US3166163A

US3166163A - Metal door construction

Info

Publication number: US3166163A
Application number: US157475A
Authority: US
Inventors: James A Wahlfeld
Original assignee: Individual
Current assignee: Individual
Priority date: 1961-12-06
Filing date: 1961-12-06
Publication date: 1965-01-19
Anticipated expiration: 1982-01-19

Description

Jan. 19, 1965 J. A. WAHLFELD METAL DOOR CONSTRUCTION 2 Sheets-Sheet 1 Filed Dec. 6, 1961 INVENTOR: JAMES A. WAHLFELD ATT'YS Jan. 19, 1965 J. A. WAHLFELD METAL DOOR CONSTRUCTION 2 Sheets-Sheet 2 Filed Dec. 6, 1961 INVENTOR: JAMES A. WAHLFELD United States PatentO.

3,166,163 METAL DOBR GNSTRUCTESN .iames A. ,Jahifeld, 216 W. Strati'ord Drive, Peoria, lili- Filed Dec. 6, 1961, Ser. No. 157,475 2 (Ilairns. (ill. 89-46} This invention relates in general to door constructionv and in particular to the formation and structure of metallic doors.

The use of metal doors, especially aluminum doors, has in recent years found many applications, not only for use as an external storm door for the home, but as en trance and internal doors of most or" the modern stores, factories and oilice buildings of today. This explosive expansion of uses for metallic door structures has been profounded not only by their characteristic design advantages but from an economical aspect. From the ultimate purchasers viewpoint there are many obvious advantages to the metallic door construction; durability, rigidity, elimination of repetitive finishing, light in weight, to name but a few. From the manufacturers view, there are also many advantages, especially with the modern processes for forming extruded metal parts; uniformity of material, improved quality control, readily adaptable to assembly line production and elimination of massive material wastes are but a few of the more obvious advantages. i

The strength of a metallic door construction is primarily determined by the formation and securern'ent of the four corner junctures formed by the mating top, bottom over a right angle bracket to' secure the mating frame members. Each of the prior devices or methods have provided, to some degree, a securement of the four junctures of the door construction but lack several desirable characteristics and advantages. When welding the mating frame members together, either internally or externally, there is created a discoloring of the metal; if externally welded, and additional finishing operation is required to blend the weld with the surface. Internal weld ing has been found in previous metallic door constructions to be unsatisfactory because of difliculty in forming a positive weld within the members and because of the small weld area afiorded by the desired thin Wall structure of the mating members. The use of an internal right angle bracket not only increases the overall cost per unit, but one usually experiences a separation of'the mating frame members after repeated use of the door.

It is therefore the primary object of this invention to provide an improved metallic door construction which eliminates the shortcomings of the prior art devices and methods. a V

it is a specific object of this invention to provide an improved metallic door construction having total surfaceto-surface contact at right angles between matingmembers to attain maximum rigidity over the entire corner juncture. v l

Another object of this invention is to provide an in proved metallic door construction which is formed from extruded channel members designed to interlock with one another at the corner junctures.

A still further object of this invention is to provide an improved metallic door construction which is formed from extruded metallic channel members designed to interlock with one another at the corner junctureswherein an internal area of interlock of mating members is readily a cessible to be welded together.

A further object of this invention is to provide an im- I 3,156,13 Patented Jan. to, less proved metal door construction which permitspositive interlocking securernent of mating frame members at the corner junctures which is accomplished entirely within tne frame members without afiecting the desired external finished surface.

A Still further object of this invention is to provide an skilled in the art, from the following description, dr-aW- ings relating thereto, and the appended claims;

In the accompanying drawings, which show a preferred embodiment of the present invention, like numerals refer to like parts throughout the several viewsin which: 7

FIG. 1 is a view in side elevation'of the door construction of this invention in the assembled condition with, a

glass panel mounted therein;

FIG. 2 is a fragmentary sectional View of a side member taken along the line 22 of PEG. 1;

FIG. 3 is a fragmentary sectional iew of atop frame member taken along the line 3-3 of FIG. 1;

PEG. 4 is a fragmentary sectional view of a bottom frame 7 frame member taken along the line d-4 of 516 1;

FIG. 5 is a fragmentary exploded view in frontfperspective of a corner juncture of the frame members with a portion of one frame member cut away to illustrate the interlocking of the mating frame members; and

FIG. 6 is a fragmentary view in front perspective illusement of the members.

of the detailed description to follow, the door structure of this invention is primarily characterized by the unique interlocking or meshing of mating frame members at the corner junctions which affords maximum desired rigidity and presents -a greater internal surface, area of mating parts to permit a positive securernent by weldin By way of example, the drawings illustrate an exterior storm door structure for the home and will be described as formed from an aluminum alloy, but it is to be understood that the structural formation of this invention is readily adaptable for other door constructions and may be formed from otler metals such as bronze, steel, etc, and plastics that may be readily extruded into thev desired channel frame members. V

Referring now to the'drawings, more specifically to FIGS. 1, 2, 3 and 4, the door structure of this invention is indicated generally by the numeral it) and includes side frame members 12, a top frame member 14, and a bottom frame member 16. As shown in FIG-1, the fram members, when in the assembled condition, receive a 'preassembled removable unitary window frame member l having a metallic border Zllabout the sidesrthereof. It being obvious thata unitary preassembled screen or solid member may also be substituted for the window member 18. A door latch 22, has been illustrated and may be of any suitable conventional latch on the market 7 todayr reference is now made to FIGS. and 6 for a detailed 31 formed at the juncture of the top wall 28 with the 7 side wall 24 is a ridge 32, the inner side of which the border 20 'of the windowframe 18 may abut when in the .installed position. the inner side of the ridge 32 is a groove 34 having an In' contiguous relationship with angularly disposed side wall 36 as a continuation of the inner side of the ridge 32. The other side wall 38 of position, a retaining latch mechanism, similar to that shown in the Conrad Reissued Patent 24,520, mounted at spaced intervals in the border 20, provides a blade member 42 to pivot inwardly to interlock with the groove 34. 'The angular side wall '36 aiding in guiding the blade member 42 into the groove with the ide Walls 36 and 38-spaced apart at the lower or innermost point of the groove sufiiciently to receive the blade member 42.

The bottom wall provides a planar surface, 44 with an extending reinforced rib 46, as a continuation of side wall 24, having a' flat surface 48 parallel to surface 44. On the other side an extending rib 50, as a continuation of side wall 26, is illustrated as having a rounded configuration terminating at the same elevation as surface. 48 of the extending rib 46. a

Referring now specifically to FIG. 3, the top frame member 14, extruded in the desired contours as'previously described, provides an exterior, side wall 52 and a parallel interior side wall 54, a top wall 56 and a parallel bottom wall 58.

Side walls

52 and 54 join the top wall 56 at right angles and extend, past the top wall a short distance to form

identical edges

60 and 62. In similar manner, the side walls 52 and'54 join the bottom wall 53 at right angles with the ide wall 52 extending past-the bottom wall a substantial distance toform an edge 64.

Positioned between the side walls 52' and 54 in parallel relationship is a rib member 66 secured along itsledges to top wall 56 and bottom wall 58. The rib member 66 is disposed off center of the space between

side walls

54 and 56, being spaced from side wall 56 the exact same distance asthe center of groove 34 is from side wall 24 of the side frame member 12 :Therelationship of the rib member 6 6with the groove 34 will be readily understandable from thedescription to follow as to the joining of the frame members. Centrally disposed on the outer surface of bottom wall 58 is a depending holding rib 68' having a rounded lower edge. As readily seen in FIG.

3, the rib 68 interlocks with a groove 70in the upper surface of the border20 of window member 18. The interlocking of the rib 68 with groove 70 in conjunction with the latching mechanisms previously described secures the window rigidly againstthe-frame members.

Referring now toFIG. 4, the bottom frame member 16 provides identical configuration as the top frame member 14 just describedexcept the rib member 68. centrally disposed on the outer surface of thebottom wall has been eliminated to permit easy installation of the window member 18 and to provide a flat surface for the top surface of the border 20 toguide upon,.and the member 16 is inverted 180 relative to the position of member 14.. In

description of the unique interlocking and securement of these frame members to form the door structure. To

achieve maximum clarityin showing and describing the corner junctures, FIGS. 5 and 6 illustrate the upper righthand corner juncture of FIG. 1 as viewed from the inner side. As 'best seen in FIG. 5, the end surface of top frame member 14 is formed to provide a mating contour configuration identical to the contoured surface/28 0f 7 side frame member 12. The rib 66 of frame member 14 extends outwardly past the end. surface? of. the frame member 14. a distance suflicientto extend into and past the innermost surface of groove 34 when the frame members are assembled. The groove 34 of frame member 12 has the bottom wall thereof removed, preferably by a saw cut, as at 72, a length sufiicientto receive therib 66 of frame member 14.

With the frame members prepared as just described, the mating surfaces are interlocked as seen in FIG. 6. Themating of the various contours and the extension of rib 66 into the groove 34, open at 72, interlocks the two frame members together with the majority of the mating surfaces abutting one another at right angles. With the end of rib 66 extending through the groove 34 adjacent the open end of frame member 12, not only is a greater surface area available'for welding, that is, the thickness of the rib '66 with the thickness of the side walls of groove 34 on both sides thereof, ,butis readily accessible to perform the welding operation since the channels forming the side frame member are open at their end andis accomplished entirely upon the inner rib members Whereby the heat generated therefrom will not discolor or affect the outer exposed decorative surfaces.

The combination of the permanent securement by welding of the rib 66 to the sides of the groove 34 over the entire width of the juncture with the total mating surfaces interlocked and abutting one another at right angles,

there is provided maximum strength and rigidity toresist all of the compressive, tensile or torsional forces that a door structure will encounter. In addition, it is obvious that not only is the ultimate of strength and rigidity attained by the door structure of this invention, but the joining of the frame members at right angles in interlocking relationship provides an overall outer geometrically balanced door design.

Although the invention has been described in connection with a specific embodiment, the principles involved are susceptible of num'erousother applications which will readily occur to persons skilled in the art. The invention is therefore to be limited only as indicated by the scope of the appended claims.

What is claimed:

1. An all metal door frame structure comprising open ended first tubular frame members each substantially rectangular in cross section and having the opposed inner edges thereof .angularly contoured including a ridge member extending outwardly from said inner edges, a groove extending inwardly from said inner edges adjacent said ridge and open at the bottom thereof to the interior of said frame members adjacent the ends thereof,

said ridge'member and groove being centrally offset-ad-' jacent a side wall of said first frame members; second tubular frame members each having-end surfaces thereof angularly contoured for reception of the inner edges of said first frame members including an internal rib member integrally formed therein throughout its length in parallel relation with the side walls of said second frame members and extending outwardly past the end surfaces thereof and centrally. olfset adjacent to one of the side walls for alignment with said grooves and terminally exposed in said groove openings to the interior of said first frame members for access through said open ends; and

means accessible throughsaid open ends integrally securing said second frame members at right angles to 'said first frame members with said extending rib member secured in said groove at said openings to provide a unitary door frame structure.

2. The invention is called for in claim 1 wherein said grooves are tapered to guide said rib member into place and said opening comprises a. slotting of the innermost surface of the groove of the first frame members to permit the extending rib of said second frame members to pass therethrough, and wherein said means integrally securing said second frame members at right angles to said first frame member comprises Weld means securing the end of the rib to the under surface of the groove throughout the length of the rib member exposed therein.

UNITED STATES PATENTS Koontz May 22, 1951 Kessler Nov. 11, 1952 Kiefer Mar. 9, 1954 Sigler et a1. Apr. 23, 1957 Bianca June 9, 1959 FOREIGN PATENTS Great Britain Nov. 21, 1951

Claims

1. AN ALL METAL DOOR FRAME STRUCTURE COMPRISING OPEN ENDED FIRST TUBULAR FRAME MEMBERS EACH SUBSTANTIALLY RECTANGULAR IN CROSS SECTION AND HAVING THE OPPOSED INNER EDGES THEREOF ANGULARLY CONTOURED INCLUDING A RIDGE MEMBER EXTENDING OUTWARDLY FROM SAID INNER EDGES, A GROOVE EXTENDING INWARDLY FROM SAID INNER EDGES ADJACENT SAID RIDGE AND OPEN AT THE BOTTOM THEREOF TO THE INTERIOR OF SAID FRAME MEMBERS ADJACENT THE ENDS THEREOF, SAID RIDGE MEMBER AND GROOVE BEING CENTRALLY OFFSET ADJACENT A SIDE WALL OF SAID FIRST FRAME MEMBERS; SECOND TUBULAR FRAME MEMBERS EACH HAVING END SURFACES THEREOF ANGULARLY CONTOURED FOR RECEPTION OF THE INNER EDGES OF SAID FIRST FRAME MEMBERS INCLUDING AN INTERNAL RIB MEMBER INTEGRALLY FORMED THEREIN THROUGHOUT ITS LENGTH IN PARALLEL RELATION WITH THE SIDE WALLS OF SAID SECOND FRAME MEMBERS AND EXTENDING OUTWARDLY PAST THE END SURFACES THEREOF AND CENTRALLY OFFSET ADJACENT TO ONE OF THE SIDE WALLS FOR ALIGNMENT WITH SAID GROOVES AND TERMINALLY EXPOSED IN SAID GROOVE OPENINGS TO THE INTERIOR OF SAID FIRST FRAME MEMBERS FOR ACCESS THROUGH SAID OPEN ENDS; AND MEANS ACCESSIBLE THROUGH SAID OPEN ENDS INTEGRALLY SECURING SAID SECOND FRAME MEMBERS AT RIGHT ANGLES TO SAID FIRST FRAME MEMBERS WITH SAID EXTENDING RIB MEMBER SECURED IN SAID GROOVE AT SAID OPENINGS TO PROVIDE A UNITARY DOOR FRAME STRUCTURE.