GB2574228A

GB2574228A - Door, door-system and method

Info

Publication number: GB2574228A
Application number: GB1808880.7A
Authority: GB
Inventors: Byron Turner Frederick
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-05-31
Filing date: 2018-05-31
Publication date: 2019-12-04
Anticipated expiration: 2038-05-31
Also published as: GB2574228B; GB201808880D0

Abstract

The door 10 comprises opposed first and second side sections 12, 14, opposed top and bottom sections 16, 18, a front panel 42, a rear panel 40, at least one corner block 60 and at least one brace member 30. The first and second side sections each having a profiled internal surface 22 comprising a side channel 24 in which the front panel is slidingly received. The top and bottom sections each have a profiled internal surface comprising an end channel in which end channels the front panel is received and securely located. The profiled surfaces may further comprise a further side channel 24 in which the rear panel is slidingly received and the top and bottom sections may comprise a further end channel to secure the rear panel within. Also disclosed is a door system suitable for use as a flood prevention door system and a method of constructing a door.

Description

DOOR, DOOR-SYSTEM AND METHOD

FIELD OF THE INVENTION

The present invention relates to a door, door-system and method of assembling a door. Particularly, but not exclusively, the present invention relates to a flood-defence door which is constructed to withstand the pressure of flood water and which is sufficiently light-weight so as to be useful on an everyday basis and without compromise of its sealing capability. Aspects of the invention relate to a door, to a door-system, and to a method.

BACKGROUND OF THE INVENTION

The protection of domestic dwellings, commercial and other buildings from the devastating and damaging effects of floods is an important issue. In particular the effective safeguarding of domestic dwellings is a growing concern. Various passive and other flood defence systems have been provided in recent years to homeowners in order to safeguard those homes from further flood damage. The damage that flood water can do to a home can be devastating and complete refurbishments are often needed which take time and incur significant costs. Homeowners may need to be temporarily re-housed and insurance policies often do not meet all of the costs actually incurred by homeowners after flood damage to their property. Both local councils, insurance companies and homeowners alike are all concerned with flood defences.

Doors to properties are an obvious vulnerability and are often a first point of water ingress during a flood. Typical door structures are not necessarily, specifically designed for being flood defence barriers. Accordingly, other considerations, for example the requirements for doors to be lightweight, easy and quick to manufacture, easy and quick to install, as low cost as possible, easy to operate yet having a high-level of security, all heavily influence typical domestic door designs. Requirements for flood defence doors (referred herein as flood doors) do not necessarily match the requirements for typical every day, domestic doors. In recent years however high demand for new flood doors on a short timescale has led to some manufactures of “normal” doors trying to embellish and adjust their normal door designs in order to offer for sale a flood-door. However, it is now known that such doors fail. The pressure that flood water can put on a door can cause the door to twist relative to its frame which compromises the complex locking systems that such doors often also have. Once a lock and catch are out of alignment, the door can be difficult to use on a daily basis. This can be a particular problem for the elderly. In an attempt to withstand flood pressures, doors have been made thicker and heavier, but this does not necessarily make the door more successful as a flood barrier, but it does make it harder to use on a daily basis.

The present invention seeks to provide an improvement in the field of flood-proof or floodresistant re-closeable entry-ways, gateways or doorways that has particular application for domestic dwellings, but which may be utilised in industrial or commercial sites. The invention may be retro-fitted into a dwelling, existing flood-barrier system or used as a supplementary flood-defence door-way installed in front of an existing door-way or gateway.

SUMMARY OF THE INVENTION

Aspects of the invention provide a door, a flood door system, and a method as claimed in the appended claims.

According to a first aspect of the invention for which protection is sought, there is provided a unit which may be used as a door, the unit or door comprising: a frame structure having: opposed first and second side sections; and opposed top and bottom sections. The unit or door further comprising: a front panel; a rear panel; at least one corner block; and at least one brace member. The first and second side sections each having a profiled internal surface comprising a side channel in which side channels the front panel is slidingly received. Said opposed top and bottom sections each having a profiled internal surface comprising an end channel in which end channels the front panel is received and securely located. The front and rear panels may be of uniform or different thickness, style, decor and material type. The front and rear panels are preferably solid such that the unit can be used as a flood prevention door. In other applications, the use of solid panels may not be necessary. The panels may be formed of a different material to the frame structure and may for example be metal sheets, plastic panels or composite materials that preferably are water-proof or water-resistant and optionally, washable.

Optionally, said profiled internal surfaces of said first and second side sections each comprises a further side channel in which further side channels the rear panel is slidingly received; and said profiled internal surfaces of said opposed top and bottom sections each comprises a further end channel in which further end channels the rear panel is received and securely located.

Optionally, said brace member has a first end block at a first end thereof and a second end block at a second end thereof. Each end block is complementarily shaped and formed for fitting into the profiled internal surface of the first or the second side section, such that said brace member can be slidingly received and securely located within the door.

Optionally, each corner block is complementarily shaped and formed for fitting into the profiled internal surfaces of a first or second side section; and a top or bottom section, for providing rigidity and strength to the door. The bracing members can be located strictly horizontally or at an angle between the first and second side sections. In dependence upon the application of and size of the door, the size, weight, number of and precise location of the or each brace members can be selected. In this way, the present invention permits for the easily customisable and easily tailored door based upon the unique method of door construction now disclosed herein. One or more brace type members may be used to hold house or otherwise support door furniture including for example and without limitation, a letter box. In dependence upon known, expected or anticipated flood depths, a brace member can be located at an elevation within the door such that the letter box does not represent a vulnerability to ingress of flood water.

The first and second side sections and the opposed top and bottom sections have mitred ends that fit against a mitred end of an adjacent top, bottom, first side or second side section respectively. However rather than reply on outer welded joints and screw fixed joints into hollow or channelled profiled extrusions, the door construction of the present arrangement beneficially comprises four corner blocks located internally of (i.e. within) the mitred end corners. The corner blocks provide strength and rigidity and like the brace members help to prevent against the door from twisting under the pressure from food water. Each corner block may be of solid construction, and may be formed from wood, metal, plastics material.

Optionally, the corner blocks and the end blocks are dovetail type shapes in other words they have an outwardly tapered shape which can only slide into the oppositely, similarly and complementarily shaped side channel or end channel.

A door according to any preceding claim wherein the profiled internal surface of the first and second side sections and of the top and bottom sections have the same shape.

According to another aspect of the invention for which protection is sought, there is provided a door system suitable for use as a flood prevention door system, which comprises: an outer frame; and a door according to any of the relevant preceding paragraphs. The door being moveable relative to the outer frame for closing and sealing an opening defined, at least in part, by the outer frame.

Optionally, the outer frame is also formed from a series of sections each having a profiled internal surface and a smooth planar external surface.

Optionally, the profiled internal surfaces of the outer frame are the same shape and configuration as the profiled internal surfaces of said first and second side sections and said top and bottom sections.

According to yet another aspect of the invention for which protection is sought, there is provided a method of constructing a door, the method comprising:

(i) locating a corner block at one mitred end of each of first and second side sections;

(ii) locating said corner blocks at each mitred end of a bottom section;

(iii) slidingly receiving and securely locating the first and second end blocks of a brace member into the profiled internal surfaces of the first and second side sections respectively;

(iv) affixing the first and second end blocks of the brace member to the first and second side sections respectively;

(v) slidingly locating side edges of the front panel within the channels of the profiled internal surfaces of the first and second side sections;

(vi) locating a bottom end of the front panel within the channel of the profiled internal surface of the bottom end section;

(vii) slidingly locating side edges of the rear panel within the further side channels of the profiled internal surfaces of the first and second side sections;

(viii) locating a bottom end of the rear panel within the further channel of the profiled internal surface of the bottom end section;

(ix) locating said corner blocks at each mitred end of the top section;

(x) locating said corner blocks at one mitred end of each of the first and second side sections such that the top section is adjacent to each of the first and second side section;

(xi) locating a top end of the front panel within the channel of the profiled internal surface of the top end section; and (xii) locating a top end of the rear panel within the further channel of the profiled internal surface of the top end section.

The side sections can be cut to a required length and as such the method easily permits doors, gates, other closable items or even non-closable panels to be tailor made or custom built to purpose. By using shaped corner blocks that first slide into the bottom section and which can be affixed thereto using screw-fittings for example; and then by further relative sliding movement fitting the corner blocks into the first and second side sections, a sturdy square-Ushaped intermediate structure is formed. Into this various brace members, and other blocks and be slidingly fitted and located. Blocks for hinges, locks and other features as required can be slid into the profiled channels of the first and/or second side sections and optionally held in a chosen position by screw-type or other suitable fixings. Because the rear and front panels are then slid in, they again can be customised, pre-painted or pre-finished, sized as required and so on, without any major change being needed to the assembly equipment and process, or to the construction of the door. Additionally, the door can be in-filled, as required for the door application with one or more materials, selected in dependence upon application.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIGURE 1 is an isometric view showing inside a frame of a door structure according to an embodiment of the invention wherein only a rear-panel is shown so that the interior of the door can be seen;

FIGURE 2 is part of a side section (mitred ends of which are not shown in this view), showing its profiled internal surface and an adjustment block or locating block for use in the door system according to an embodiment of the invention;

FIGURE 3A is a section view through the door structure shown in Figure 1 albeit without the rear panel;

FIGURE 3B is a section view through the door structure shown in Figure 1 albeit with both the rear panel and front panel illustrated; and

FIGURE 4 is a corner block according to an embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

Detailed descriptions of specific embodiments of the frame structures, doors, door systems and methods of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. Indeed, it will be understood that the frame structures, doors, door systems and methods described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

A framework 12, 14, 16, 18, is shown in Figure 1, and this forms the basis of a new door structure 10. Whereas the framework 12, 14, 16, 18 is described and illustrated in the context of a door structure 10, and particularly but not exclusively one for use as a flood prevention door system, it will be appreciated that the framework 12, 14, 16, 18 may be used in other applications. The framework 12, 14, 16, 18 provides an internal profiled shape that allows, in this case door components, to be slidingly loaded into the part-formed door structure in a variety of arrangements. In this way, the framework 12, 14, 16, 18 and its modular, easily customisable assembly process, may have many and various beneficial applications, for example, for doors, gates, windows, other closeable openings, for housing solar panels, for forming fences or other barriers and the like.

The illustrative door system 10 shown here in is suitable for use as a flood-defence door 10 that can be easily assembled, installed and easily operated on a daily basis as a normal household door capable of easy and repeated, opening and closing; secure closing and locking. The door 10 provides a water-tight or water-resistant against an outer frame (not shown) thus making the door 10, draughtproof as well as water-tight. As additional options the door may be made of or contain materials to enable it to be heat-insulative and/or sound-proof and/or fire retardant.

As shown in Figure 1, a door 10 according to aspects of the present disclosure comprises an internally profiled frame structure 12, 14, 16, 18 comprising: opposed first and second side sections 12, 14; opposed top and bottom sections 16, 18. Door components can be slidingly loaded into the frame structure 12, 14, 16, 18 and securely interlocked in place due to the use of one or more location blocks or end blocks 32, 34. In the presently illustrated arrangement a dovetail fit between the internally profiled frame structure 12, 14, 16, 18 and one or more location blocks or end blocks 32, 34 enables quick assembly of the door structure 10, precise adjustability of the location of components loaded into the door 10; and a secure, tight and robust structure that does not merely rely on long screws extending into hollow profiled extrusions. In this way the door structure 10 is resistant to twisting, bending and warping.

The door system 10 also comprises a front panel (not shown in Figure 1, but see 42 in Figure 3B); a rear panel 40; at least one corner block 60; and at least one brace member 30. The corner blocks 60 are optionally, but preferably of solid construction such that they provide a rigid support at the corners where mitred ends 46 of adjacent sections of the frame structure 5 12, 14, 16, 18 are joined together. A corner block 60 is shown in Figure 4. As illustrated in

Figure 4 (and also shown in Figure 1), the corner block 60 is optionally about a 90° corner piece on order to provide a right-angled corner in the rectangular door structure 10 illustrated. The corner block 60 additionally comprises components sized to mate with, fit into or otherwise interlock and co-operate with the profiled internal surface 22 of the first and second side 10 sections 12, 14, and the top and bottom sections 16, 18. The use of one or more, and in this embodiment, four corner blocks 60, further contributes to the robustness of the overall door structure 10. In addition to the physical dove-tail interlocking of the corner block 60 with the profiled internal surface 22 of the first and second side sections 12,14 and the top and bottom sections 16, 18, screws may also be used to affix the corner blocks 60 and first and second 15 side sections 12,14, and the top and bottom sections 16,18 together. This arrangement does not merely rely on long screws extending into hollow profiled extrusions as in some prior art arrangements. By increasing the density of the frame work at its corners, the resulting door structure 10 is more resistant to twisting, bending and warping and yet at the same time, is cost effective, efficient in the amount of material it requires and is relatively light-weight.

As illustrated in Figures 1 - 4, the first and second side sections 12, 14 each have a profiled internal surface 22. The profiled internal surface 22 may in other arrangements differ from that shown herein, however, the functional facility provided by the shape of the profiled internal surface 22 can be described as:

• a first side channel 24 sized, shaped and proportioned such that a front panel 42 is slidably receivable and locatable therein by being clamped between an outer run of the first side channel 24 and one or more of: a corner block 60; an end block of a brace member 30; and a hinge block;

• a further side channel 24 also sized, shaped and proportioned such that a rear panel 40 is slidably receivable and locatable therein, also by being clamped between an outer run of the further side channel 24 and one or more of: a corner block 60; an end block of a brace member 30; and a hinge block; and • a main channel disposed between said first and further side channels 24, 26, the main channel for slidably receiving and locating any one or more of: a corner block 60; an end block of a brace member 30; and a hinge block for example.

In other non-illustrated embodiments, the profiled internal surface 22 of the frame structure 12, 14, 16, 18 may comprise additional or alternative shaping and/or additional or alternative features.

The profiled internal surface 22 of the first and second side sections 12, 14 may be similar or identical (or different) to that of the top or bottom sections 16, 18. However, there are benefits in them having the identical profile and that is the case in the present arrangement.

A method of construction of the door 10 will now be described, it will be appreciated that the components may be assembled in a different order or sequence to that now described without departing from the present disclosure. The door 10 optionally may be assembled by locating a corner block 60 at each mitred end 46 of the bottom section 18. Then a first end 46 or bottom end 46 of each of the first and second side sections 12, 14 is moved relative to the corner blocks 60 installed in the bottom section 18. The profiled internal surfaces 22 of the first and second side sections 12, 14 mate with and interlock with the corner blocks 60. The profiled internal surfaces 22 of the first and second side sections 12, 14 may be slid onto parts of the corner blocks 60. Screws may be used on either or both of the first and second side sections 12, 14 and bottom section 18. The mitred ends 46 of the first and second side sections 12, 14 and bottom section 18, may be welded together as well. In this way a secure attachment between the bottom section 18 and the first and second side sections 12, 14 is formed and the part-formed structure as a square U-shape with an open top end.

To provide rigidity to the door structure 10 to mitigate against warping, twisting and bending of the door (which sometimes happens to existing doors and inevitably leads to failure of the door during a flood because it no longer sealingly fits against its door frame), one or more 5 brace members 30 are loaded into the door structure 10. The optional use of end blocks 32, 34 (attached to or integrally formed with the bracing member 30) allows the bracing member to be slid or loaded into the profiled internal surfaces 22 of the first and second side sections 12, 14 by relative movement of the brace member 30 and the part-formed square U-shaped door structure 10. If required, the end blocks 32, 34 can be fixed at a particular location, for example by the means of screws. The brace member 30 may transversely extend across the door structure, substantially at right angles to the first and second side section 12, 14 and/or one or more brace members 30 may be positioned at a different angle (i.e. diagonally between the first and second side sections 12,14). Figure 3A shows a section view of the door structure 10 once a bracing member 30 has been installed in a horizontal configuration.

In addition to the brace members 30, one or more blocks (see Figure 3 for example) may be loaded into one or both of the first and second side sections 12, 14 to provide a means by which hinges, locks, handles or other security or locking features can be attached to the door structure.

Before during or after installation of the internal components into the door structure 10, the rear panel 40 can be installed. To do this side edges of the rear panel 40 are slotted into the further side channels 26 provided in the first and second side sections 12, 14.

Once all of the internal components of the door structure 10 have been loaded, the front panel 42 can be installed. To do this side edges of the front panel 42 are slotted into the side channels 24 provided in the first and second side sections 12, 14. Figure 3B shows a section view of the completed door structure.

To complete the door structure 10 two further corner blocks 60 are loaded into the mitred ends 46 of the top section 16 and affixed thereto (optionally using any suitable affixing means, such as screws). Then the top section 16 along with its corner blocks 60 are then loaded into the door structure, such that the rear and front panels 42, 40 are fitted into end channels of the top section 16 and such that the corner blocks 60 are located in the first and second side sections.

The completed door structure 10 can then be installed into an outer frame on site, in a domestic dwelling as required. The outer frame may optionally be constructed from the same extruded profile used for the first and second side sections 12,14 and top and bottom sections 16, 18.

The profile used for the first and second side sections 12,14 and top and bottom sections 16, 18 and for the outer frame may be formed from a variety of suitable materials, for example metal (for example Aluminium), wood, or plastics material and may be formed as an extruded length of material.

The corner blocks 60 may be formed from a single unit, for example by pressure die casting or injection moulding, or may be formed from two welded or joined pieces. The corner blocks 60 may be formed from metal, for example pressed steel or aluminium as non-limiting examples. The provision of preferably, but-optionally, dove-tail profiled solid corner blocks provides rigidity and strength. Additionally the provision of one or more adjustable position brace members 30 or custom-position brace members 30 integrates robustness without excessive weight.

The door structure 10 is easy to assemble and the use of dove-tail profiled location blocks or hinge blocks that slidably locate in the profiled side sections 12, 14 permits the easy selection of the position of hinges, locks and letter-boxes. Further advantageously, the door structure 10 allows for the position of a location block for example, to be adjusted. In this way, should an outer frame move relative to the door structure 10 and a lock from the door and catch in the outer frame become out of alignment, the location block can be adjusted for realignment of the lock and catch thus ensuring proper sealing, and continued proper and easy operation of the door. It is known that in some current households, where existing “flood-doors” have warped or twisted and the lock and catch come out of alignment because the door is no longer properly aligned within the outer door frame, that door manufacturers have “fixed” this issue by providing the household with a lever to crank the door handle with in order to force the locks to catch. This is not a satisfactory solution and is not practical for elderly or young users of the door!

It can be appreciated that various changes may be made within the scope of the present invention, for example, in other embodiments of the invention it is envisaged that the brace member may be provided by a rod or other cross-sectionally shaped section rather than a square section as shown in Figure 1. Whereas a main region of the profiled section is inwardly tapered (see Figure 3A and 3B) and whereas the location blocks (see Figure 2), corner blocks 60 (see Figure 4) and brace member end blocks 32, 42 (see Figures 3A and 3B) are similarly outwardly tapered to provide a dove-tail type fitting, it is envisaged that other shapes of profileand complementary shaped blocks may be suitable for use in other arrangements and the invention described herein is not necessarily limited to the use of trapezoidal or dove-tail complementary shaping in order to provide a door system, wherein complementarily shaped and co-operative components are slidingly fitted into side sections.

Claims

1. A door comprising: opposed first and second side sections; opposed top and bottom sections; a front panel; a rear panel; at least one corner block; and at least one brace member, said first and second side sections each having a profiled internal surface comprising a side channel in which side channels the front panel is slidingly received and said opposed top and bottom sections each having a profiled internal surface comprising an end channel in which end channels the front panel is received and securely located.

2. A door according to claim 1 wherein said profiled internal surfaces of said first and second side sections each comprises a further side channel in which further side channels the rear panel is slidingly received; and said profiled internal surfaces of said opposed top and bottom sections each comprises a further end channel in which further end channels the rear panel is received and securely located.

3. A door according to claim 1 or 2 wherein said brace member has a first end block at a first end thereof and a second end block at a second end thereof, wherein each end block is complementarily shaped and formed for fitting into the profiled internal surface of the first or the second side section, such that said brace member can be slidingly received and securely located within the door.

4. A door according to any preceding claim wherein each corner block is complementarily shaped and formed for fitting into the profiled internal surfaces of a first or second side section; and a top or bottom section, for providing rigidity and strength to the door.

5. A door according to any preceding claim 4 wherein each of the first and second side sections and the opposed top and bottom sections have mitred ends that fit against a mitred end of an adjacent top, bottom, first side or second side section respectively, and wherein the door comprises four corner blocks located within said mitred ends.

6. A door according to claim 4 or 5 wherein each corner block is of solid construction.

7. A door according to any preceding claim wherein the profiled internal surface of the first and second side sections and of the top and bottom sections have the same shape.

8. A door system suitable for use as a flood prevention door system, the door system comprising: an outer frame; and a door according to any of claims 1 to 7, said door being moveable relative to the outer frame for closing and sealing an opening defined, at least in part, by the outer frame.

9. A door system according to claim 8 wherein the outer frame is also formed from a series of sections each having a profiled internal surface and a smooth planar external surface.

10. A door system according to claim 8 wherein the profiled internal surfaces of the outer frame are the same shape and configuration as the profiled internal surfaces of said first and second side sections and said top and bottom sections.

11. A method of constructing a door according to any of claims 1 to 7, the method comprising:

(i) locating one of said at least one corner block at each mitred end of the bottom section;

(ii) locating the bottom section and said corner blocks at an end of the first and the second side sections;

(iii) slidingly receiving and securely locating the first and second end blocks of said brace member into the profiled internal surfaces of the first and second side sections respectively;

(iv) slidingly locating side edges of the front panel within the channels of the profiled internal surfaces of the first and second side sections;

(v) locating a bottom end of the front panel within the channel of the profiled internal surface of the bottom end section;

(vi) slidingly locating side edges of the rear panel within the further side channels of the profiled internal surfaces of the first and second side sections;

(vii) locating a bottom end of the rear panel within the further channel of the profiled internal surface of the bottom end section;

(viii) locating one of said at least one corner block at each mitred end of the top section;

(ix) locating said top section and said corner blocks at an end of the first and second side sections such that the top section is adjacent to each of the first and second side sections;

(x) locating a top end of the front panel within the channel of the profiled internal surface of the top end section; and (xi) locating a top end of the rear panel within the further channel of the profiled internal surface of the top end section.