WO1997036078A1

WO1997036078A1 - Doors

Info

Publication number: WO1997036078A1
Application number: PCT/GB1997/000791
Authority: WO
Inventors: Thomas Patrick Moloney
Original assignee: Thomas Patrick Moloney
Priority date: 1996-03-23
Filing date: 1997-03-21
Publication date: 1997-10-02
Also published as: GB9606235D0; GB2311553A; AU2037297A; EP0888488A1; GB9705935D0

Abstract

A door, for example for use in industrial and commercial premises, designed to be pushed open by pedestrians or vehicles such as forklift trucks, comprises at least one member (2, 3) integrally formed with mounting means (10), by which it is mounted in an opening for use, and coupling means (14, 15) at which at least one panel (4) is retained to the frame member. The or each frame member is preferably a pultrusion or extrusion of fibre reinforced plastics material. Preferably it is hollow and the mounting means and coupling means extend for its length, the mounting means being, for example, of circular or rectangular cross section and the coupling means being opposed flanges (14, 15) between which an edge of the or each panel is secured. The panel or panels may be rigid, for example of glass or a plastics material. Bearing assemblies (6, 7) are applied to the or each frame member for pivotally mounting it, and so the door, in an opening and spring loaded return pivot means (44) normally urge the frame member, and hence the door, to a closed position.

Description

DOORS

This invention relates to doors, particularly, though not exclusively, for use in industrial and commercial premises, which normally stand closed but are designed to be pushed open readily by pedestrians or by forklift trucks or other vehicles used on the premises, and after the pedestrians or vehicles have passed through the openings they close, and which comprise at least one frame member and at least one panel.

Doors of this kind are known in various forms. One such door comprises essentially a frame member or members carrying, substantially in suspension, a panel or panels of heavy duty sheet plastics material. These doors are available in a variety of sizes, standard and non-standard, which require the panels and frame members to be cut to different sizes. As the frame members are commonly made from steel, welded together where necessary, cutting and assembling doors of different sizes presents difficulties, requiring a fairly high degree of skill.

It is an aim of the present invention to provide a door which may be more easily assembled in any required size.

According to a first aspect of the invention, there is provided a door comprising at least one frame member and at least one panel , the frame member having mounting means by which it is mounted and retained in an opening for use and coupling means at which the panel is received and retained to the frame member, the mounting means and coupling means being integrally formed together. The mounting means and coupling means may be integrally formed together by any suitable technique, e.g. moulding or casting, but preferably by pultrusion or possibly extrusion.

A variety of materials can be used for the frame member. A fibre reinforced material may be used such as, for example, polyester reinforced with glass fibre or carbon fibre, reinforced epoxy resin or other suitable plastics material . Preferably the material is substantially rigid. In the application of the door for industrial premises, for example, the chosen material may typically have stiffness characteristics similar to those of 5mm thick 60mm OD steel tube or 5mm thick 46mm OD steel tube. Pultruded glass fibre reinforced polyester has such characteristics, and has the advantage of being much lighter. Such a material may also be corrosion, chemical and fire resistant. Glass fibre reinforced polyester may be coated with a surface veil, producing a smooth finish which is easy to maintain.

The mounting means and/or the coupling means of the frame member may be provided along the entire length of the frame member. This allows the frame member to be cut into any required length to suit the size of opening in which the door is to be used and to receive the panel or panels. Alternatively the mounting means and/or the coupling means may be provided at discrete locations along the frame member. These may be provided at the same or different discrete locations.

The frame member is preferably hollow, but may be solid.

The mounting means may be substantially circular in cross section, or may be any other suitable shape e.g. rectangular including square. The coupling means may take the form of a pair of opposed flange members providing a space therebetween in which the or each panel is received and retained. The flanges may be adapted to flex to accommodate different thicknesses of the panel or panels in the space between them. The panel or panels may be retained by being of a frictional fit between the flanges, or by means of fasteners such as bolts or studs. Such fasteners may be inserted through each flange and the panel or panels. A cover or covers may be provided for attachment to the coupling means at at least one of the flanges so as to fit over the fasteners in order to conceal them and provide a smooth finish. The cover or covers may be adapted, for example by the provision of flanges to define a socket or sockets, to receive and locate insulation on the frame member covering at least one side surface of the or each panel.

The flanges may be integral extensions of the mounting means. In a preferred embodiment, the mounting means is hollow, for example of tubular substantially circular or rectangular cross-section, with an opening along one side extending longitudinally of the frame member. The flanges of the coupling means are integrally formed on and extend portions of the mounting means alongside the opening.

A bearing assembly may be provided at either end of the frame member to retain the door in an opening for use. The bearing assemblies may be attached to a jamb of the opening, or the floor or structural part of a building in which the opening to be closed by the door in use is provided. In addition, or alternatively, the bearing assemblies may be provided at various points along the length of the frame member. The bearing assemblies may comprise a cylinder or cone, or comparable protrusion, substantially received within the frame member, about or on which the door may pivot. The frame member may be mounted in a horizontal or vertical position in the opening. The door may pivot in one direction or two opposite directions from an original position. Preferably the door is able to pivot through at least 90° in opposite directions from an original position.

The door may include a return pivot assembly which enables it, on being pivoted, to return to its original, preferably closed, position. The return pivot assembly may comprise a torsion spring, preferably substantially received within the frame member. On pivoting of the door, loading of the spring will return the door to its original position.

The or each panel of the door may be of a rigid material capable of self-support e.g glass, PVC, rubber or polycarbonate. Alternatively the panel or panels may be of a non-rigid material e.g a flexible plastics material.

Two or more panels may be retained by the frame member. There may be two or more frame members. A joint member may be provided to join two of the frame members together.

Doors in accordance with the present invention may be provided in combination.

In one embodiment, two of the doors are provided to be mounted together in an opening, each door having a vertical and a horizontal frame member, the horizontal frame member being joined to the top of the vertical frame member by a joint member. The vertical frame members are mounted on lower and upper bearing assemblies provided at each end thereof. Return pivot assemblies are provided in each door to return them to closed positions. Panels of sheet plastics material are received and retained by the frame members of each door. Such doors are suitable for use in commercial and industrial applications, and for instance, can be opened by driving through them with, for example, a fork-lift truck. The lower bearing assembly may be adapted so that on direct impact upon the vertical frame member, the member will snap off the bearing assembly without permanent damage. A conventional steel frame member would tend to buckle on such impact.

A kit of parts for assembly into a door in accordance with the first aspect of the invention herein defined may comprise: one or more lengths of frame member, one or more panels, one or more joint members, one or more bearing assemblies and one or more pivot assemblies.

The same kit may be used to assemble doors of various different sizes. Assembly is quick and easy and may be undertaken by relatively unskilled labourers, in comparison to the assembly of conventional doors of this kind.

According to a second aspect of the invention there is provided a method of assembling a door in accordance with the foregoing first aspect of the invention, comprising the steps of: cutting a length or lengths of frame member to the required size or sizes, joining the frame members, if required, using joint members, attaching a panel or panels to the frame member or members, and attaching a bearing assembly or assemblies and a return pivot assembly to the, or one, frame member.

The assembled door can be mounted in an opening for use by means of two or more of the bearing assemblies. The method may comprise additional steps of fastening the panel or panels to the frame member or members using fastening means, and fitting a cover or covers to the frame member or members to conceal the fastening means. The cover or covers may be clipped or slid into place.

The method may comprise a further step of fitting a cap to one or each exposed end of the frame member or members. The cap or caps may be tapped into place.

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

Figure 1 is a front view of a door according to the present invention,

Figure 2 is a cross-sectional view of a frame member,

Figure 3 is a front view of a joint member,

Figure 4 is a front view of a first component of a lower bearing assembly,

Figure 5 is a front view of a second component of the lower bearing assembly,

Figure 6 is a front view of a third component of the lower bearing assembly, Figure 7 is a side view of an upper bearing assembly, together with a return pivot assembly ,

Figure 8 is a top plan view of a cover, and

Figure 9 is a fragmentary section showing a modification.

Figure 1 shows an assembled door 1 comprising a first frame member 2, a second frame member 3 and a panel 4. The door is mounted for use in an opening 5 by means of a lower bearing assembly 6 and an upper bearing assembly 7. The frame members 2, 3 are joined together by a joint member 8, and a return pivot assembly 44 (Figure 7) is connected to the upper bearing assembly 7 and is received within the frame member 2. The frame member 3 has a cap 9

The frame members each comprise a hollow pultruded section of glass fibre reinforced polyester (Figure 2) . This has the stiffness characteristics of 60mm OD steel tube (5mm thick) and is coated with a surface veil giving a smooth finish.

Mounting means 10 is provided along the length of each frame member, and is generally tubular and of substantially circular cross- section having an opening 11 in one side defined between ends 12 and 13. These are integrally formed with flanges 14 and 15 which comprise coupling means which again extends along the length of the frame member. A space is provided between the flanges 14, 15 forming a slot 16 in which a panel (not shown) is received. Studs 17 are used to retain the panel in the slot 16. Covers 18 and 19 (of UPVC extrusion) are clipped or slid into channels on the outside of each flange to conceal the studs 17, thereby giving a smooth , wipe-clean finish. The frame members are joined together using a joint member 8 (Figure 3) . This comprises a casting of steel tubes 20, 21 forming a right angle, which are attached to and supported by a corner section 22. The steel tubes each have a radial fin 23, 24 extending along its length. In use, the frame members are slid over the steel tubes, until they abut the corner section 22. The fins 23, 24 locate in the slot 16 of the coupling means of each frame member, thereby preventing them from twisting. In an alternative embodiment, the fins may be omitted, and there may be a frictional fit between the steel tubes and the frame members such that they are prevented from twisting or rotating.

The door 1 is mounted and retained in the opening 5 by means of lower and upper bearing assemblies 6,7. Figures 4, 5 and 6 show three components which make up the lower bearing assembly 6. A first component (Figure 4) comprises a plate 25 on which is a cone 26. The plate 25 is bolted to the foot of the opening 5 for the door. A second component of the bearing assembly (Figure 5) comprises a locking collar 27, a concave bearing 28 and sleeve 29. The bearing is adjustable in height, allowing the height of the door to be adjusted as required. The sleeve 29 is screwed into a tubular holder 30 which forms a third component of the bearing assembly (Figure 6) . The holder 30 has a radially projecting fin 31 adapted to fit between the flanges 14, 15 on the frame member 2.

In use the holder 30 is slid up inside the first frame member 2, with the fin 31 located and fastened between the flanges 14, 15. The sleeve 29 is screwed into the holder, and the frame member and bearing assembly components placed on the cone 26. The height of the bearing 28 is adjusted as required, and the bearing 28 locked into position using the locking collar 27. The sleeve 29 is rotatable, about the cone 26, and hence the holder and the entire door can pivot about the lower bearing assembly .

The upper bearing assembly 7 (Figure 7) comprises a plate 32 provided with a lug 41. The plate is welded to a disc 33, and a bar 34 is attached perpendicularly at one end, co-axially , to the disc 33 and at the other end is provided with a removable radial pin 43.

The return pivot assembly 44 (Figure 7) connected to the upper bearing assembly 7 comprises a helical torsion spring 37 which, at one, upper, end is secured to an annular tension adjusting element 42, and, at the other, lower, end is secured to an annular disc 35. The disc 35 is formed with a chamfered edge 36 which extends from and along approximately one third of the circumference of the lower surface of the disc 35.

In order to fit the return pivot assembly 44 to the upper bearing assembly 7, the pin 43 is removed from the bar 34 and the torsion spring 37 , adjusting element 42 and disc 35 are slid onto the bar so as to surround it co-axially. The pin 43 is then replaced to hold the return pivot assembly in place, whilst allowing its components to rotate around the bar.

The upper bearing assembly 7 together with the return pivot assembly 44 is then dropped into the vertical steel tube 21 of the joint member 8, which is held in the frame member 2. The tension adjusting element 42 of the return pivot assembly protrudes from the top of the tube 21 , such that this element is easily accessible. The plate 32 of the upper bearing assembly 7 is bolted in position at the top of the opening 5. The bottom of the frame member 2 is located on the lower bearing assembly 6, and the height of the door adjusted, as previously described, so that the frame member 3 does not snag on the top of the opening 5. The torsion spring 37 and the disc 35 are of sufficient size to hold the steel tube 21 and hence the frame member 2 in a substantially vertical position, whilst allowing the tube and frame member, and thus the door, to rotate about the pivot assembly and the upper bearing assembly.

When the return pivot assembly 44 is dropped into the steel tube 21 , it is positioned such that the chamfered edge 36 locates against an abutment, not shown, provided on the tube. When the door is in place, the tension adjusting element 42, which is provided with holes 42 around its outer surface, is adjusted so that the door resists unintentional opening e.g. by wind. A tension pin 40 is then inserted into the closest clockwise hole 42^! to the lug 41 on the plate 32, and the tension on the tension adjusting element 42 released. The pivot assembly turns slightly so that the pin 40 locates against the lug 41 . The pivot assembly is therefore held at the top by the lug 41 and at the bottom by the abutment on the tube 21. Rotational play in the door is therefore reduced.

On rotation of the door, and hence the steel tube 21 , in a first direction, the abutment on the tube picks up the edge 36 and rotates the disc 35 and hence the torsion spring 37. The pin 40 abuts the lug 41 and prevents rotation of the top of the spring assembly. This loads the spring from the bottom such that when the door is released the force in the spring causes the door to return to its original position. On rotation of the door in the opposite direction, an edge of the corner section 22 of the joint member 8 picks up the tension pin 40 and rotates the tension adjusting element 42 and hence the torsion spring 37. The edge 36 abuts the pin 43 on the bar 34, and prevents rotation of the bottom of the spring. This loads the spring from the top, such that when the door is released the force in the spring causes the door to return to its original position.

The exposed end of the frame member 3 is fitted with a cap 9

(Figure 8) . This has the same basic cross-sectional shape as the frame member but comprises a solid plate 38. A knurled tubular section 39 of the cap 4 is tapped into the open end of the frame member 3.

A modification is shown in Figure 9. Here a frame member 45, again formed as a pultruded section of glass fire reinforced polyester, comprises mounting means 46 of elongated rectangular cross-section having an opening 47 extending centrally along one of its longer sides. Parallel flanges 48 formed integrally with the mounting means 46 extend from opposite sides of the opening 47 for the length of the frame member and constitute coupling means. A slot 50 formed by the space between the flanges 48 receives and locates a rigid panel 51 , for example of glass, polythene or polycarbonate. At the narrower ends 52, of the rectangular section of the mounting means 46 are L-shaped extensions 53 , leg limbs 54 of which extend in the same direction as, and parallel to, the flanges 48. The extensions 53 and adjacent narrower ends 52 of the mounting means define sockets 55 in which polycarbonate sheets 56 are received and located. The sheets 56 extend parallel to and are spaced from opposite sides of the rigid panel 51 . Insulation 57 is sandwiched between the panel 51 and the sheets 56. The extensions 53, adjacent narrow ends 52 of the mounting means and the outer sides of the flanges 48 constitute further coupling means retaining the sheets 56 and insulation 57 relative to the mounting means. Retention of the panel 51 in the slot 50 and of the sheets 56 in the sockets 55 may be by friction, suitable bonding or by fastenings such as studs. Frame members of the form described and as shown in Figure 9 may be provided at more than one edge of the panel 51 . They may be provided at a side edge and top and bottom edges of the panel. Joint members may connect the frame members together at corners of the panel, the joint members having parts which locate in the ends of the interiors of the mounting means of the frame members.

Claims

1 . A door comprising at least one frame member (2,3;45) and at least one panel (4;51) , characterised in that the frame member (2,3;45) , mounting means (10;46) by which it is mounted and retained in an opening for use and coupling means (4, 15;48) at which the panel (4;51) is received and retained to the frame member and the mounting means and coupling means are integrally formed together.

2. A door according to Claim 1 characterised in that the mounting means (10;46) and coupling means (4, 15;48) are integrally formed together by pultrusion.

3. A door according to Claim 1 characterised in that the mounting means (10;46) and coupling means (14, 15;48) are integrally formed together by extrusion.

4. A door according to any preceding claim characterised in that the frame member (2,3;45) is made of a fibre reinforced plastics material.

5. A door according to claim 4 characterised in that the frame member (2,3;45) is made of glass or carbon fibre reinforced polyester.

6. A door according to any preceding claim characterised in the mounting means (10;46) and the coupling means (14, 15;48) of the frame member (2,3;45) are provided along the entire length of the frame member.

7. A door according to any preceding claim characterised in the coupling means comprises a pair of opposed flange members (14, 1 5 ;48) between which a space (16;50) is defined in which the or each panel (4;51) is received and retained.

8. A door according to claim 7 characterised in that the or each panel (4;51) is retained to the coupling means by fasteners (17) inserted through the flanges (14, 15;48) and the panel.

9. A door according to claim 8 characterised in that a cover or covers (18, 19) is or are attached to the coupling means at at least one of the flanges 14, 15;48) to conceal the fasteners (17) .

10. A door according to claim 9 characterised in that the or each cover (18, 19) is adapted to receive and locate insulation on the frame member (2, 3) covering at least one side surface of the or each panel 4.

1 1. A door according to any of claims 7 to 10 characterised in that the mounting means (10;46) is hollow with an opening (16;47) along one side extending longitudinally of the frame member (2,3;45) and the flanges (14, 15;48) of the coupling means are integrally formed on and extend portions of the mounting means alongside the opening.

12. A door according to any preceding claim characterised in that the mounting means (46) has additional coupling means (55) formed integrally therewith whereby insulation material (57) is retained to the frame member (45) covering at least one side surface of the or each panel (51) .

13. A door according to any preceding claim characterised in that there are two of the frame members (2, 3) joined together by a joint member (8) .

14. A door according to any preceding claim characterised in that bearing assemblies (6, 7) are provided at the frame member (2, 3) , or one of the frame members, whereby the door is adapted to be retained in an opening for use for closing the opening at least in part.

15. A door according to claim 14 characterised in that at least one of the bearing assemblies (6) comprises a cylinder or cone, or comparable protrusion (26) substantially received within the, or the respective, frame member (2, 3) about or on which the door is pivotable.

16. A door according to claim 14 or claim 15 characterised in that the bearing assemblies include a bearing assembly (6) at the bottom of the door which comprises a plate (25) adapted to be secured at a foot of an opening for the door, a protrusion (26) on the plate, a bearing (28) with which the protrusion (26) co-operates and is adjustable longitudinally with respect to the, or the respective, frame members (2, 3) for adjustment of the height of the door for use, and a locking collar (27) whereby the bearing (28) is locked in adjusted positions.

17. A door according to any of claims 14 to 16 characterised in that the bearing assemblies include a bearing assembly (7) connected to a spring- loaded return pivot assembly (44) which urges the frame member (2, 3) , and hence the panel or panels (4) towards an original position of the door.

18. A door according to claim 16 characterised in that the spring loading of the return pivot assembly (44) is provided by a torsion spring (37) which is substantially received within the frame member.

19. A door according to claim 18 characterised in that the bearing assembly (7) to which the return pivot assembly (44) is connected comprises a bar (34) which is adapted to be fixed at an opening for the door, the torsion spring (37) is helical and located co-axially on the bar (34) , and the return pivot assembly further comprises a disc (3) and a tension adjusting element (42) both located on the bar, the torsion spring being secured at one end to the disc and the disc being retained to the frame member (2, 3) to pivot with the frame member, and the torsion spring being secured at an opposite end to the tension adjusting element which is adjustable relative to the bar to vary the loading of the torsion spring.

20. A method of assembling a door as claimed in any of claims 17 to 19 characterised in that it comprises the steps of: cutting a length or lengths of frame member (2,3;45) to the required size or sizes, joining the frame members, if required, using joint members (8) , attaching a panel or panels (4, 51 ) to the frame member or members and attaching a bearing assembly or assemblies (6, 7) and a return pivot assembly (44) to the, or one, frame member.