GB2549340A

GB2549340A - Door

Info

Publication number: GB2549340A
Application number: GB1608322.2A
Authority: GB
Inventors: Myung Taek No
Original assignee: Trinity Glass International
Current assignee: Trinity Glass International
Priority date: 2016-04-11
Filing date: 2016-05-12
Publication date: 2017-10-18
Anticipated expiration: 2036-05-12
Also published as: GB201608322D0; GB2549340B; KR101898768B1; KR20170116520A

Abstract

A door which comprises outer 10 and inner 12 door skins moulded in a contoured pattern with concaved portions 14. A urethane foam layer 16 is formed between the door skins, and horizontal frames 18 and vertical frames (Fig. 3,19) are disposed between the door skins at the top and bottom and the sides of the door respectively. The door includes a reinforcement metal plate 30, located on the back surface of one door skin and punched with a plurality of holes which allow the liquid urethane to pass through, fixing the plate in position. It also includes a reinforcement lumber plate 20 disposed on the back surface of a door skin and located at a plane portion 17 of the door. The metal plate may be fitted between and supported by the horizontal or vertical frames and may have bent portions at each end which are in contact with the frames. The lumber plate may be made of laminated veneer lumber (LVL).

Description

DOOR

Technical Field

The present invention relates to a door and, more particularly, to a door with improved strength that is provided with a reinforcement lumber plate like laminated veneer lumber LVL and a reinforcement metal plate that are located on a urethane layer formed therein, thus having sufficient structural strength to prevent intrusion from the outside and further allowing an intermediate portion thereof to be easily machined.

Background Art A glassfiber reinforced plastic GRP door, which is widely used, largely includes a pair of door skins molded with sheet molding compound SMC and urethane foams formed between the pair of door skins. The sheet molding compound used for molding the door skins includes various components like glassfibers so as to improve the strength thereof.

As suggested in Korean Patent Application Laid-open No. 10-2012-58052, given patterns are generally molded on the front surface of the GRP door (hereinafter, referred simply to as 'door') to improve the outer appearance of the door. As one of the methods for molding given patterns on the surface of the door, especially, on the outer door skin exposed to the outside from a house, concaved lines are formed on the outer door skin in such a manner as to obtain the contour having a desired pattern .

On the door having the inner door skin and the outer door skin and the urethane layer formed therebetween, however, the formation of the concaved portions on the outer door skin of the door causes the strength of the door to be substantially reduced. Generally, the door is means for limiting or admitting the entrance to the house, but if the strength of the door is decreased, the intrusion from the outside may occur, thus providing no safety in view of security.

Technical Problem

Accordingly, the present invention has been made in view of the above-mentioned problems occurring in the prior art, and it is an object of the present invention to provide a door with sufficiently improved structural strength.

It is another object of the present invention to provide a door having good machinability on an intermediate portion thereof so that a separate attachment can be fixed thereto.

According to the present invention, the improvement of the structural strength of the door means that the damage of the door can be prevented from the intrusion from the outside, thus providing a high degree of security. According to the present invention, further, the easiness in machining on a portion of the door means that a structure for attaching a separate attachment like a mailbox to the door can be easily machined and at the same time means that the structural safety of the door can be sufficiently ensured even if the machining is conducted on a portion of the door.

Technical Solution

To accomplish the above-mentioned objects, according to the present invention, there is provided a door including: an outer door skin and an inner door skin having concaved portions molded concavely in such a manner as to have a linear shape, on at least one side thereof; a urethane layer formed between the outer door skin and the inner door skin; a pair of horizontal frames disposed on the top and bottom portions of the door between the outer door skin and the inner door skin in a horizontal direction of the door; a pair of vertical frames disposed on both side end portions of the door between the outer door skin and the inner door skin in a vertical direction of the door; a reinforcement metal plate located on the back surface of the door skin on which the concaved portions are formed in such a manner as to be fixed thereto by means of the urethane layer and having a plurality of holes punched thereon to allow liquid urethane filling between the outer door skin and the inner door skin to pass therethrough; and a reinforcement lumber plate disposed on the back surface of the door skin corresponding to the plane portion formed on both sides of the concaved portions.

According to the present invention, desirably, the reinforcement metal plate is supportedly fitted to any of the pair of horizontal frames and the pair of vertical frames. In this case, desirably, the reinforcement metal plate is located in the horizontal direction of the door and supportedly fitted between the pair of vertical frames.

According to the present invention, desirably, both side end portions of the reinforcement metal plate are bent with a given margin, and the bent portions of the reinforcement metal plate are surface-contacted with the pair of horizontal frames or the pair of vertical frames.

According to the present invention, desirably, the reinforcement metal plate is supportedly fitted between the pair of vertical frames, and the reinforcement lumber plate is supportedly located in such a manner as to come into contact with top of the reinforcement metal plate.

According to the present invention, desirably, the reinforcement lumber plate is made of laminated veneer lumber LVL.

Advantageous Effects

According to the present invention, the door is configured to have a sufficient structural strength through the LVL and metal plate disposed between the inner door skin and the outer door skin even if the thickness of the urethane layer is decreased due to the concaved portions formed on the surface of the door.

In addition, the strength of the back surfaces of the concaved portions formed concavely inwardly from the surface of the door is improved by means of the location of the reinforcement metal plate thereon, and the strength of the back surfaces of the plane portions of the surface of the door is improved by means of the location of the reinforcement lumber plate thereon, so that the whole door strength can be sufficiently improved, thus basically preventing the intrusion from the outside to provide many advantages in view of security.

Moreover, the reinforcement lumber plate is located fixedly on the back surfaces of the plane portions of the door formed at the intermediate height of the door. The reinforcement lumber plate serves to reinforce the whole door strength and to improve machinability on a portion where the reinforcement lumber plate is located. For example, a given portion of the door has to be machined so as to attach a given attachment like a mailbox thereto, and in this case, the portion where the reinforcement lumber plate is located has a relatively high thickness, so that it is easily machined and not decreased in the structural strength thereof.

Description of Drawings FIG.l is a front view showing a structure of a door according to a first embodiment of the present invention. FIG.2 is a longitudinal sectional view showing the door according to the first embodiment of the present invention. FIG. 3 is a cross-sectional view showing the door according to the first embodiment of the present invention. FIG.4 is a front view showing a structure of a door according to a second embodiment of the present invention. FIG. 5 is a longitudinal sectional view showing the door according to the second embodiment of the present invention.

Detailed Description

Hereinafter, an explanation on a door according to preferred embodiments of the present invention will be in detail given with reference to the attached drawing. First, a door according to a first embodiment of the present invention will be described with reference to FIGS.l to 3.

As shown in FIGS.l to 3, a door according to the first embodiment of the present invention includes a pair of door skins 10 and 12 molded with sheet molding compound SMC and a urethane layer 16 formed between the pair of door skins 10 and 12. The pair of door skins 10 and 12 includes the outer door skin 10 exposed to the exterior of a house and the inner door skin 12 exposed to the interior of the house.

Further, the door includes concaved portions 14 formed on the pair of door skins 10 and 12 and the urethane layer 16 in such a manner as to be molded concavely when viewed on the inside and outside thereof. The concaved portions 14 are formed to allow given patterns to be molded on the front and back surfaces of the door, and as shown in FIG.l, for example, rectangular patterns are formed through the concaved portions 14.

So as to form the rectangular patterns, accordingly, the concaved portions 14 are formed by connecting rectangular lines to form rectangular edges. Further, plane portions 17 (each having an inner plane portion 17a and an outer plane portion 17b) are formed on the inner and outer surfaces of the door around the concaved portions 14. In this case, the concaved portions 14 are portions wherein the thickness of the door is substantially reduced, so that the door has low strength on the concaved portions 14.

According to the present invention, therefore, the strength of the concaved portions 14 where the thickness of the door is low and the strength of the plane portions 17 formed between the concaved portions 14 (See FIG. 2) are improved at the same time. So as to improve the strength of the concaved portions 14, first, a reinforcement metal plate 30 is located between the outer door skin 10 and the inner door skin 12 corresponding to the back surfaces of the concaved portions 14, and the internal structure of the reinforcement metal plate 30 can be appreciated from FIGS .1 and 3.

In this case, the reinforcement metal plate 30 desirably has a plurality of holes punched thereon, through which urethane is supplied uniformly to the space between the pair of door skins 10 and 12, thus allowing the urethane layer 16 to be uniformly formed. In the state where the reinforcement metal plate 30 is disposed, that is, the liquid urethane is supplied and foamed between the pair of door skins 10 and 12 and then solidified. At this time, the liquid urethane passes through the plurality of holes formed on the reinforcement metal plate 30.

The reinforcement metal plate 30 and a reinforcement lumber plate 20 as will be discussed later are indicated by solid lines as shown in FIG.l so as to clearly express them, but since the reinforcement metal plate 30 is located on the inner surface of the outer door skin 10, actually, it should be indicated by dotted lines.

In case where the door is manufactured with the outer door skin 10 and the inner door skin 12, generally, frame members are interposed between the outer door skin 10 and the inner door skin 12 in such a manner as to be located surroundingly along the outer edges of the outer door skin 10 and the inner door skin 12, thus making a given distance maintained between the outer door skin 10 and the inner door skin 12 and forming the urethane layer 16 in the space between the outer door skin 10 and the inner door skin 12. FIG.2 shows a pair of horizontal frames 18 disposed on the top and bottom portions of the door in a horizontal direction of the door, and FIG.3 shows a pair of vertical frames 19 disposed on both side end portions of the door in a vertical direction of the door. As shown in FIG.2, each horizontal frame 18 includes an outer horizontal frame 18a located on the outermost position of the door and molded with a synthetic resin material to prevent moisture from entering the door and an inner horizontal frame 18b made of lumber (for example, LVL) in such a manner as to be brought into contact with the inner surface of the outer horizontal frame 18a.

As shown in FIG.3, further, each vertical frame 19 includes an outer vertical frame 19a located on the outermost position of the door to prevent moisture from entering the door and an inner vertical frame 19b made of lumber (for example, LVL) in such a manner as to be brought into contact with the inner surface of the outer vertical frame 19a. In this case, the reinforcement metal plate 30 is desirably supportedly located in such a manner as to come into contact with the inner surfaces of the vertical frames 19.

That is, the reinforcement metal plate 30 is supported against the pair of door skins 10 and 12, and in this case, it is desirable that the reinforcement metal plate 30 is maintained at its fixed position, while sufficiently resisting the pressure of the urethane supplied thereto. Accordingly, the outer surfaces of the reinforcement metal plate 30 in the horizontal direction are desirably supported in such a manner as to come into contact with the inner surfaces of the vertical frames 19. If necessary, the end portions of the reinforcement metal plate 30 are bent to about 90° with a given margin in a vertical direction thereof, and the bent portions are surface-contacted with the vertical frames 19.

As shown in FIG.3, the reinforcement metal plate 30 is somewhat bent, which is caused by a given curvature occurring when it is fitted between the vertical frames 19. Like this, if the reinforcement metal plate 30 is supportedly fitted between the vertical frames 19, it can be firmly supported thereagainst, without having any movement in the horizontal direction by means of the pressure generated upon the filling of the urethane.

According to the first embodiment of the present invention, the reinforcement metal plate 30 is located on the intermediate portion of the door in the horizontal direction of the door. This is because the concaved portions 14 are formed most collectively on the intermediate portion of the door where the reinforcement metal plate 30 is disposed in the horizontal direction of the door. Further, the intermediate portion of the door is the weakest portion upon the intrusion from the outside, and accordingly, the reinforcement metal plate 30 is embeddedly located on the intermediate portion of the door, thus improving the strength of the door.

According to the present invention, the reinforcement metal plate 30 has the plurality of holes through which the urethane passes, and it is good enough to dispose the reinforcement metal plate 30 on the back surfaces of the concaved portions 14 of the door skins 10 and 12. Of course, the reinforcement metal plate 30 is not limited in position as shown in FIGS.l to 3.

Next, an explanation on the reinforcement lumber plate 20 disposed on the plane portions 17 between the concaved portions 14 will be explained. The reinforcement lumber plate 20 is desirably made of LVL in view of the strength, but it may be not limited thereto.

The reinforcement lumber plate 20 is desirably maintained in position when it is interposed between the concaved portions 14, and as shown in FIG.2, the reinforcement lumber plate 20 is desirably disposed between the concaved portions 14 spaced apart from each other by a given distance in an up and down direction. Further, the reinforcement lumber plate 20 desirably comes into contact with top of the reinforcement metal plate 30 so as to maintain its position.

Referring to FIGS.2 and 3, for example, the reinforcement lumber plate 20 is desirably located supportedly on top of the reinforcement metal plate 30. Under the configuration, the reinforcement metal plate 30, which is supportedly fitted between the pair of vertical frames 19, supports the reinforcement lumber plate 20 more rigidly, while more advantageously maintaining the accurate position thereof under the pressure of the urethane filling thereto. Even under the configuration, more desirably, the reinforcement lumber plate 20 is supported against the concaved portions 14 formed concavely from the front surface of the outer door skin 10 and convexedly from the back surface thereof.

As shown in FIGS.l and 2, one reinforcement lumber plate 20 is disposed on the intermediate portion of the door in the horizontal direction of the door. Of course, the intermediate portion of the door has to be improved in strength, and if necessary, a given external attachment may be located on the intermediate portion of the door. For example, a mailbox may be attached to the front surface of the door in which the reinforcement lumber plate 20 is embedded.

In this case, the reinforcement lumber plate 20 is fixed to the back surface of the outer door skin 10 of the door, and through temporary machining of the reinforcement lumber plate 20, a structure for supporting the external attachment like mailbox may be formed in a convenient way. Further, the reinforcement lumber plate 20 is not necessarily limited in position as shown in FIGS.l and 2, but of course, it may be located between the concaved portions 14 in such a manner as to be fixed by means of the urethane layer 16.

For example, the reinforcement lumber plate 20 may be located on the upper portion of the door as well as on the lower portion of the door when viewed from the front surface of the door. Further, as shown, the reinforcement lumber plate 20 is located horizontally, but of course, it may be located vertically to a given length. Further, a plurality of reinforcement lumber plates 20 may be located on the door, and as mentioned above, the reinforcement lumber plate 20 is desirably molded with LVL.

Referring now to FIGS.4 and 5 showing a door according to a second embodiment of the present invention, the reinforcement metal plate 30 as mentioned above is located on the door, and further, another reinforcement metal plate 40 is disposed on top of the reinforcement lumber plate 20 in a horizontal direction of the door. The configuration and installation of the reinforcement metal plate 40 are the same as of the reinforcement metal plate 30, and further, the configuration of the door according to the second embodiment of the present invention is the same as of the door according to the second embodiment of the present invention except that the reinforcement metal plate 40 is additionally located. Therefore, the detailed explanation on the reinforcement metal plate 40 will be avoided for the brevity of the description.

As described above, the door according to the present invention is configured wherein the back surfaces of the concaved portions 14, which are weak in strength, are improved by means of the location of the reinforcement metal plate 30 thereon and the plane portions formed between the concaved portions 14 are improved in strength by means of the location of the reinforcement lumber plate 20 like LVL thereon. If the reinforcement lumber plate 20 is disposed on the intermediate portion of the door, accordingly, the structure for attaching the given attachment to the door may be easily machined and at the same time the decrement of the strength of the door can be sufficiently prevented.

While the present invention has been described with reference to the particular illustrative embodiments, it is not to be restricted by the embodiments but only by the appended claims. It is to be appreciated that those skilled in the art can change or modify the embodiments without departing from the scope and spirit of the present invention.

Claims

1. A door comprising: an outer door skin and an inner door skin having concaved portions molded concavely in such a manner as to have a linear shape, on at least one side thereof; a urethane layer formed between the outer door skin and the inner door skin; a pair of horizontal frames disposed on the top and bottom portions of the door between the outer door skin and the inner door skin in a horizontal direction of the door; a pair of vertical frames disposed on both side end portions of the door between the outer door skin and the inner door skin in a vertical direction of the door; a reinforcement metal plate located on the back surface of the door skin on which the concaved portions are formed in such a manner as to be fixed thereto by means of the urethane layer and having a plurality of holes punched thereon to allow liquid urethane filling between the outer door skin and the inner door skin to pass therethrough; and a reinforcement lumber plate disposed on the back surface of the door skin corresponding to the plane portion formed on both sides of the concaved portions.

2. The door according to claim 1, wherein the reinforcement metal plate is supportedly fitted to any of the pair of horizontal frames and the pair of vertical frames.

3. The door according to claim 2, wherein both side end portions of the reinforcement metal plate are bent with a given margin, and the bent portions of the reinforcement metal plate are surface-contacted with the pair of horizontal frames or the pair of vertical frames.

4. The door according to claim 1, wherein the reinforcement metal plate is supportedly fitted between the pair of vertical frames, and the reinforcement lumber plate is supportedly located in such a manner as to come into contact with top of the reinforcement metal plate.

5. The door according to claim 1, wherein the reinforcement lumber plate is made of laminated veneer lumber LVL.

6. A door constructed and arranged substantially as described in relation to Figs. 1-3 or Figs. 4-5 of the accompanying drawings .