GB2478580A

GB2478580A - A bi-fold door frame member

Info

Publication number: GB2478580A
Application number: GB201004034A
Authority: GB
Inventors: Chris Armes; Adrian Redshaw
Original assignee: HL Plastics Ltd
Current assignee: Liniar Ltd
Priority date: 2010-03-11
Filing date: 2010-03-11
Publication date: 2011-09-14
Anticipated expiration: 2030-03-11
Also published as: GB201004034D0; GB2478580B

Abstract

A frame member 30, for use in a door panel of a bi-fold door assembly (Fig 7A) comprises first and second faces 32, 34 between which extend first and second sides 36, 38. The first side 36 includes a bead member 40 which preferably lies adjacent to the first face 32 and against which a glazing panel is abuttable. The second side 38 includes first and second seal forming abutments 42, 44. Each seal forming abutment 42, 44 extends laterally relative to the first face 32 to the same extent. Preferably the seal forming abutments 42 44 are spaced apart from one another to define a hardware recess 48 between them. The hardware recess 48 may include an insert member which defines a Eurogroove. The frame member may be formed from extruded plastic, for example PVCu. A bi-fold door and bi-fold door assembly is also claimed. The assembly comprises a plurality of bi-fold doors manufactured from multiple frame members 30.

Description

IMPROVEMENTS IN OR RELATING TO

BI-FOLD DOOR ASSEMBLIES

This invention relates to a frame member for use in a door panel of a bi-fold door assembly, a door panel for use in a bi-fold door assembly, and a bi-fold door assembly.

Conventional bi-fold door assemblies are available in a wide range of folding door panel configurations, as illustrated schematically in Figure 1. As shown, the known assemblies may include a main door panel in conjunction with the folding doors.

In a typical bi-fold door assembly 10 each door panel 12 is fabricated from one or two known frame members 14 which support a glazing panel (not shown in Figure 1). A first frame member 16 has a generally Z-shaped cross-sectional profile and so is known as a "1' frame member 18, as shown in Figure 2(a), and a second frame member 20 has a generally T-shaped cross-sectional profile and so is known as a T" frame member 22, as shown in Figure 2(b).

Z and T frame members 18, 22 are useful and allow for the ready fabrication of a number of the wide range of known bi-fold door configurations.

However, one drawback with conventional Z and T frame members 18, 22 arises when attempting to assemble particular bi-fold door configurations.

For example, in a so-called scheme 440 bi-fold door configuration, as illustrated schematically in Figure 3, the arrangement of door panels 12 results in one door panel 12 (the outermost door panel marked with an asterisk in Figure 3) having to include Z and T frame members 18, 22 on opposite sides of a glazing panel 24 supported thereby in order to suitably interface with an adjacent door panel 12 or outer frame member 26.

As a result it is necessary to fabricate the door panel 12 from both Z and T frame members 18, 22. As illustrated schematically in Figure 4, such fabrication is difficult because the respective cross-sectional profiles of the Z and T frame members 18, 22 do not conform to one another. As a result there is a need to fabricate a makeshift interface between the Z and T frame members 18, 22 which is time-consuming and can be unsightly.

There is a need, therefore, to obviate the requirement to fabricate a makeshift interface between differing frame members within a door panel while maintaining the wide range of possible folding door panel configurations.

According to a first aspect of the invention there is provided a frame member, for use in a door panel of a bi-fold door assembly, comprising first and second faces between which extend first and second sides, the first side including a bead member lying adjacent to the first face and against which a glazing panel is abuttable, the second side including first and second seal-forming abutments, each of the seal-forming abutments extending laterally relative to the first face to the same extent.

The provision of first and second seal-forming abutments, each of which extends laterally to the same extent, ensures that each of the first and second abutments of one frame element lying with its first side facing the first side of another identical frame element is able to cooperate with the corresponding abutment of the other frame member to create first and second seal formations between the frame members.

As a result, adjacent door panels may each be fabricated from the same, single frame element while being able to abut one another to generate first and second seal formations therebetween, e.g. as necessary for external and internal sealing functions in a bi-fold door assembly, and thereby maintaining a wide range of configurations in which the said door panels can be arranged.

Preferably the first and second seal-forming abutments are mutually spaced from one another to define a hardware recess lying therebetween. The inclusion of a hardware recess provides the opportunity to house bi-fold door mounting assemblies which would otherwise need to be accommodated in an outer frame of a bi-fold door assembly.

Optionally at least a portion of the hardware recess includes an insert member mutually engaged therewith, the or each insert member defining a Eurogroove. The inclusion of one or more insert members advantageously provides the option of the hardware recess selectively housing the aforementioned mounting assemblies and conventional bi-fold door hardware such as lock assemblies.

In a preferred embodiment of the invention at least one seal-forming abutment lies adjacent to the first or second face. Having at least one seal-forming abutment lie adjacent to a face of the frame member allows the fabrication of a door panel in which at least one face thereof presents a uniform and desirably solid appearing profile to a user.

The first seal-forming abutment may lie adjacent to the first face and the second seal-forming abutment may lie adjacent to the second face. Such an arrangement allows a door panel fabricated from the frame member to present a uniform and solid appearing profile to a user when viewed from both sides, e.g. inside and outside a bi-fold door assembly.

Preferably the hardware recess is equally spaced from each of the first and second faces. Equally spacing the hardware recess in this manner ensures that adjacent door panels, each being fabricated from the same, single frame element, are able to abut one another to generate first and second seal formations therebetween while opening and closing in opposite senses, e.g. inwards and outwards, relative to one another. Thus, such features further maintain a wide range of possible door panel configurations.

According to a second aspect of the invention there is provided a door panel, for use in a bi-fold door assembly, comprising a door frame fabricated from a plurality of frame members as described herein above, the door frame having first and second faces between which extend a plurality of internal sides and a plurality of external sides, the plurality of internal sides together defining a continuous bead formation lying adjacent to the first face and against which a glazing panel is abuttable, the external sides together defining continuous first and second seal-forming abutment formations, each of the first and second abutment formations extending outwards relative to the first face to the same extent.

As a result, adjacent door panels may each be fabricated from the same, single frame element while being able to abut one another, via the first and second seal-forming abutment formations lying along adjacent external sides of the door panels, to generate first and second seal formations therebetween, and thereby maintain a wide range of configurations in which the said door panels can be arranged.

Optionally the first and second seal-forming abutment formations are mutually spaced from one another to define a continuous hardware recess formation lying therebetween.

Preferably at least a portion of the hardware recess formation includes an insert member mutually engaged therewith, the or each insert member defining a Eurogroove.

At least one seal-forming abutment formation may lie adjacent to the first or second face.

In a further preferred embodiment of the invention the first seal-forming abutment formation lies adjacent to the first face and the second seal-forming abutment formation lies adjacent to the second face.

In another preferred embodiment of the invention the hardware recess formation is equally spaced from each of the first and second faces.

The foregoing features of the door panel share the advantages of the corresponding features of the aforementioned frame member.

According to a third aspect of the invention there is provided a bi-fold door assembly comprising an outer frame having moveably mounted therein at least one pair of door panels as described hereinabove, the door panels in the or each pair being foldably coupled to one another along respective first foldably coupled external sides to define a foldable door pair, the foldable door pair being moveable between open and closed configurations, each of the first and second abutment formations lying along the first foldably coupled external side of one door panel in a foldable door pair cooperating with the corresponding abutment formation lying along the first foldably coupled external side of the other door panel in the foldable door pair while the foldable door pair is in the closed configuration to create first and second seal formations between the door panels in the foldable door pair.

The ability to create first and second seal formations between door panels in a foldable door pair allows for the assembly of a wide range of bi-fold door configurations. Each configuration includes door panels fabricated from same, single frame member, and so obviates the need to fabricate door panels from differing frame members.

A preferred embodiment of bi-fold door assembly includes first and second foldable door pairs, the first and second foldable door pairs being foldably coupled to one another along a second foldably coupled external side of a respective door panel in each foldable door pair to define a foldable door group, the foldable door group being moveable between open and closed configurations, each of the first and second abutment formations lying along the second foldably coupled external side of the door panel in one foldable door pair in the foldable door group cooperating with the corresponding abutment formation lying along the second foldably coupled external side of the door panel in the other foldable door pair in the foldable door group while the foldable door group is in the closed configuration to create first and second seal formations between the foldable door pairs in the foldable door group, the hardware recess formation lying along the second foldably coupled external side of the door panel in one foldable door pair in the foldable door group cooperating with the hardware recess formation lying along the second foldably coupled external side of the door panel in the other foldable door pair in the foldable door group while the foldable door group is in the closed configuration to define a first hardware cavity, the first hardware cavity receiving a first mounting assembly including a primary roller assembly to constrain movement of the second foldably coupled external sides relative to the outer frame, the first hardware cavity receiving the majority of the primary roller assembly.

The ability to create first and second seal formations between the foldable door pairs in the foldable door group maintains the seal integrity of the door group allowing the provision of a wide range of bi-fold door configurations.

Meanwhile the provision of a first hardware cavity which receives the majority of a primary roller assembly reduces the extent to which the outer frame must accommodate the primary roller assembly, and so allows the outer frame to be shallower, and thereby easier for a user to cross, than would be the case in a conventional bi-fold door assembly.

Optionally the bi-fold door assembly includes a plurality of foldable door pairs foldably coupled to one another along second foldably coupled external sides of respective door panels in each foldable door pair to define an enlarged foldable door group, the enlarged foldable door group being moveable between open and closed configurations, each first hardware cavity defined by respective cooperating second foldably coupled external sides while the enlarged door group is in the closed configuration receiving the majority of a primary roller assembly.

Such an arrangement expands further the range of possible bi-fold door configurations while maintaining the ability to fabricate each door panel from the same, single frame member.

Preferably the hardware recess formation lying along a free external side and an adjacent external side of a door panel in at least one foldably coupled door pair defines a second hardware cavity, the second hardware cavity receiving a second mounting assembly including a secondary roller assembly to constrain movement of the free external side relative to the outer frame, the second hardware cavity receiving a majority of the secondary roller assembly.

The provision of a second hardware cavity which receives the majority of a secondary roller assembly allows for movement of the free external side of a door panel to be constrained, as desired, without the need to increase the depth of the outer frame to accommodate a substantial portion of the secondary roller assembly.

A still further preferred embodiment of the bi-fold door assembly includes a further door panel as described hereinabove, the further door panel being foldably coupled to a foldable door pair along a third foldably coupled external side of the further door panel and a third foldably coupled external side of a door panel in the foldable door pair to define an uneven foldable door group, the uneven foldable door group being moveable between open and closed configurations, each of the first and second abutment formations lying along the third foldably coupled external side of the further door panel cooperating with the corresponding abutment formation lying along the third foldably coupled external side of the door panel in the foldable door pair while the uneven foldable door group is in the closed configuration to create first and second seal formations between the further door panel and the foldable door pair, the hardware recess formation lying along the third foldably coupled external side of the further door panel cooperating with the hardware recess formation lying along the third foldably coupled external side of the door panel in the foldable door pair while the uneven foldable door group is in the closed configuration to define a third hardware cavity identical to the first hardware cavity, the third hardware cavity receiving the first mounting assembly and the majority of the primary roller assembly included therein.

The ability to create first and second seal formations between the further door panel and the foldable door pair in the uneven foldable door group maintains the seal integrity of the door group and so allows the provision of an even wider range of bi-fold door configurations.

Meanwhile the provision of a third hardware cavity, identical to the first hardware cavity, which receives the majority of a primary roller assembly maintains the minimal extent to which the outer frame must accommodate the primary roller assembly, and so continues to allow the outer frame to be shallower than in a conventional bi-fold door assembly.

Optionally the bi-fold door assembly includes a further door panel as described hereinabove pivotably coupled to the outer frame to define a main door, the first and second seal-forming abutment formations lying along a free external side of the door panel lying adjacent to the main door including a jamb insert mutually engaged therewith to define an enlarged seal-forming abutment, the enlarged seal-forming abutment cooperating with the first and second abutment formations lying along a free external side of the main door while the door assembly is in a closed configuration to create first and second seal formations between the main door and the adjacent door panel.

Such an arrangement expands still further the range of possible bi-fold door configurations while maintaining the ability to fabricate each door panel from the same, single frame member.

Preferably at least one of the first and second seal-forming abutment formations in a door panel includes an elongate interlock member protruding thereform, the or each interlock member being received in a retention formation formed in a cooperating seal-forming abutment in an adjacent door panel while the respective door panels are in a closed configuration.

The inclusion of one or more interlock members that is received in a cooperating seal-forming abutment in an adjacent door panel while the door panels are in a closed configuration provides a barrier to ingress of a foreign object, such as a screwdriver or spade, into respective portions of the corresponding hardware recess formations, and so improves the security of the bi-fold door assembly.

Optionally jamb portions of the outer frame include elongate cap inserts releasably secured relative thereto to conceal respective fixings securing the outer frame to a surrounding support substrate. Concealing such fixings provides the bi-fold door assembly with a neat appearance and allows a user to clean the outer frame more easily.

A threshold portion of the outer frame may include a guide insert releasably secured relative thereto to guide the path of primary and secondary roller assemblies relative to the outer frame and to conceal respective fixings securing the outer frame to a surrounding support substrate. Such a feature provides similar appearance and cleaning improvements to the aforementioned cap inserts.

In another preferred embodiment of the invention the threshold portion protrudes not more than 15mm relative to the surrounding support substrate. Limiting the extent to which the threshold portion protrudes relative to the surrounding support substrate in this manner helps to ensure that the threshold portion is easy to cross, e.g. by a user in a wheelchair.

There now follows a brief description of preferred embodiments of the invention, by way of non-limiting example, with reference being made to the accompanying drawings in which: Figure 1 shows a conventional range of bi-fold door configurations in schematic form; Figure 2(a) shows a cross-sectional view of a conventional Z frame member; Figure 2(b) shows a cross-sectional view of a conventional T frame member; Figure 3 shows a schematic view of one conventional bi-fold door configuration which is difficult to manufacture; Figure 4 illustrates schematically the fabrication difficulties arising with some conventional bi-fold door configurations; Figure 5 shows a first cross-sectional view of a frame member according to a first embodiment of the invention; Figure 6 shows a second cross-sectional view of the frame member shown in Figure 5; Figure 7(a) shows a perspective view of a portion of a bi-fold door assembly according to a first embodiment of the invention; Figure 7(b) shows a schematic cross-sectional view from above of the bi-fold door assembly shown in Figure 7(a); Figure 8 shows an enlarged portion of the bi-fold door assembly shown in Figures 7(a) and 7(b); Figure 9 shows a schematic cross-sectional view of a bi-fold door assembly according to a second embodiment of the invention; Figure 10 shows an enlarged portion of the bi-fold door assembly shown in Figure 9; Figure 11 shows another enlarged portion the bi-fold door assembly shown in Figure 9; Figure 12 shows a further enlarged portion the bi-fold door assembly shown in Figure 9; Figure 13 shows a still further enlarged portion of the bi-fold door assembly shown in Figure 9; and Figure 14 illustrates schematically a portion of a bi-fold door assembly according to a third embodiment of the invention.

A frame member according to a first embodiment of the invention is designated generally by the reference numeral 30.

The frame member 30 may be extruded from a plastics material such as un-plasticised polyvinyl chloride (PVCu).

The frame member 30 comprises first and second faces 32, 34 between which extend first and second sides 36, 38. The first side 36 includes a bead member 40 which lies adjacent to the first face 32 and against which, in use, a glazing panel (not shown in Figure 1) is abuttable. A detachable bead member (not shown) is engagable with the first side 36 to retain the glazing panel. The second side 38 includes first and second seal-forming abutments 42, 44.

Each seal-forming abutment 42, 44 includes a retention formation 46 which retains, by way of mutual engagement, a seal member (not shown for clarity). Each seal member is abuttable with a similar, opposed seal member or an opposed seal surface to create a seal formation between the said sealing elements. Such a seal formation is configured to inhibit the transmission of fluid or foreign bodies as desired. For example, a seal formation which in use lies on an exposed external side of a bi-fold door assembly may be configured to inhibit the ingress of weather elements such as rain and dust. A similar seal formation, which in use lies on an internal side of a bi-fold door assembly, may be configured as a secondary barrier to the aforementioned weather elements and/or to inhibit the transmission of warm air through the door assembly.

Each seal-forming abutment 42, 44 extends laterally relative to the first face 32 of the frame member 30 to the same extent.

The seal-forming abutments 42, 44 are also mutually spaced from one another to define a hardware recess 48 which lies therebetween. At least a portion of the hardware recess 48 includes an insert member 50 mutually engaged therewith, as shown in Figure 6.

Each of the hardware recess 48 and the insert member 50 may include mutually engageable formations 52 to retain the insert member 50 relative to the hardware recess 48. In the embodiment shown the insert member 50 includes a pair of resiliently deformable, opposed, legs 54 each of which includes a barb formation 56 at a distal end 58 thereof. The hardware recess 48 includes a pair of opposed recess formations 60 each of which receives a respective barb formation 56.

The insert member 50 defines a Eurogroove which has a known configuration that permits interoperability with conventional door furniture such as handles, locks and the like.

As shown in Figures 5 and 6, the first seal-forming abutment 42 lies adjacent to the first face 32, the second seal-forming abutment 44 lies adjacent to the second face 34, and the hardware recess 48 is equally spaced from each of the faces 32, 34. In other embodiments of the invention (not shown) one or both of the seal-forming abutments 42, 44 may be spaced from a corresponding face 32, 34, and the hardware recess 48 may be unevenly spaced from the faces 32, 34.

A door panel according to a first embodiment of the invention is designated generally by the reference numeral 70, as shown in Figure 7(a).

The door panel 70 shown includes a door frame 72 fabricated from four frame members 30, as described above. Other door frames 72 of the invention (not shown) may be fabricated from fewer or more than four frame members 30.

The door frame 72 has first and second faces 74, 76 between which extend four internal sides 78 and four external sides 80.

The four internal sides 78 together define a continuous bead formation 82 which lies adjacent to the first face 74 and against which a glazing panel (not shown in Figure 7(a))

is abuttable.

The four external sides 80 together define continuous first and second seal-forming abutment formations 84, 86, each of which extends outwards relative to the first face 74 to the same extent.

The first and second seal-forming abutment formations 84, 86 are mutually spaced from one another to define a continuous hardware recess formation 88 lying therebetween. At least a portion of the hardware recess formation 88 includes an insert member (not shown in Figure 7(a)) mutually engaged therewith. The insert member defines a Eurogroove.

In the embodiment shown the first seal-forming abutment formation 84 lies adjacent to the first face 74 of the door frame 72 and the second seal-forming abutment formation 86 lies adjacent to the second face 76, and the hardware recess formation 88 is equally spaced from each of the first and second faces 74, 76. In other embodiments of the invention (not shown) the first and second seal-forming abutment formations 84, 86 and the hardware recess formation 88 may be arranged differently.

Figures 7(a) and 7(b) show a bi-fold door assembly 100 according to a first embodiment of the invention.

The bi-fold door assembly 100 includes an outer frame 102 in which are moveably mounted two pairs of door panels 70, as described hereinabove. Each door panel includes a glazing panel 98.

Other embodiments of the invention may include a smaller or larger number of pairs of door panels.

The door panels 70 in each pair are foldably coupled to one another along respective first foldably coupled external sides 104 to define respective first and second foldable door pairs 106, 108.

In the embodiment shown the first foldable door pair 106 is foldably coupled with a jamb portion of the outer frame 102 to define an innermost door pair, while the second foldable door pair 108 is unconnected with a jamb portion of the outer frame 102 and so defines an outermost foldable door pair. In other embodiments of the invention (not shown) the second foldable door pair 108 may be foldably coupled with a jamb portion of the outer frame 102 while the first foldably door pair 106 is unconnected with a jamb portion of the outer frame 102.

Each foldable door pair 106, 108 is moveable between open and closed configurations.

Figure 7(a) shows the first and second door pairs 106, 108 in a partially opened configuration, and Figure 7(b) shows the first and second door pairs 106, 108 in the closed configuration.

Each of the first and second abutment formations 84, 86 lying along the first foldably coupled external side 104 of one door panel 70 in the first foldable door pair 106 cooperates with the corresponding abutment formation 84, 86 lying along the first foldably coupled external side 104 of the other door panel 70 in the first foldable door pair 106, while the first foldable door pair is in the closed configuration, to create first and second seal formations 110, 112 (only shown in part) between the door panels 70 in the first foldable door pair, as illustrated schematically in Figure 7(b).

Similarly, each of the first and second abutment formations 84, 86 lying along the first foldably coupled external side 104 of one door panel in the second foldable door pair 108 cooperates with the corresponding abutment formation 84, 86 lying along the first foldably coupled external side of the other door panel 70 (while the second foldable door pair 108 is in the closed configuration) to create said first and second seal formations 110, 112 (only shown in part).

In addition, the first and second foldable door pairs 106, 108 are foldably coupled to one another along a second foldably coupled external side 114 of a respective door panel 70 in each foldable door pair 106, 108 to define a foldable door group 116.

The foldable door group 116 is moveable between open and closed configurations.

Each of the first and second abutment formations 84, 86 lying along the second foldably coupled external side 114 of the door panel 70 in one foldable door pair 106 cooperates with the corresponding abutment formation 84, 86 lying along the second foldably coupled external side 114 of the door panel 70 in the other foldable door pair 108, while the foldable door group 116 is in the closed configuration, to create first and second seal formations 110, 112 (only shown in part) between the first and foldable door pairs 106, 108, as illustrated schematically in Figure 8.

The hardware recess formation 88 lying along the second foldably coupled external side 114 of the door panel 70 in one foldable door pair 106 cooperates with the hardware recess 88 lying along the second foldably coupled external side 114 of the door panel 70 in the other foldable door pair 108, while the foldable door group 116 is in the closed configuration, to define a first hardware cavity 118.

The first hardware cavity 118 receives a first mounting assembly 120 which includes a primary roller assembly 122 to constrain movement of the second foldably coupled external sides 114 relative to the outer frame 102. The first hardware cavity 118 receives a majority of the primary roller assembly 122, i.e. more than half of the primary rollers 124 in the primary roller assembly 122 are able to sit within the first hardware cavity 118 while the foldable door group 116 is in the closed configuration, as shown schematically in Figures 8 and 13.

The hardware recess formation 88 lying along a free external side 126 and an adjacent external side 128 of the outermost door panel 70 in the foldable door group 116 defines a second hardware cavity 130, as shown schematically in Figure 7(b).

The second hardware cavity 130 receives a second mounting assembly 132 which includes a secondary roller assembly 134. The secondary roller assembly 134 is smaller than the primary roller assembly 122 and constrains movement of the free external side 126 relative to the outer frame 102. The second hardware cavity 130 receives a majority of the secondary roller assembly 134, i.e. more than half of the secondary rollers 136 in the secondary roller assembly 134 are able to sit within the second hardware cavity 130.

In use the primary and secondary roller assemblies 122, 134 guide and support the foldable door group 116 and allow a user to move the first and second foldable door pairs 106, 108 between the open and closed configurations. In the closed configuration respective abutment formations 84, 86 cooperate with one another, or an abutting portion of the outer frame 102, to create seal formations 110, 112 which inhibit the transmission of undesirable elements such as rain, wind, and heat, through the door assembly 100.

A bi-fold door assembly 140 according to a second embodiment of the invention is shown schematically in Figure 9.

The second bi-fold door assembly 140 is a so-called "Scheme 651" door assembly, and is similar to the first bi-fold door assembly 100. Common features share the same reference numerals.

The second bi-foid door assembly 140 includes first and second foldable door pairs 106, 108 together with a further door panel 142 that is foldably coupled to the outermost foldable door pair 108 to define an uneven foldable door group 144. The further door panel 142 is essentially identical to the aforementioned door panels 70.

The uneven foldable door group 144 is moveable between a closed configuration, as shown in Figure 9, and an open configuration.

The outermost door panel 70 in the outermost foldable door pair 108 includes a third foldably coupled external side 146 which is foldably coupled to a corresponding third foldably coupled external side 146 of the further door panel 142.

Each of the first and second abutment formations 84, 86 lying along the third foldably coupled external side 146 of the further door panel 142 cooperates with the corresponding abutment formation 84, 86 lying along the third foldably coupled external side 146 of the outermost door panel 70, while the uneven foldable door group 144 is in the closed position, to create first and second seal formations 110, 112 (only shown in part) between the further door panel 142 and the outermost foldable door pair 108.

The hardware recess formation 88 lying along the third foldably coupled external side 146 of the further door panel 142 cooperates with the hardware recess formation 88 lying along the third foldably coupled external side 146 of the outermost door panel 70, while the uneven foldable door group 144 is in the closed configuration, to define a third hardware cavity 148 which is essentially identical to the first hardware cavity 118.

The third hardware cavity 148 receives a first mounting assembly 120 and the majority of the primary roller assembly 122 included within the first mounting assembly 120.

The second bi-fold door assembly 140 also, additionally, includes a still further door panel that is pivotally coupled to the outer frame 102 to define a main door 150.

The first and second abutment formations 84, 86 lying along a free external side 126 of the door panel lying adjacent to the main door 150, i.e. the further door panel 142 in the embodiment shown, is mutually engaged with a jamb insert 152 to define an enlarged seal-forming abutment 154. The jamb insert 152 includes a pair of protrusions 156 each of which is snap-fittingly engaged with a corresponding retention formation 46 in the further door panel 142, as shown most clearly in Figure 10.

The enlarged seal-forming abutment 154 cooperates with the first and second abutment formations 84, 86 lying along a free external side 126 of the main door 150, while the door assembly is in a closed configuration, as shown in Figure 10, to create first and second seal formations 110, 112 (only shown in part) between the main door 150 and the further door panel 142.

In the second bi-fold door assembly 140 shown, the first abutment formation 84 lying along the second foldably coupled external side 114 of the first foldable door pair 106 includes an elongate interlock member 158, as illustrated schematically in Figure 11.

The interlock member 158 is mutually engaged with the retention formation 46 in the first abutment formation and protrudes relative thereto. While the second bi-fold door assembly 140 is in the closed configuration the interlock member 158 is received in a corresponding retention formation 46 in the first abutment formation 84 of the adjacent door panel 70 in the second foldable door pair 108.

In other embodiments of the invention (not shown) the interlock member may be integrally formed or mutually engaged with this or other abutment formations, and/or received in differing cooperable abutment formations.

Jamb portions 160 of the outer frame 102 include cap inserts 162 that are releasably secured relative thereto, as illustrated schematically in Figure 12, to conceal the fixings (not shown) which secure the outer frame 102 to a support substrate (not shown).

A threshold portion 166 of the outer frame 102 includes a guide insert 168 which is releasably secured relative thereto, as illustrated schematically in Figure 13. The guide insert 168 guides the path of the primary and secondary roller assemblies 122, 134 relative to the outer frame 102 and conceals any fixings securing the threshold portion 166 to the support substrate.

A lintel portion (not shown) of the outer frame 102 also includes a guide insert 168. The guide insert 168 along the lintel portion guides the path of similar roller assemblies relative to the outer frame, while concealing any fixings.

A bi-fold door assembly 170 according to a third embodiment of the invention is shown in Figure 14.

The third bi-fold door assembly 170 is similar to the first and second bi-fold door assemblies 100; 140 and identical features share the same reference numerals.

The third bi-fold door assembly 170 has a modified threshold portion 172 which does not protrude relative to a surrounding support substrate by more than 15mm.

Claims

CLAIMS: 1. A frame member, for use in a door pane! of a bi-fold door assembly, comprising first and second faces between which extend first and second sides, the first side including a bead member lying adjacent to the first face and against which a glazing panel is abuttable, the second side including first and second seal-forming abutments, each of the seal-forming abutments extending laterally relative to the first face to the same extent.
2. A frame member according to Claim I wherein the first and second seal-forming abutments are mutually spaced from one another to define a hardware recess lying therebetween.
3. A frame member according to Claim 2 wherein at least a portion of the hardware recess includes an insert member mutually engaged therewith, the or each insert member defining a Eurogroove.
4. A frame member according to Claim 2 or Claim 3 wherein at least one seal-forming abutment lies adjacent to the first or second face.
5. A frame member according to Claim 4 wherein the first seal-forming abutment lies adjacent to the first face and the second seal-forming abutment lies adjacent to the second face.
6. A frame member according to any of Claims 2 to 5 wherein the hardware recess is equally spaced from each of the first and second faces.
7. A door panel, for use in a bi-fold door assembly, comprising a door frame fabricated from a plurality of frame members according to any of Claims 1 to 6, the door frame having first and second faces between which extend a plurality of internal sides and a plurality of external sides, the plurality of internal sides together defining a continuous bead formation lying adjacent to the first face and against which a glazing panel is abuttable, the external sides together defining continuous first and second seal-forming abutment formations, each of the first and second abutment formations extending outwards relative to the first face to the same extent.
8. A door panel according to Claim 7 wherein the first and second seal-forming abutment formations are mutually spaced from one another to define a continuous hardware recess formation lying therebetween.
9. A door panel according to Claim 8 wherein at least a portion of the hardware recess formation includes an insert member mutually engaged therewith, the or each insert member defining a Eurogroove.
10. A door panel according to any of Claim 8 or Claim 9 wherein at least one seal-forming abutment formation lies adjacent to the first or second face.
11. A door panel according to Claim 10 wherein the first seal-forming abutment formation lies adjacent to the first face and the second seal-forming abutment formation lies adjacent to the second face.
12. A door panel according to any of Claims 8 to 11 wherein the hardware recess formation is equally spaced from each of the first and second faces.
13. A bi-fold door assembly comprising an outer frame having moveably mounted therein at least one pair of door panels according to any of Claims 8 to 12, the door panels in the or each pair being foldably coupled to one another along respective first foldably coupled external sides to define a foldable door pair, the foldable door pair being moveable between open and closed configurations, each of the first and second abutment formations lying along the first foldably coupled external side of one door panel in a foldable door pair cooperating with the corresponding abutment formation lying along the first foldably coupled external side of the other door panel in the foldable door pair while the foldable door pair is in the closed configuration to create first and second seal formations between the door panels in the foldable door pair.
14. A bi-fold door assembly according to Claim 13 including first and second foldable door pairs, the first and second foldable door pairs being foldably coupled to one another along a second foldably coupled external side of a respective door panel in each foldable door pair to define a foldable door group, the foldable door group being moveable between open and closed configurations, each of the first and second abutment formations lying along the second foldably coupled external side of the door panel in one foldable door pair in the foldable door group cooperating with the corresponding abutment formation lying along the second foldably coupled external side of the door panel in the other foldable door pair in the foldable door group while the foldable door group is in the closed configuration to create first and second seal formations between the foldable door pairs in the foldable door group, the hardware recess formation lying along the second foldably coupled external side of the door panel in one foldable door pair in the foldable door group cooperating with the hardware recess formation lying along the second foldably coupled external side of the door panel in the other foldable door pair in the foldable door group while the foldable door group is in the closed configuration to define a first hardware cavity, the first hardware cavity receiving a first mounting assembly including a primary roller assembly to constrain movement of the second foldably coupled external sides relative to the outer frame, the first hardware cavity receiving the majority of the primary roller assembly.
15. A bi-fold door assembly according to Claim 14 including a plurality of foldable door pairs foldably coupled to one another along second foldably coupled external sides of respective door panels in each foldable door pair to define an enlarged foldable door group, the enlarged foldable door group being moveable between open and closed configurations, each first hardware cavity defined by respective cooperating second foldably coupled external sides while the enlarged door group is in the closed configuration receiving the majority of a primary roller assembly.
16. A bi-fold door assembly according to any of Claims 13 to 15 wherein the hardware recess formation lying along a free external side and an adjacent external side of a door panel in at least one foldably coupled door pair defines a second hardware cavity, the second hardware cavity receiving a second mounting assembly including a secondary roller assembly to constrain movement of the free external side relative to the outer frame, the second hardware cavity receiving a majority of the secondary roller assembly.
17. A bi-fold door assembly according to any of Claims 13 to 15 including a further door panel according to any of Claims 8 to 12, the further door panel being foldably coupled to a foldable door pair along a third foldably coupled external side of the further door panel and a third foldably coupled external side of a door panel in the foldable door pair to define an uneven foldable door group, the uneven foldable door group being moveable between open and closed configurations, each of the first and second abutment formations lying along the third foldably coupled external side of the further door panel cooperating with the corresponding abutment formation lying along the third foldably coupled external side of the door panel in the foldable door pair while the uneven foldable door group is in the closed configuration to create first and second seal formations between the further door panel and the foldable door pair, the hardware recess formation lying along the third foldably coupled external side of the further door panel cooperating with the hardware recess formation lying along the third foldably coupled external side of the door panel in the foldable door pair while the uneven foldable door group is in the closed configuration to define a third hardware cavity identical to the first hardware cavity, the third hardware cavity receiving the first mounting assembly and the majority of the primary roller assembly included therein.
18. A bi-fold door assembly according to any of Claims 13 to 17 including a further door panel according to any of Claims 8 to 12 pivotably coupled to the outer frame to define a main door, the first and second seal-forming abutment formations lying along a free external side of the door panel lying adjacent to the main door including a jamb insert mutually engaged therewith to define an enlarged seal-forming abutment, the enlarged seal-forming abutment cooperating with the first and second abutment formations lying along a free external side of the main door while the door assembly is in a closed configuration to create first and second seal formations between the main door and the adjacent door panel.
19. A bi-fold door assembly according to any of Claims 13 to 18 wherein at least one of the first and second seal-forming abutment formations in a door panel includes an elongate interlock member protruding thereform, the or each interlock member being received in a retention formation formed in a cooperating seal-forming abutment in an adjacent door panel while the respective door panels are in a closed configuration.
20. A bi-fold door assembly according to any of Claims 13 to 19 wherein jamb portions of the outer frame include elongate cap inserts releasably secured relative thereto to conceal respective fixings securing the outer frame to a surrounding support substrate.
21. A bi-f old door assembly according to any of Claims 13 to 20 wherein a threshold portion of the outer frame includes a guide insert releasably secured relative thereto to guide the path of primary and secondary roller assemblies relative to the outer frame and to conceal respective fixings securing the outer frame to a surrounding support substrate.
22. A bi-fold door assembly according to Claim 21 wherein the threshold portion protrudes not more than 15mm relative to the surrounding support substrate.
23. A frame member generally as herein described with reference to and/or as illustrated in Figures 5 to 14 of the accompanying drawings.
24. A door panel generally as herein described with reference to and/or as illustrated in Figures 5 to 14 of the accompanying drawings.
25. A bi-fold door assembly generally as herein described with reference to and/or as illustrated in Figures 5 to 14 of the accompanying drawings.Amendments to the claims have been filed as follows CLAIMS: 1. A frame member, for use in a door panel of a bi-fold door assembly, comprising first and second faces between which extend first and second sides, the first side including a bead member lying adjacent to the first face and against which a glazing panel is abuttable, the second side including first and second seal-forming abutments mutually spaced from one another to define a hardware recess lying therebetween, each of the seal-forming abutments extending laterally relative to the first face to the same extent, and at least a portion of the hardware recess including an insert member mutually engaged therewith, the or each insert member defining a Eurogroove, 2. A frame member according to Claim 1 wherein at least one seal-forming abutment lies adjacent to the first or second face.3. A frame member according to Claim 2 wherein the first seal-forming abutment lies adjacent to the first face and the second seal-forming abutment lies adjacent to the second face.4. A frame member according to any preceding claim wherein the hardware ***.. 20 recess is equally spaced from each of the first and second faces. *SS,IIII... * I5. A door panel, for use in a bi-fold door assembly, comprising a door frame *** fabricated from a plurality of frame members according to any of Claims 1 to 4, the door frame having first and second faces between which extend a plurality of internal sides and a plurality of external sides, the plurality of internal sides together defining a continuous bead formation lying adjacent to the first face and against which a glazing panel is abuttable, the external sides together defining continuous first and second seal-forming abutment formations mutually spaced from one another to define a continuous hardware recess formation lying therebetween, each of the first and second abutment formations extending outwards relative to the first face to the same extent, and at least a portion of the hardware recess formation including an insert member mutually engaged therewith, the or each insert member defining a Eurogroove.6. A door panel according to Claim 5 wherein at least one seal-forming abutment formation lies adjacent to the first or second face.7. A door panel according to Claim 6 wherein the first seal-forming abutment formation lies adjacent to the first face and the second seal-forming abutment formation lies adjacent to the second face.8. A door panel according to any of Claims 5 to 7 wherein the hardware recess formation is equally spaced from each of the first and second faces.9. A bi-fold door assembly comprising an outer frame having moveably mounted therein at least one pair of door panels according to any of Claims 8 to 12, the door panels in the or each pair being foldably coupled to one another along respective first foldably coupled external sides to define a foldable door pair, the foldable door pair being moveable between open and closed configurations, each of the first and second abutment formations lying along the first foldably coupled external side of one door panel in a foldable door pair cooperating with the corresponding abutment formation lying along the first foldably coupled external side of the other door panel in the foldable door pair while the foldable door pair is in the closed configuration to create first and second seal formations between the door panels in the foldable door pair.10. A bi-fold door assembly according to Claim 9 including first and second foldable door pairs, the first and second foldable door pairs being foldably coupled to one another along a second foldably coupled external side of a respective door panel in each foldable * SS*.I * door pair to define a foldable door group, the foldable door group being moveable between open and closed configurations, each of the first and second abutment formations lying along the second foldably coupled external side of the door panel in one foldable door pair in the foldable door group cooperating with the corresponding ::. abutment formation lying along the second foldably coupled external side of the door panel in the other foldable door pair in the foldable door group while the foldable door group is in the closed configuration to create first and second seal formations between the foldable door pairs in the foldable door group, the hardware recess formation lying along the second foldably coupled external side of the door panel in one foldable door pair in the foldable door group cooperating with the hardware recess formation lying along the second foldably coupled external side of the door panel in the other foldable door pair in the foldable door group while the foldable door group is in the closed configuration to define a first hardware cavity, the first hardware cavity receiving a first mounting assembly including a primary roller assembly to constrain movement of the second foldably coupled external sides relative to the outer frame, the first hardware cavity receiving the majority of the primary roller assembly.11. A bi-fold door assembly according to Claim 10 including a plurality of foldable door pairs foldably coupled to one another along second foldably coupled external sides of respective door panels in each foldable door pair to define an enlarged foldable door group, the enlarged foldable door group being moveable between open and closed configurations, each first hardware cavity defined by respective cooperating second foldably coupled external sides while the enlarged door group is in the closed configuration receiving the majority of a primary roller assembly.12. A bi-fold door assembly according to any of Claims 9 to 11 wherein the hardware recess formation lying along a free external side and an adjacent external side of a door panel in at least one foldably coupled door pair defines a second hardware cavity, the second hardware cavity receiving a second mounting assembly including a secondary roller assembly to constrain movement of the free external side relative to the outer frame, the second hardware cavity receiving a majority of the secondary roller assembly.13. A bi-fold door assembly according to any of Claims 9 to 11 including a further door panel according to any of Claims 5 to 8, the further door panel being foldably s.. 20 coupled to a foldable door pair along a third foldably coupled external side of the further * door panel and a third foldably coupled external side of a door panel in the foldable door * S....* pair to define an uneven foldable door group, the uneven foldable door group being ** moveable between open and closed configurations, each of the first and second * 5* abutment formations lying along the third foldably coupled external side of the further door panel cooperating with the corresponding abutment formation lying along the third foldably coupled external side of the door panel in the foldable door pair while the uneven foldable door group is in the closed configuration to create first and second seal formations between the further door panel and the foldable door pair, the hardware recess formation lying along the third foldably coupled external side of the further door panel cooperating with the hardware recess formation lying along the third foldably coupled external side of the door panel in the foldable door pair while the uneven foldable door group is in the closed configuration to define a third hardware cavity identical to the first hardware cavity, the third hardware cavity receiving the first mounting assembly and the majority of the primary roller assembly included therein.14. A bi-fold door assembly according to any of Claims 9 to 13 including a further door panel according to any of Claims 5 to 8 pivotably coupled to the outer frame to define a main door, the first and second seal-forming abutment formations lying along a free external side of the door panel lying adjacent to the main door including a jamb insert mutually engaged therewith to define an enlarged seal-forming abutment, the enlarged seal-forming abutment cooperating with the first and second abutment formations lying along a free external side of the main door while the door assembly is in a closed configuration to create first and second seal formations between the main door and the adjacent door panel.15. A bi-fold door assembly according to any of Claims 9 to 14 wherein at least one of the first and second seal-forming abutment formations in a door panel includes an elongate interlock member protruding thereform, the or each interlock member being received in a retention formation formed in a cooperating seal-forming abutment in an adjacent door panel while the respective door panels are in a closed configuration.16. A bi-fold door assembly according to any of Claims 9 to 15 wherein jamb portions of the outer frame include elongate cap inserts releasably secured relative thereto to conceal respective fixings securing the outer frame to a surrounding support substrate.17. A bi-fold door assembly according to any of Claims 9 to 16 wherein a threshold a...* portion of the outer frame includes a guide insert releasably secured relative thereto to * . . . guide the path of primary and secondary roller assemblies relative to the outer frame and to conceal respective fixings securing the outerframeto a surrounding support substrate.18. A bi-fold door assembly according to Claim 17 wherein the threshold portion :*f.. protrudes not more than 15mm relative to the surrounding support substrate.S SI.I19. A frame member generafly as herein described with reference to and/or as illustrated in Figures 5 to 14 of the accompanying drawings.20. A door panel generally as herein described with reference to and/or as illustrated in Figures 5 to 14 of the accompanying drawings.21. A bi-fold door assembly generally as herein described with reference to and/or as illustrated in Figures 5 to 14 of the accompanying drawings.