GB2611565A

GB2611565A - An end cap

Info

Publication number: GB2611565A
Application number: GB2114422.5A
Authority: GB
Inventors: Redshaw Adrian
Original assignee: Garner Aluminium Extrusions Ltd
Current assignee: Garner Aluminium Extrusions Ltd
Priority date: 2021-10-08
Filing date: 2021-10-08
Publication date: 2023-04-12
Also published as: GB202114422D0

Abstract

An end cap 26a for a hollow door threshold; where the end cap has an engagement formation 34a-f which engages with the threshold, a jamb portion 36 to connect to a door jamb, a capping face 38 extending in an external direction and closing the hollow threshold; and an opening 40 in the capping face connected to a fluid path from the hollow threshold to the opening, so liquid may drain away and where the opening 40 is located remotely to the jamb portion. The engagement formation may be an arm which is fitted into a channel and there may be a second arm. The jamb portion may have an alignment feature and there may be a wall on the capping face to prevent the end cap from being inserted into the threshold too far. A frame assembly for a door, such as a bi-fold door, is also disclosed.

Description

An End Cap

FIELD

The present teachings relate to an end cap for fitting to an end of a door threshold, and a frame assembly for a door, such as a bi-fold door.

BACKGROUND

Bi-fold door assemblies are typically used to close openings in internal or external walls of buildings, for example domestic or commercial buildings. When the wall is external, the door is exposed to environmental conditions.

Typically, the bi-fold door comprises an outer frame including a threshold, and at least two door leaves. As the opening usually extends over a considerable length, a plurality of door leaves are hinged together in order to close the opening. For example, three or four door leaves may be hinged together and when open, fold against each other in a concertina fashion. The door leaves are slidably supported by the outer frame, either by being suspended from an upper track in the outer frame or by a combination of an upper and a lower track in the outer frame. In order to lock the sliding and/or pivoting door leaves relative to each other and relative to the outer frame, a number of latching mechanisms are commonly provided.

The threshold includes the lower track for slidably supporting the bi-fold door, and supports the rest of the outer frame. The threshold also serves the function of draining fluid out of the bi-fold door. Typically, the fluid enters a hollow profile of the threshold and is directed out of the edge of the threshold. This aims to stop water collecting in the track and directs it away from the building. However, problems occur with fluid building up in the track and entering the building. This can cause damp which can damage to the fabric of the building.

Additionally, it is important that the components of the bi-fold door are correctly positioned and correctly aligned to maintain a seal when the bi-fold door is closed, and to ensure the latching mechanisms function correctly. As the fitter generally fits the components of the bi-fold boor by measurement and eye, the process is subject to human error which can result in incorrect positioning and misalignment.

The present teachings seek to overcome or at least mitigate one or more problems associated with the prior art.

SUMMARY

A first aspect of the teachings provides an end cap for fitting to an end of a door threshold having a hollow external profile, the end cap comprising an engagement formation configured to engage the end of the door threshold; a jamb portion arranged to receive a door jamb; a capping face extending at least in a direction towards an external side of the end cap to close the hollow profile; an opening located in the capping face, wherein the opening is configured to be in fluid communication with the hollow profile so as to define a drainage flow path therebetween, and wherein the opening optionally is located remote from the jamb portion.

Advantageously, the flow path facilitates drainage out of the threshold via the opening. In particular for thresholds of bi-fold doors in which liquid that enters the lower channel is drained to the ends of the threshold via the hollow profile, the opening being located remote from the jamb portion ensures liquid flows away from the wall of the building in which the end cap is fitted, thereby reducing the risk of damp causing damage to the fabric of the building.

The capping face may comprise an external edge, and the opening may be located closer to the external edge than the jamb portion.

Advantageously, the opening being located towards the external edge helps to ensure the liquid is drained a sufficient distance away from the wall of the building to reduce the risk of damp.

The jamb portion may comprise a seat configured to abut a keep mounted to the door jamb portion, and the seat may extend a predetermined height from the jamb portion.

Advantageously, the predetermined height of the seat is fixed relative to the threshold, meaning when the keep is supported on the seat, the keep is a known height above the threshold. This means that when components, for example a retaining member of a latching mechanism, engage the keep, the component is correctly aligned with corresponding components without requiring careful measurement on the part of the fitter.

The jamb portion may be formed on part of the engagement formation.

Advantageously, the jamb portion being located on the engagement formation helps to ensure the door jamb is correctly aligned relative to the end cap without relying on precision of the fitter. Additionally, the jamb portion being part of the end cap reduces the number of additional components needed to mount the door jamb to the end cap.

The engagement formation may comprise a formation located on the capping face configured to fix the capping face to the hollow profile.

Advantageously, the fixing of the capping face to the hollow profile helps to prevent water from leaking out of the hollow profile, and has the aesthetic benefit of hiding the hollow profile from view.

The formation located on the capping face may be a lip.

The lip may be located on an inner surface of the capping face.

The lip may be configured to receive a sealing material so as to create a seal between the end cap and the hollow profile of the threshold.

Advantageously, the lip creates a surface on which a sealing material can be supported, and helps to ensure the seal remains between the perimeters of the hollow profile and the capping face. This helps to prevent leakage out of the hollow profile.

The lip may extend at least partially along an uppermost edge of the capping face.

The lip may extend at least partially along a lowermost edge of the capping surface.

Advantageously, having a lip on the uppermost and lowermost edges helps to maintain a seal around the majority of the perimeter of the connection.

The engagement formation may comprise a first arm configured to be received by a corresponding formation of the threshold, for example a channel.

Advantageously, the engagement arm helps to correctly align the end cap relative to the threshold, which may help to improve sealing. Additionally, the engagement arm is compact as it extends into the threshold, and easy to install.

The first arm may be located proximate the capping face.

Advantageously, as it is particularly important the capping face is aligned and secured to the hollow profile to inhibit leakage, first arm being located proximate the capping face helps to improve the security of the connection between the capping face and the hollow profile.

The engagement formation may comprise a second arm configured to be received by a corresponding formation of the threshold, for example a second channel.

The second arm may be located proximate an internal side of the end cap.

Advantageously, the inclusion of a second arm helps to further improve alignment and further restricts movement of the end cap relative to the threshold at the internal side of the end cap.

The engagement formation may further comprise at least one bore configured to receive a fixing.

The engagement may comprise a first bore configured to extend in a direction perpendicular to a longitudinal axis of the threshold, and/or the engagement formation may comprise a second bore configured to extend in a direction parallel to the longitudinal axis of the threshold.

The jamb portion may comprise an alignment feature configured to engage with the door jamb.

Advantageously, this helps to align the door jamb relative to the threshold, as well as the end cap relative to the threshold, using one compact engagement formation.

Additionally, the alignment feature helps to restrict movement of the door jamb once it has been fitted.

The capping face may be substantially planar.

Advantageously, a planar surface is easier to seal against the hollow profile, and has aesthetic benefits.

The jamb portion may comprise an abutment wall. The abutment wall and the capping surface may be substantially planar, and the capping face may extend from the abutment wall.

Advantageously, the abutment wall closes the channel in the threshold to prevent water leaking past the end cap.

The capping face and the abutment wall may act as a stop configured to prevent the end cap from being inserted into the threshold a distance greater than a length of the engagement formation.

Advantageously, this restricts movement of the end cap meaning the end cap is inserted the correct distance into the threshold, thereby helping to ensure the end cap is flush to the end of the threshold. Additionally, the correct positioning of the end cap helps to ensure the engagement features of the end cap are correctly aligned and correctly positioned.

The abutment wall may comprise a cut-out section configured to receive the door 10 jamb.

Advantageously, the cut-out section creates space into which a protruding section of the jamb can be received. This further improves alignment of the door jamb, and inhibits movement of the doorjamb between the boundaries of the cut-out section.

The end cap may be integrally and monolithically formed e.g., as injection moulded plastics.

Advantageously, this is a simple way of manufacturing the end cap without the need to join the different parts of the end cap (e.g., the capping face and the jamb portion) together.

A further aspect of the teachings provides a frame assembly for a door, such as a bi-fold door, the frame assembly comprising a threshold comprising a hollow external profile extending at least partially along a longitudinal axis of the threshold; and an end cap according to the first aspect fitted to an end of the threshold.

The threshold may comprise a first corresponding formation for engaging with an engagement formation, for example a first channel.

The threshold may comprise a second corresponding formation for engaging with the engagement formation, for example a second channel.

The frame assembly may further comprise a door jamb extending in a generally vertical direction.

The door jamb may be received by the jamb portion.

The door jamb may comprise a corresponding formation to engage with the jamb portion.

The corresponding formation may include a hollow profile and/or a protrusion. The hollow profile may extend along an elongate length of the door jamb.

The frame assembly may further comprise a keep extending in the generally vertical direction, wherein the keep may be mounted to the door jamb, and wherein the keep may comprise at least one attachment location.

The keep may abut a seat of the jamb portion such that the keep may be a predetermined height above the threshold.

The threshold may comprise an elongate channel configured to slidably receive a rolling element mounted to door leaf.

A third aspect of the teachings provides an end cap for fitting to an end of a door threshold having a hollow external profile, the end cap comprising an engagement formation configured to engage the end of the door threshold; a jamb portion arranged to receive a door jamb; a capping face extending at least in a direction towards an external side of the end cap to close the hollow profile, wherein the jamb portion comprises a seat configured to abut a keep mounted to the door jamb portion, and the seat extends a predetermined height from the jamb portion.

Optional features of the third aspect are set out in claims 1,2 and 3 to 25 appended hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described with reference to the accompanying drawings, in which: Figure 1 is a front view of a bi-fold door in a closed position, having a threshold assembly according to an embodiment of the present teachings; Figure 2 is a perspective view of the bi-fold door of Figure 1 in an open position; Figure 3 is a cross-sectional view of a threshold on the plane y-y of Figure 1 but without an end cap fitted; Figure 4 is cross-sectional view of the threshold of Figure 3 on the plane y-y but with an end cap of the present teachings fitted to an end thereof; Figure 5 is an isometric view of the end cap of Figure 4; Figures 6, 7A and 7B are isometric views of the end cap of Figure 4 being fitted to the threshold of Figure 3; Figures 8 is an isometric view of the threshold assembly of Figure 1 being assembled; and Figure 9 is an isometric view of the threshold assembly of Figure 1.

DETAILED DESCRIPTION OF EMBODIMENT(S)

Referring firstly to Figure 1, a bi-fold door of an embodiment of the present teachings is generally indicated at 10. The bi-fold door 10 includes a frame assembly 11 including a threshold assembly 12, door jambs 22a, 22b, and a header 13. The frame assembly 11 fits in an opening 9 in a wall 8, for example an external wall, of a domestic or commercial building. The bi-fold door 10 also includes at least two door leaves 14a-d slidably mounted to the frame assembly 11, in this embodiment four door leaves 14a-d.

Bi-fold doors 10 of this type are typically used in external walls of domestic and commercial buildings. It is therefore necessary that the door 10 meets requirements for sealing against water ingress and draining fluid from the door 10.

The term "closed position" refers to the position of the door leaves 14a-d when it is substantially co-planar with the frame assembly 11. The term "open position" refers to the position of the door leaves 14a-d when they are in any other position within the frame assembly 11.

Each door leaf 14a-d includes a frame 16a-d and a glazing unit 18a-d. It shall be appreciated that although the glazing units 18a-d in this embodiment are double glazing units, alternative glazing units, for example triple glazing or opaque panels, may be used. The door leaves 14a-d are connected at a side edge of each door leaf 14a-d, such that the door leaves 14a-d are arranged in series.

As illustrated in Figure 2, the door leaves 14a-d are connected to each other at a pivot axis A2, A3, A4 via at least one hinge 17b-d. In this embodiment, four hinges are used at each pivot axis to connect adjacent door leaves 14a-d, however in alternative embodiments any number of hinges or any suitable hinge mechanism may be used. The hinge mechanism may be selected depending on the size and weight of each of the door leaves 14a-d, and/or the hinging requirements.

When the bi-fold door 10 is in the closed position of Figure 1, the door leaves 14a, 14d are connected at a side edge to the frame assembly 11. Door leaf 14a is hinged about a pivot axis Al to a first side of the frame assembly 11 via at least one hinge 17a. However, the door leaf 14a may be hinged to a second side of the frame assembly 11, or releasably connected to either side of the frame assembly 11. The door leaf 14d may be fixed relative to the door jamb 22b using a latching mechanism 19a. The latching mechanism 19a includes a latching member, for example a handle, mounted to the door leaf 14d and driving a plurality of latch bolts or hooks. A corresponding keep 24 (Figure 9) is mounted to the frame assembly 11 to receive the latch bolts or hooks.

In an alternative embodiment (not shown), an additional door leaf may be provided between the fourth door leaf 14d and the door jamb 22a. The additional door leaf may be hinged to the door jamb 22a at a first side and releasable connected to the adjacent door leaf 14d at a second side or hinged to the door leaf and latchable to the door jamb 22a. This enables the additional door leaf to function as a conventional door such that the user can enter and exit the building without having to concertina the door leaves 14a-d.

As described above, the door leaves 14a-d are slidably connected to the frame assembly 11, meaning the door leaves 14a-d are retained within the frame assembly 11, whilst being moveable relative to the frame assembly 11. In addition, the relative pivoting of the door leaves 14a-d enables the door leaves 14a-d to concertina towards the first side and/or the second side of the frame assembly 11, depending upon configuration.

The door leaves 14a-d include at least one rolling element for facilitating sliding of the door leaves 14a-d relative to the frame assembly 11. The rolling element may include, by way of example, a set of wheels. It shall be appreciated that any suitable rolling element may be used.

The location and number of rolling elements is dependent on the number of door leaves and the hinging requirements. In the embodiment of Figure 1, where there are four door leaves 14a-d, a first set of rolling elements (not shown) is located substantially coaxially with the pivot axis A3 between the second and third door leaves 14b, 14c, and a second set of rolling elements is located substantially coaxially with a pivot axis A5 of the fourth door leaf 14d. Therefore, the hinge axis A3 between the second and third door leaves 14b, 14c and the hinge axis A5 of the fourth door leaf 14d are free to slide linearly relative to the frame assembly 11, however movement outside a plane of the frame assembly 11 is restricted.

The pivot axes A2, A4 between the first and second door leaves 14a, 14b and the third and fourth door leaves 14c, 14d are free to slide relative to the frame assembly 11, as well as being free to move outside the plane of the frame assembly 11 to allow the door leaves 14a-d to concertina together.

In this embodiment, the frames 16a-d, and the frame assembly 11 are manufactured from metal. Typically, the frames 16a-d and the frame assembly 11 are aluminium. The frames 16a-d and the frame assembly of this embodiment comprise a 6063T6 aluminium alloy. However, it shall be appreciated that any other suitable material may be used. In one alternative, the frames 16a-d, and the frame assembly 11 are of some other suitable material, such as some other 6063 series aluminium alloy, or a 6060 series aluminium alloy.

However, the frames 16a-d and/or the frame assembly 11 may include features or components of some non-metallic or composite material, such as plastics material or wood. In particular, the frame assembly 11 may comprise external and internal aluminium profiles, which provide structural strength to frame assembly 11, with a thermal break 39 of plastics or foam material sandwiched therebetween.

The frame assembly 11 and the frames 16a-d are manufactured from extruded aluminium members, however in alternative embodiments, any suitable manufacturing method may be used.

In this embodiment, the frame assembly 11 includes a threshold 20, the keep 24 and an end cap 26. It shall be appreciated that in alternative embodiments, any of these features may be included or omitted.

Figure 3 and 4 show a cross-sectional view of the threshold 20 on the plane z-z respectively without and with the end cap 26a in place. The threshold 20 extends in a generally horizontal direction and includes a hollow external profile 20a extending at least partially along a longitudinal axis of the threshold and defining a sill 32. The threshold 20 is fixed to a lowermost side of the opening 9 of the building, for example using fasteners. In this embodiment, the threshold 20 is fixed to the opening 9 using a plurality of fasteners spaced at regular intervals along a longitudinal axis x of the threshold 20.

The threshold 20 further includes an engagement formation 30a-d for engaging with the end cap 26, a thermal break 39 defining an elongate channel 33a, a track 33b, and an internal upstand 37. It shall be appreciated that in alternative embodiments, any combination of these features may be included and/or omitted.

The elongate channel 33a receives the track 33b for slidably receiving the rolling element of the door leaves 14a-d. In order to support the track 33b in the correct position, the elongate channel 33a includes shoulder portions. In alternative embodiments, first and second elongate channels may be provided, for example for supporting left and right wheels of the rolling element. Alternatively, the track 33b may be omitted and the rolling element may be supported directly in the elongate channel 33a.

The elongate channel 33a and/or the track 33b include at least one drain (not shown) for facilitating the flow of liquid (e.g., rainwater) out of the elongate channel 33a and into the hollow profile 20a of the threshold.

The internal upstand 37 and the thermal break 39 are located towards the interior side of the door 10. The upstand 37 extends in the generally vertical direction. The upstand 37 engages with interior surfaces of the door leaves 14a-d when the door is in the closed position. The upstand 37 may include a gasket (not shown) for sealing the door 10 from the ingress of moisture in the closed position.

The sill 32 extends along the entirety of the longitudinal axis x of the threshold 20. The sill 32 extends from the threshold 20 towards the exterior side of the door 10.

In this embodiment, the hollow external profile 20a at least partially extends along a longitudinal axis of the sill 32. The sill 32 includes an upper surface extending in a sloped direction generally downwardly.

The internal aluminium profile includes the upstand 37, and the external aluminium profile includes the sill 32. The upstand 37 and the sill 32 are mounted to opposing sides of the thermal break 39. The thermal break 39 serves the function of reducing the flow of heat energy between the inside and the outside of the building. The thermal break 39 is manufactured from a plastics (e.g., uPVC or polyamide) or foam material, and is sandwiched between the interior and exterior sides of the door. The thermal break 39 extends along the longitudinal axis x of the threshold 20.

In this embodiment, the engagement formation 30a-d includes a portion 30a defined by the hollow external profile 20a, a portion 30b defined by the elongate channel 33a, a first groove 30c extending along the longitudinal axis x, and a second groove 30d extending along the longitudinal axis x. It shall be appreciated that in alternative embodiments, any of the formations 30a-d may be included or omitted, or any suitable formation may be used to engage the end cap 26a, 26b.

The door jambs 22a, 22b extend in the generally vertical direction. The door jambs 22a, 22b are fixed to the opening 9 of the building using fasteners or any suitable fixing.

It shall be appreciated that for reasons of conciseness and brevity, only door jamb 22a will be described herein. However, the door jamb 22b is of substantially the same configuration.

The door jamb 22a is mounted to the end cap 26a at a first end, and to the header 13 at a second end remote from the first end. The door jamb 22a includes a formation to engage with the end cap 26a. In this embodiment, the formation includes at least one hollow profile (not shown) extending along an elongate length of the door jamb 22a. The formation also includes a protrusion 28a and first and second recesses 28b, 28c, illustrated in Figure 8. In alternative embodiments, the formations 28a-c may be any suitable formation, or alternatively the hollow profile may extend only partially along the elongate length of the door jamb 22a.

The keep 24 (Figure 9) extends in the generally vertical direction and is substantially planar. The keep 24 is mounted to the door jamb 22a on an opposing side of the door jamb 22 to the side fixed to the opening 9 of the building. The keep 24 includes at least one attachment location 24a, illustrated in Figure 9, to enable the keep 24 to be mounted to the jamb 22a by screws. In the embodiment of Figure 9, the keep 24 is a continuous keep, that is an elongate plate to which a plurality of recesses or apertures 19b (one visible) are mounted to receive and engage hooks or bolts of the latching mechanism 19a.

Figure 4 shows a cross-sectional view on the plane y-y of the end cap 26a fitted to the threshold 20. In this embodiment, there are two mirror-image end caps 26a, 26b of substantially the same configuration fitted to opposing ends of the threshold 20. In this embodiment the end caps are formed in a single piece e.g., injection moulded plastics material, but may in other embodiments may be die cast metal, for example or manufactured from multiple pieces.

The end cap 26a includes an engagement formation 34 for engaging the end of the door threshold 20, a jamb portion 36 arranged to receive the door jamb 22a, a capping face 38 extending at least in a direction towards an external side of the end cap 26 and an opening 40 located in the capping face 38. It shall be appreciated that in alternative embodiments, any combination of these figures may be included or omitted. The end cap 26a facilitates drainage out of the door 10, whilst having the aesthetic benefit of covering the internal profiles of the door components.

The capping face 38 includes an external edge 38a. The capping face 38 is substantially planar, and configured to conform to the shape of the external hollow profile 20a. An upper surface of the capping face 38 is generally angled in a downward direction relative to the remainder of the end cap 26. This corresponds to the shape of the threshold 20.

The capping face 38 is configured to act as a stop to prevent the end cap 26 from being inserted into the threshold a distance greater than a length of the engagement formation 34.

The opening 40 is configured to be in fluid communication with the external hollow profile 20a so as to define a drainage flow path therebetween. The opening 40 is located remote from the jamb portion 36. In this embodiment, the opening 40 is located closer to the external edge 38a than the jamb portion 36. The opening 40 is located towards a lowermost edge of the capping face 38 so as to allow liquid to drain away with minimal accumulation in the hollow profile 20a. In alternative embodiments, the opening 40 may be located in any suitable location on the capping face 38.

In this embodiment, the capping face 38 includes a first and a second rectangular opening 40a, 40b. However, in alternative embodiments, there may be any suitable number of openings of any suitable shape. For example, there may be one circular 30 opening.

In this embodiment, the engagement formation 34 includes engagement formations 34a-f. Specifically, the engagement formation 34 includes a formation 34a located on the capping face 38, a first arm 34b, a second arm 34c, at least one bore 34d for fixing the end cap 26 to the door jamb 22, at least one bore 34e for fixing the end cap 26 to the threshold 20, and a third arm 34f. It shall be appreciated that in alternative embodiments, any of the formation 34a, first arm 34b, second arm 34c, bores 34d, 34e and/or third arm 34f may be included or omitted. For example, the engagement formation 34a-f may include formation 34a and the first arm 34b.

The formation 34a is configured to fix the capping face 38 to the hollow external profile 20a of the threshold 20. In this embodiment, the formation 34a is in the form of a lip 34a located on an inner surface of the capping face 38. The lip 34a extends at least partially along an uppermost edge of the capping face 38. The lip 34a also extend at least partially along a lowermost edge of the capping face 38.

In the embodiment of Figure 3, the lip 34a extends along the majority of a perimeter of the capping face 38. The opening 40 is located in between a first and second end of the lip 34a.

The lip 34a is configured to receive a sealing material (not shown) so as to create a seal between the end cap 26 and the hollow external profile 20a of the threshold 20. As the lip 34a extends along a majority of the perimeter of the capping face 38, this helps to seal the capping face 38. A thickness of the lip 34a in the direction parallel to the longitudinal axis x is greater than a thickness of the capping face 38 in the direction parallel to the longitudinal axis x. This helps to create a sufficiently sized sealing surface for receiving the sealing material.

The first arm 34b is configured to be received by the corresponding formation of the threshold 20, in this embodiment the first groove 30c, as illustrated in Figure 4. The first arm 34b extends along the longitudinal axis x of the threshold 20. The first arm 34b is located proximate the capping face 38. This helps to improve the security of the connection between the capping face 38 and the external hollow profile 20a of the threshold. The first arm 34b is substantially rectangular. The first arm 34b extends from above the uppermost edge of the lip 34a.

As well as helping to secure the end cap 26a to the threshold 20, the first arm 34b aids the alignment of the end cap 26a relative to the threshold 20. This may help to improve sealing between the end cap 26a and the threshold 20.

The first arm 34b also includes a threshold alignment feature for engaging with the groove 30c, and/or a jamb alignment feature 42a for engaging with the door jamb 22a. In this embodiment, the threshold alignment feature includes a first and second elongate relief, extending along opposing sides of the first arm 34b. The groove 30c of the threshold 20 includes side walls extending towards a longitudinal axis of the first arm 34b, which are received within the reliefs, thus aiding the alignment, and locating of the end cap 26 relative to the threshold 20. It shall be appreciated that in alternative embodiments, any suitable alignment feature may be used, or the alignment feature may be omitted altogether.

The jamb alignment feature 42a of this embodiment is in the form of an upstand 42a extending in the direction perpendicular to the longitudinal axis x of the threshold 20. The upstand 42a is received within the one of the hollow profiles of the door jamb 22a.

The second arm 34c is of substantially the same configuration to the first arm 34b.

The second arm 34c includes the threshold alignment features and jamb alignment feature 42b of substantially the same configuration to those of the first arm 34b. The jamb alignment feature 42b is received within one of the hollow profiles of the door jamb 22a. The second arm 34c is received in the second groove 30d of the engagement formation. The second arm 34c is located proximate an internal side of the end cap 26. This helps to improve alignment and restrict movement at the internal side of the end cap 26.

The at least one bore 34e for fixing the end cap 26a to the threshold 20 includes three bores 34e in this embodiment for receiving three fixings 35e, as illustrated in Figures 7A and 7B. Two of the bores 34e extend in a direction perpendicular to a longitudinal axis x of the threshold 20. One of the bores 34d extends in a direction parallel to the longitudinal axis x of the threshold 20. The parallel bore 34d extends through a thickness of the end cap 26, from an external side to an internal side. In this embodiment, one of the perpendicular bores 34e is located on the first arm 34b, and the other of the perpendicular bores 34e is located on the second arm 34c.

The at least one bore 34d for fixing the end cap 26a to the door jamb 26 includes three bores 34d, in this embodiment for receiving three fixings 35d. This is illustrated in Figure 8. The three bores 34d extend in a direction perpendicular to the longitudinal axis x of the threshold 20. One of the bores 34d is located on the body of the engagement formation 34f, one of the bores 34d is located on the first arm 34b, and one of the bores 34d is located on the second arm 34c.

The third arm 34f is substantially rectangular and extends from the abutment wall 48 along the longitudinal axis x of the threshold 20. When the door 10 is assembled, the third arm 34f is received within the channel 33a of the threshold 20. The third arm 34f includes a shoulder 37. The shoulder 37 abuts against the shoulder of the elongate channel 33a when the end cap 26a is assembled. This helps to ensure the correct positioning of the end cap 26a relative to the threshold 20.

The uppermost surface of the first arm 34b is coplanar with the shoulder of the third arm 34f.

It shall be appreciated that in alternative embodiments, any suitable fastening mechanism may be used to fix the end cap 26a to the threshold 20 and the door jamb 22a. Alternatively, any suitable number of bores and corresponding fixings may be used, arranged in any suitable orientation.

The jamb portion 36 includes an alignment feature 44 configured to engage with the door jamb 22, a seat 46 and an abutment wall 48. It shall be appreciated that in alternative embodiments, any combination of these features may be included or omitted.

The jamb portion 36 is at least partially located on the engagement formation 34a-f. In this embodiment, the alignment feature 44 of the jamb portion 36 is located on the third arm 34f. This helps to ensure the door jamb 22a is aligned relative to the end cap 26a, as well as reducing the number of additional components needed to mount the door jamb 22a to the end cap 26a The alignment feature 44 receives the protrusion 28a of the door jamb 22a. The alignment feature 44 extends in the direction perpendicular to the longitudinal axis x. As well as correctly aligning the door jamb 22a, the alignment feature 44 restricts movement of the door jamb 22a in a plane perpendicular to the plane of the opening 9. The alignment feature 44 includes a surrounding wall 44a defining an internal volume 44b. The protrusion 28a includes a corresponding profile, having grooves for receiving the surrounding wall 44a, and a body for locating within the internal volume 44b. It shall be appreciated that the alignment feature 44 and the hollow profile may be any suitable shape to facilitate inter-engagement and relative alignment of the door jamb 22a.

The seat 46 is configured to abut the keep 24, which is mounted to the door jamb 22a. Therefore, the alignment feature 44 extends from the seat 46. The seat 46 extends from the third arm 34f, for example from a top surface of the third arm 34f.

The seat 46 extends a predetermined height from the jamb portion 36. A lower edge of the keep 24 abuts a top surface of the seat 46 when the door 10 is assembled. This means the top surface of the seat 46 provides a datum level and that the keep 24 is a known height about the threshold 20, which helps to correctly align the components described above, such as the recesses or apertures 19b. The seat 46 also includes a shoulder 46a that is a continuation of the shoulder of the third arm 34f for locating the end cap 26 relative to the threshold 20.

The abutment wall 48 forms a cover and prevents the internal profile of the end cap 26 from being visible when the bi-fold door 10 is assembled. Additionally, the abutment wall 48 closes the grooves 30c, 30d and the elongate channel 33a in the threshold 20 to prevent water leaking past the end cap 26. The abutment wall 48 is substantially planar, and therefore corresponds to the shape of the end of the threshold 20, which is also substantially planar. This helps to ensure the end cap 26a is flush to the end of the threshold 20.

The abutment wall 48 extends from the capping face 38. The capping face 38 and the abutment wall are substantially coplanar. In this embodiment, the capping face 38 and the abutment wall 48 are integral, however in alternative embodiments the capping face 38 may be manufactured separately and fastened to the abutment wall 48 using any suitable mechanism. Along with the capping face 38, the abutment wall 48 also acts as a stop to prevent the end cap 26 being inserted into the threshold 20 a distance greater than the engagement formation 34.

The abutment wall 48 includes a cut-out section 50 for receiving the door jamb 22a. The cut-out section 50 receives a protruding part of the door jamb 22a between the first and second recesses 28b, 28c. It shall be appreciated that in alternative embodiments, the cut-out section 50 may be omitted.

With reference to Figures 6 to 9, a method of assembling the frame assembly 11 of the bi-fold door 10 shall be described hereafter.

The end cap 26a is inserted into the end of the threshold 20, as illustrated in Figure 6. Sealant is applied to the engagement formation 34a of the capping face 38. The first, second and third arms 34b, 34c and 34f are slidably received within the first and second grooves 30c, 30d and the portion of the elongate channel 33a of the threshold 20. The engagement formation 34a is located within the external hollow profile 20a of the threshold, and as the sealant sets, a durable seal is formed between the end cap 26a and the threshold 20.

The perpendicular bores 34e illustrated in Figure 7A are pre-drilled to facilitate screwing of the fixings 35e. The parallel bore 34e illustrated in Figure 7B is provided as a screw port, such that the fixing 35e is self-tapping. The fixings 35e are screwed into the perpendicular bores 34e and the parallel bore 34e. This fixes the position of the end cap 26 relative to the threshold 20. The process is repeated for end cap 26b.

The first and second door jambs 22a, 22b are secured to the header 13 to form a substantially U-shaped frame. The U-shaped frame is then mounted to the threshold 20. The door jambs 22a, 22b are located on the jamb portions 36 of the end caps 26a, 26b. The alignment feature 44, jamb alignment features 42a, 42b and cut-out section 50 engage with the respective features of the jamb portion 36 such that the door jambs 22a, 22b are correctly aligned with respect to both the threshold 20 and the end caps 26a, 26b.

Bores in the threshold (not shown) aligned with bores 34d located in the first, second and third arms 34b, 34c, 34? are pre-drilled to facilitate screwing of the fixings 35d. The fixings 35d are inserted into an underside of the threshold 20 and screwed into the bores 34d in the end cap 26 and into corresponding screw ports (not shown) in the jamb door profile 22a.

The keep 24 is located such that its lower edge abuts the seat 46. The keep 24 is screwed to the door jamb 22 using any suitable fixing. Components, such as the recesses or apertures 19b, are mounted to the keep 24. This completes the frame assembly 12.

The frame assembly 12 is offered up to the opening 9. The threshold 20 is secured to the base of the opening 9 using fixings. The jambs 22a, 22b are fixed to the sides of the opening 9, and the header 13 is fixed to the uppermost side of the opening 9.

Although the teachings have been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope as defined in the appended claims.

For example, although described in relation to bi-fold door, the teachings may be applicable to thresholds for other closures such as sliding doors where the threshold may have a similar drainage requirement.

Claims

Claims 1. An end cap for fitting to an end of a door threshold having a hollow external profile, the end cap comprising: an engagement formation configured to engage the end of the door threshold; a jamb portion arranged to receive a door jamb; a capping face extending at least in a direction towards an external side of the end cap to close the hollow profile; an opening located in the capping face, wherein the opening is configured to be in fluid communication with the hollow profile so as to define a drainage flow path therebetween, and wherein the opening is located remote from the jamb portion.
2. The end cap according to claim 1, wherein the capping face comprises an external edge, and wherein the opening is located closer to the external edge than the jamb portion.
3. The end cap of claim 1 or claim 2, wherein the jamb portion comprises a seat configured to abut a keep mounted to the door jamb portion, and wherein the seat extends a predetermined height from the jamb portion.
4. The end cap of any preceding claim, wherein the jamb portion is formed on part of the engagement formation.
5. The end cap of any preceding claim, wherein the engagement formation comprises a formation located on the capping face configured to fix the capping face to the hollow profile.
6. The end cap of claim 5, wherein the formation located on the capping face is a lip.
7. The end cap of claim 6, wherein the lip is located on an inner surface of the capping face, wherein the lip is configured to receive a sealing material so as to create a seal between the end cap and the hollow profile of the threshold.
8. The end cap of claim 7, wherein the lip extends at least partially along an uppermost edge of the capping face, optionally wherein the lip extends at least partially along a lowermost edge of the capping surface.
9. The end cap according to any preceding claim, wherein the engagement formation comprises a first arm configured to be received by a corresponding formation of the threshold, for example a channel.
10.The end cap according to claim 9, wherein the first arm is located proximate the capping face.
11.The end cap according to any preceding claim, wherein the engagement formation comprises a second arm configured to be received by a corresponding formation of the threshold, for example a second channel, optionally wherein the second arm is located proximate an internal side of the end cap.
12.The end cap according to any preceding claim, wherein the engagement formation further comprises at least one bore configured to receive a fixing, optionally wherein the engagement comprises a first bore configured to extend in a direction perpendicular to a longitudinal axis of the threshold, and/or wherein the engagement formation comprises a second bore configured to extend in a direction parallel to the longitudinal axis of the threshold.
13.The end cap according to any preceding claim, wherein the jamb portion comprises an alignment feature configured to engage with the door jamb.
14.The end cap according to any preceding claim, wherein the capping face is substantially planar.
15.The end cap according to any preceding claim, wherein the jamb portion comprises an abutment wall, wherein the abutment wall and the capping surface are substantially planar, and wherein the capping face extends from the abutment wall.
16.The end cap according to claim 15, wherein the capping face and the abutment wall act as a stop configured to prevent the end cap from being inserted into the threshold a distance greater than a length of the engagement formation.
17.The end cap of claim 15 or claim 16, wherein the abutment wall comprises a cut-out section configured to receive the door jamb.
18.The end cap of any preceding claim, wherein the end cap is integrally and monolithically formed e.g., as injection moulded plastics.
19.A frame assembly for a door, such as a bi-fold door, the frame assembly comprising: a threshold comprising a hollow external profile extending at least partially along a longitudinal axis of the threshold; and an end cap according to any preceding claim fitted to an end of the threshold.
20.The frame assembly according to claim 19, wherein the threshold comprising a first corresponding formation for engaging with an engagement formation, for example a first channel, optionally wherein the threshold comprises a second corresponding formation for engaging with the engagement formation, for example a second channel.
21.The frame assembly according to claim 19 or claim 20, further comprising a door jamb extending in a generally vertical direction, wherein the door jamb is received by the jamb portion.
22.The frame assembly of claim 21, wherein the door jamb comprises a corresponding formation to engage with the jamb portion, optionally wherein the corresponding formation includes a hollow profile and/or a protrusion, and optionally wherein the hollow profile extends along an elongate length of the doorjamb.
23.The frame assembly according to any one of claim 19 to 22, further comprising a keep extending in the generally vertical direction, wherein the keep is mounted to the door jamb, and wherein the keep comprises at least one attachment location.
24.The frame assembly according to claim 23, wherein the keep abuts a seat of the jamb portion such that the keep is a predetermined height above the threshold.
25.The frame assembly according to any one of claim 19 to 24, wherein the threshold comprises an elongate channel configured to slidably receive a rolling element mounted to door leaf.