GB2318378A

GB2318378A - Fixing profiled mouldings to skinned doors

Info

Publication number: GB2318378A
Application number: GB9620555A
Authority: GB
Inventors: Paul Cruise; Anthony Addams; Geoffrey Perkin; David Hodges
Original assignee: DOOR PANELS PLC
Current assignee: DOOR PANELS PLC
Priority date: 1996-10-02
Filing date: 1996-10-02
Publication date: 1998-04-22
Also published as: GB9620555D0

Abstract

Profiled mouldings 10 are secured to a door 2 by fixing members 6. The profiles may be purely decorative, or be used to mount an infill panel 4. Each fixing member is fitted into a drilled aperture with slotted serrated portions 8 standing proud of the door surface. Corresponding serrated recesses 12 allow the profiles to be to be fitted over the fixing members, and be non-releasably secure. Adhesive tape 14 positioned between the profiled mouldings and the door/infill panel provides additional fixing of the profiled mouldings. In a further embodiment fig. 7 (not shown) the fixing member is replaced by a dowel and the profiled mouldings are secured purely by adhesive means.

Description

DOOR AND METHOD OF CONSTRUCTION The present invention relates to a door and method of constructing a door. In the following description the term "door" is used to refer to a door or door panel.

It is known to provide doors comprising plastics sheets laminated together. The sheets are shaped, for example by vacuum forming, in order to give relief effects, as for example mouldings and panelling. The sheets are then laminated together by spraying with a curable adhesive and pressing. Depending on the customer requirements, the door may comprise two sheets of plastics with a sandwich core such as styrofoam. Plywood, steel or aluminium reinforcement sheets may also be provided between the sheets.

If a glazing panel is required in the door, an appropriate aperture for the panel may be cut in the various components before assembly or in the door after assembly of the components. In the former case the glazing panel is located in place prior to pressing. In the latter case, the panel is located in place by abutment against one of the plastics sheets which is provided with a slightly undersized aperture. The panel may be secured by adhesive or the like, and/or with a plastic trim.

In general such doors are coated according to customer requirements. For example, plastics coatings giving a desired colour may be used or a woodgrain foil may be applied. Such decorative coatings may be applied to the external surface of the plastics sheets before or after assembly.

When woodgrain foil is applied and laminated to the edges and, especially, outer corners of the profiled parts of the plastics sheets. Such stress points are exacerbated by heat and, given that a woodgrain foil door may absorb considerable heat and for example when exposed to the sun may rise to a temperature of about 7 OOC, cracking of the foil frequently occurs, from profile corners. In the industry there is an unacceptably high return rate on woodgrain foil doors indicating that current methods of construction are unsatisfactory.

A further problem with woodgrain foil plastics doors is that the grain runs in a single direction so that the grain effect looks wrong, particularly around the profiled parts of the plastics sheets. This detracts from the aesthetic appeal of a woodgrain door.

A still further known problem with plastics doors is that they lack the inherent security of, for example, metal doors or the like.

One known method of fixing a moulded profile member to a laminated door involves using two-piece lugs. For each lug, a slot is formed in the door and in the moulded member and one end of each part of the lug comprises an elongate stud. In use, the studs are located separately in the slots and secured therein by turning through 900C.

The other ends of the parts of the lug respectively comprise a serrated male and female member which are pressed together to provide a ratchet type fitting. Thus, part of the lug is secured to the door and the other part to the profiled member. The two parts of the lug are then pressed together to releasably secure the profiled member to the door. The profiled member can be removed by using a specially adapted thin spanner to turn one of the lug parts by 900C so that the two parts can be separated.

However such a system is relatively complicated particularly given that a large number of such lugs is typically required to fix the profiled members to the door. Furthermore, the method requires that a gap be provided so that the spanner can be inserted. Such a gap must be sealed with a gasket or the like.

According to a first aspect of the invention there is provided a door having one or more profiled members secured to one or both outer surfaces thereof, the or each profiled member being secured to the door by means of one or more fixing members located in corresponding aperture(s) in the door and extending into corresponding aperture(s) in the profiled member(s), and means for nonreleasably securing said one or more fixing members to said one or more profiled members.

Preferably, the or each fixing member is an integral one-piece member. The fixing member may comprise an elongate member, preferably of substantially square crosssection. Preferably, the or each fixing member extends through the door and into a corresponding aperture in a profiled member located on each side of the door.

Preferably there are means for securing the or each said fixing member to both such profiled members. Preferably, the profiled members substantially abut the door surface either directly or indirectly via an adhesive layer, which may be a layer of double-sided adhesive tape.

Preferably, the means for non-releasably securing the fixing(s) to the profiled member(s) is such that the or each profiled member is non-releasably secured to the door surface. The non-releasable securing means may suitably be an exclusively mechanical means, not employing an adhesive. Preferably the act of pushing a profiled member onto a fixing means in a direction axial to the fixing means effects the mechanical securement. The fixing means preferably comprises an end of a fixing member shaped to non-releasably engage in the corresponding profiled member aperture. Preferably, at least one end of the fixing member comprises a serrated portion. Typically two opposing sides of the end comprise serrated portions.

Preferably, the aperture in the profiled member comprises a corresponding serrated surface which engages the end of the fixing member in a ratchet fit so that the profiled member may be press fitted over the end of the fitting member and is non-releasably retained thereon.

Preferably the or each end of a fixing member of the invention is slotted, such that portions thereof may be flexed towards each other during assembly, and subsequently relax apart, to ease the action of securing the profiled member to the fixing member, and enhance the secureness of the connection thereby obtained.

Preferably, the apertures formed in the door and/or in the profiled members have a substantially circular or part-circular cross-section.

Alternatively or additionally the non-releasable securing means may comprise an adhesive means typically located between the end of the fixing member and the corresponding aperture in the profiled member. Such adhesive means may comprise adhesive, glue or the like or adhesive tape such as double-sided adhesive tape.

It will be appreciated that any suitable nonreleasable securing means which provides a secure, permanent attachment of a profiled member to a door body may be used.

Preferably, the profiled members comprise a profiled frame, which may have any suitable shape such as rectangular, square, circular, or oval.

Preferably, the profiled members comprise mouldings which may for example comprise plastics extrusions.

Preferably the underside of the profiled members comprises a raised or arched surface, preferably having a flat region on at least one side thereof. Preferably, the fixing member comprises the same material as the profiled member. In the latter case, use of an adhesive on the ends of the fixing member preferably fuses the fixing member and the profiled member together.

The fixing member may have a substantially uniform cross-section or may comprise a body portion having a cross-section of one dimension and one or both end portions having a cross-section of a different dimension, for example of a smaller cross-sectional dimension.

Preferably, the body portion and the end portions each have a substantially square cross-section.

The door may comprise any suitable internal structure or materials but preferably comprises a laminated structure, typically having two outer skins and central core, such as an insulating core. Preferably, at least the outer skin which is to be external of the building when the door is fitted comprises metal, typically steel.

Preferably at least one of the outer skins, and preferably both outer skins, comprise metal, typically steel.

However, the invention is equally applicable to a plastics or plastics skinned door.

According to a second aspect of the invention there is provided a method of constructing a door, the method comprising forming a plurality of apertures in a door body, locating one or more fixing members in respective apertures so that ends thereof project outwardly from the door body and securing one or more profiled members to one or both sides of the door body by non-releasably locating corresponding apertures in the profiled members over the projected ends.

Preferably the apertures in the door body are drilled and preferably they comprise through apertures. The method may include locating a fixing member in such a through aperture so that each end of the fixing member projects outwardly from a side (major surface) of the door. The method may include cutting an aperture for a panel through or adjacent to a series of fixing member apertures. The method may include locating a panel in such cut aperture before or after locating of the fixing members but prior to location of the profiled members.

Preferably the profiled members comprise one or more frames. The method may include applying adhesive to the fixing members, door body and/or panel during assembly.

The method may include suitable steps to implement any of the above described features of a door of the invention to construct such a door.

The invention will now be described further by way of example only and with reference to the accompanying drawings in which: Figure 1 is a sectional view of part of a first embodiment of door of the invention; Figure 2 is a sectional view corresponding to Figure 1 with the fixing member removed; Figure 3(a) is a sectional view of one form of fixing member suitable for use in a door of the invention; Figure 3(b) is a side view of the fixing member of Figure 3(a); Figure 3(c) is an end view of the fixing member of Figure 3(a); Figure 4 is an enlarged view of one end of the fixing member of Figure 3(a); Figure 5 is a sectional view of part of a profiled member; Figure 6 is a sectional view of one part of an alternative profiled member; Figure 7 is a sectional view similar to Figure 1 of part of a second embodiment of door of the invention; Figures 8 to 11 are schematic perspective views showing construction of one embodiment of a door of the invention; Figure 12 is a cross-sectional view of an alternative profiled member; and Figure 13 is a cross-sectional view similar to Figure 2 showing use of the profiled member of Figure 12.

Referring to Figure 1, a door 1 comprises a main door panel or body 2 having an aperture 3 formed therein. A double glazed panel 4 is located in the aperture 3. A fixing member or lug 6 extends through the thickness of the door and each end 8 thereof projects outwardly from corresponding sides of the door. A profiled member 10 is located on each side of the door and extends along the joint between the door body and the panel and extends partially over the door body and partially over the panel.

An aperture 12 formed in the profiled member fits over a projecting end of the fixing member 6. Double sided adhesive tape 14 provided between the profiled member and the door body and panel provides additional fixing of the profiled member to the door.

The door body 2 comprises a central core 16 of a closed cell polystyrene material sandwiched between two outer skins 18 of 0.5 mm gauge galvanised steel sheet covered with a woodgrain foil. Referring to Figure 2, the glazing panel 4 is located in the aperture 3 with part of the aperture forming a gap 20 between the door body and panel for receiving the fixing member.

Referring to Figure 5, the profiled member 10 comprises an elongate plastics member having a substantially flat surface 22 which in use lies adjacent the door surface and a profiled surface 24 which in use provides a profiled effect on the door. The profiled surface may have any suitable form depending on the desired aesthetic finish required. In this embodiment it has a woodgrain foil, in order to match the woodgrain foil applied to the door. The grain of the foil runs lengthwise of the profile. Figure 6 shows an alternative profiled member 10 having an alternative profiled surface 24. The profiled member 10 may have a recessed portion 26 therein for example to reduce the quantity of material used to form the member.

Referring to Figures 3(a) to 3(c), the fixing member 6 comprises a collar or body portion 28 of substantially square cross-section and of carefully predetermined dimensions. Each end of the fixing member has reduced dimensions, typically of substantially square crosssection, being an engagement portion 8 which in use projects outwardly from the door body. Each end 8 has two serrated sides 30 and a slot 32 formed centrally and parallel to the serrated sides 30 so that in use the sides 30 flex slightly towards each other as a profiled member is press fitted on the ends 8.

The aperture 12 in the profiled member is of substantially square cross-section and two sides of the aperture have serrated edges 34 which engage the serrated sides 30. The sides of the gap 20 formed by door body may be provided with apertures which are substantially circular in cross-section to assist in retaining a square cross-sectional fixing member therein (see Fig. 9).

Alternatively the apertures may be substantially square in cross-section to provide a close fit for the fixing member.

Figure 4 shows an end 8 of a fixing member in greater detail. Typically four saw-tooth edges on each side are provided to engage the profiled member. The body portion 28 facilitates correct location in the door and avoids over compression of any core material during assembly.

Referring to Figure 7, an alternative embodiment of a door of the invention comprises a door body 2 having a panel 4 such as a glass panel located therein as described above. In this case the fixing member 34 comprises a substantially uniform cross-section elongate member. The ends of the member 34 project from respective sides of the door and into corresponding apertures in the profiled member 10. Each end has a substantially flat surface 36 which is secured to a substantially flat base 38 of the aperture by means of adhesive such as glue or double sided adhesive tape. Typically glue is used and the profiled members and fixing member are formed from the same material, and a glue is used such that they fuse together.

The cross-section dimension of the fixing member is typically square as shown in Figure 7(a) and may be of any desired size, for example 10 mm square. It will be appreciated that the adhesive means may be applied along the sides of the apertures in the profiled members to secure the sides of the fixing member, to the extent that they extend within the apertures in the profiled members.

A door as described above is a high security door because of the steel skins and because of the impossibility of, or at least great difficulty in, removing an insert panel such as a glazing panel, when present. It has aesthetic and reliability advantages arising from the fact that the method does not involve the prior art technique of applying a single woodgrain foil over an entire door surface, including profiled members thereof.

Referring to Figures 8 to 11, one method of constructing a door is illustrated. The method may be used to construct a door according to any embodiment of the invention.

Figure 8 shows a door body 2 formed by laminating a flat central core 40 and two flat outer skins 42. The outer skins may comprise steel, plastics or MDF and the core may comprise styrofoam or other core material.

Referring to Figure 9, a series of holes 44 are drilled accurately, for example using an appropriate jig, in a rectangular configuration centrally of the door body.

The holes 44 may extend partially through the thickness of the door body and in that case accommodate fixing members as previously described having one projecting end.

Preferably, however the holes are through holes and of such size as to accommodate the fixing members projecting on each side of the door. The fixing members 6 are located in or through the holes 44 and profiled members having corresponding slots formed therein, and formed into a rectangular frame 10, are located over the door body so that the projecting ends fit into the contiguous slot which extends around the frame. Adhesive may be applied to the door body, fixing members and/or profiled members before assembly.

As shown in Figure 10, if a panel or glazing panel is required in the door, the aperture 46 therefor is cut before applying the fixing members and profiled members.

The aperture 46 is cut through the edges of the holes 44 or close thereto so that preferably the holes 44 still present a substantially circular cross-section. The panel is located in the aperture 46. The profiled frame 10 is then pressed down on one side of the door and a further frame 10 pressed down on the other side of the door, adhesive being applied as required.

Preferably, the fixing members are cut as short lengths from an elongate extruded member, preferably having a square cross section. By using a square crosssection the fixing members locate into round holes and provide good contact within the profiled member for maximum strength. Preferably, the profiled members comprise elongate extruded mouldings having an elongate slot formed in the underside thereof. The sides of the slot may comprise serrated edges for non-releasable engagement with a corresponding end of a fixing member.

Use of slots on the profiled members facilitates ease of assembly of the members onto the projecting of the fixing members.

As shown in Figure 11, the resultant door may comprise for example a door body 2 having a solid or nonglazed panel 48 and a glazing panel 50 each surrounded by a profiled frame 10. The profiled frame may have any shape and may for example have a curved side, when viewed from the front as in Figure 11.

Referring to Figure 12, the profiled member 10 comprises a raised or arched underside 52 which allows tolerance differences between the thickness of the glass or panel 4 and core or foam filling material 2 to be taken up. This is illustrated in Figure 13. The arch may be a continuous inward curve from one side of the profiled member to the other. Preferably however the arch is a continuous inward curve from one side of the profiled member to a region adjacent the other side of the member so that a substantially flat region 54 is provided adjacent one side of the member, the flat region 54 intended to lie adjacent the panel 4 in use thereby providing a good contact line with the panel or glass 4.

Optionally, screw fixings 16 are applied to the inner surfaces of the steel skins 6 and extend through the skins 6 and partially into the profiled members 12 to further secure the profiled members to the skins. The skins 6 are then subsequently laminated to the core 4 so that, when completed, the screws are not visible. Typically, the screw head will be flush with the inner surface of the skin to avoid interference with the lamination of the core.

It will be appreciated that the present invention is not intended to be restricted to the details of the above embodiment which is described by way of example only.

Claims

1. A door having one or more profiled members secured to one or both outer surfaces thereof, the or each profiled member being secured to the door by means of one or more fixing members located in corresponding aperture(s) in the door and extending into corresponding aperture(s) in the profiled member(s), and means for non-releasably securing said one or more fixing members to said one or more profiled members.

2. A door as claimed in claim 1, wherein the or each fixing member is an integral one-piece member.

3. A door as claimed in any preceding claim, wherein the or each fixing member extends through the door and into a corresponding aperture in a profiled member located on each side of the door.

4. A door as claimed in any preceding claim, wherein the profiled members substantially abut the door surface.

5. A door as claimed in any preceding claim, wherein the means for non-releasably securing the fixing(s) to the profiled member(s) is such that the or each profiled member is non-releasably secured to the door surface.

6. A door as claimed in any preceding claim, wherein the fixing means comprises an end of a fixing member shaped to non-releasably engage in the corresponding profiled member aperture.

7. A door as claimed in any preceding claim, wherein at least one end of the fixing member comprises a serrated portion.

8. A door as claimed in claim 7, wherein the aperture in the profiled member comprises a corresponding serrated surface which engages the end of the fixing member in a ratchet fit so that the profiled member may be press fitted over the end of the fitting member and is nonreleasably retained thereon.

9. A door as claimed in any preceding claim, wherein the or each end of the fixing member is slotted.

10. A door as claimed in any preceding claim, wherein the non-releasable securing means comprises an adhesive means located between the end of the fixing member and the corresponding aperture in the profiled member.

11. A door as claimed in any preceding claim, wherein the profiled members comprise mouldings.

12. A door as claimed in any preceding claim, wherein the underside of the profiled members comprises a raised or arched surface, having a flat region on at least one side thereof.

13. A door as claimed in any preceding claim, wherein the fixing member comprises the same material as the profiled member.

14. A method of constructing a door, the method comprising forming a plurality of apertures in a door body, locating one or more fixing members in respective apertures so that ends thereof project outwardly from the door body and securing one or more profiled members to one or both sides of the door body by non-releasably locating corresponding apertures in the profiled members over the projected ends.

15. A method as claimed in claim 14, wherein the apertures in the door body are drilled.

16. A method as claimed in claims 14 or 15, wherein the method includes locating a fixing member in such an aperture so that each end of the fixing member projects outwardly from a major surface of the door.

17. A method as claimed in claims 14, 15 or 16, wherein the method includes cutting an aperture for a panel through or adjacent to a series of fixing member apertures.

18. A method as claimed in claim 17, wherein the method includes locating a panel in such cut aperture before or after locating of the fixing members but prior to location of the profiled members.

19. A method as claimed in any preceding claim, wherein the method includes applying adhesive to the fixing members, door body and/or panel during assembly.

20. A door substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.

21. A method of constructing a door substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.