapsing inwardly by appropriate shaping of the side members and the top and bottom members. As can best be seen from Figure 1, the end of the member 10 is cut away to provide a square shoulder 16 on which the member 11 rests. Part of the member 11 is also cut away, at 17, so that there is a lapped joint between the two members.

However the cut at 17 is made at a slight angle so that there is a wedge-shaped gap 18 between the members. The space between the skins is filled with insulating material in the form of foamed plastics material and this material flows into the gaps 18 to act as adhesive between the frame members.

The top and bottom members are also retained in position on the side members by bending over the metal skins at the top and bottom to provide retaining flanges 19.

The door shown in Figures 1 and 2 can be assembled very quickly to provide a secure and solid structure, secured together not only adhesively but also mechanically, but without any need for screws, nails or other fixing members.

The frame members are first cut to shape and are then fitted into the position shown, with the top members resting on the shoulders 16. The metal skins are then bent over to form the retaining flanges 19, and are rolled at the sides to shape the flanges 15 and roll them into the slots 14. The void between the skins is then filled with the foamed insulating material.

In this embodiment the metal skins have a thickness of lmm and the finished door has an overall thickness of 44mm. The finished door has an overall height of 1800mm and an overall width of 600mm. However any desired height may be manufactured, e.g. up to 2400mm and any desired width may be manufactured, e.g. up to 1500mm.

The flanges 19 have a width of 8mm and the distance between the free edges of the two flanges is 28mm. Each member 10 has a width of 18mm at the end and 30mm between the corner joints. The shoulder 16 is 30mm below the top of the member 10 and has a width of 12mm. There is a 3mm gap between the ends of the flanges 19 and the member 10 although this distance can be varied, e.g. up to 9mm.

The width of flange 19 can also be varied as desired, e.g. up to 20mm, and the distance between the free ends of the flanges 19 can be varied, dependent upon the size of door being manufactured.

Since the side faces of the timber stile, such as 10, are exposed, hinges and other items of architectural hardware can readily be attached to the door.

The flanges 19 not only assist in retaining the top and bottom frame members in position, but also add strength to the skins 13, which will otherwise be relatively flexible about a vertical axis. The flanges 15 not only have a retaining function, but also add further rigidity to the skins, resisting any tendency for the skins to flex about a horizontal axis.

Figures 3 and 4 show a slightly modified embodiment, which is generally similar to the embodiment shown in Figures 1 and 2, but has slightly different dimensions and uses an insulation infill 20, for example of polystyrene.

3mm x 3mm cut-outs 21 are provided in the frame members, to provide additional mechanical keys between the stiles and adhesive polystyrene infill.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims (15)

1. A door or like planar member comprising a plurality of frame members arranged to form a frame, and a pair of skins between which the frame is sandwiched, the skins retaining, or assisting in retaining, the frame members in position, by means of connections which include at least one hook like connection between skin and frame member and at least one retaining flange extending over one of the frame members.

2. A door or like planar member according to Claim 1, wherein a pair of first frame members and spacer means between the first frame members are provided, the first frame members being held against the spacer means by hook like connections between the skins and the first frame members.

3. A door or like planar member according to Claim 2, wherein the first frame members are side members.

4. A door or like planar member according to Claim 2 or Claim 3, wherein each hook like connection comprises a curved flange extending around a portion of a first frame member and projecting into a groove or slot into the first frame member.

5. A door or like planar member according to Claim 4, wherein the curved flange is provided by a rolling process.

6. A door or like planar member according to Claim 2, 3, 4, or 5, wherein the spacer means comprises second frame members.

7. A door or like planar member according to Claim 6, wherein the second frame members comprise top and bottom frame members.

8. A door or like planar member according to Claim 6 or 7, wherein the second frame members are held against the first frame members by retaining flanges of the skins.

9. A door or like planar member according to any of the Claims 6 to 8, wherein each first frame member has a shoulder formed thereon, to receive one end of one of the second frame members.

10. A door or like planar member according to any of the preceding Claims wherein the space between the skins is filled with insulating material.

11. A door or like planar member according to Claim 10, wherein the insulating material is a foamed plastics material.

12. A door or like planar member according to Claim 10 or 11, wherein gaps are provided between the frame members at certain locations, the insulating material being allowed to flow into these gaps to act as adhesive between the frame members.

13. A door or like planar member according to any of the preceding Claims, wherein the frame members are of timber or like material.

14. A door or like planar member according to any of the preceding Claims, wherein the skins are of metal.

15. A door or like planar member substantially as herein described, with reference to Figures 1 and 2 or Figures 3 and 4.