WO2018091896A1

WO2018091896A1 - Modular door assembly

Info

Publication number: WO2018091896A1
Application number: PCT/GB2017/053448
Authority: WO
Inventors: Alexander SIMMONS
Original assignee: Home Decor Gb Limited
Priority date: 2016-11-17
Filing date: 2017-11-16
Publication date: 2018-05-24
Also published as: GB2556071A; GB201619445D0; GB2556071B

Abstract

The present invention relates to a modular door assembly comprising a first door module (101) having a first frame (107) and a second door module (201) having a second frame (207), wherein the first frame (107) and the second frame (207) are configured to engage with each other to form the modular door assembly.

Description

Modular Door Assembly

Field of the Invention The present invention relates to a modular door assembly comprising a first door module having a first frame and a second door module having a second frame, wherein the first frame and the second frame are configured to engage with each other to form the modular door assembly. Background of the Invention

Large quantities of doors are manufactured, installed and transported every day across a wide variety of industries. Conventionally these doors are supplied to a customer as fully assembled. However, in the home improvement and "flat-pack" furniture markets, fully assembled doors can cause the customer a number of problems. For example, standard size doors can range in height from 1 .9 metres to 2.2 metres and, therefore, customers purchasing fully assembled doors, or products which include fully assembled doors, often find it difficult to transport such doors from the store to their homes using normal vehicles. This leaves the customer with no choice but to either spend additional time and money on hiring a vehicle large enough to transport the doors or organising for the doors to be delivered. Using delivery services can mean that the customer may have to wait days, if not weeks, until the purchased door- product reaches their home. In recent years, several attempts have been made to sell standard size modular doors, or products which include such doors, in a disassembled kit form to ease the burden of transporting door-products on the customer. These attempts have largely failed for several reasons. One reason for this is because many of the disassembled door kits still contain door components in their standard sizes (e.g. stiles, frames, door panels) since providing them in any other size/form requires additional manufacturing costs to be incurred. In addition, when supplying the door components in a disassembled form, the customer is then required to follow difficult and complicated assembly instructions. Another problem associated with current disassembled door kits relates to the safety of the customer whilst constructing the doors. Many of the disassembled door kits currently available involve handling components which have unfinished and sharp profiles which can be hazardous for the customer when handling and may cause injury. Finally, since currently available disassembled door kits still include standard size door components as well as numerous other door components, assembling the final door is not only time-consuming and difficult for the customer, but also difficult for a single person to perform.

It is an objective of the present invention to obviate or one or more of mitigate the abovementioned disadvantages and to provide a modular door assembly which is easy to transport, simple to assemble and safe for the customer to handle.

UK patent application entitled "Modular Track System", co-filed by the present applicant on the same date as the present application, discloses a modular track which may be used in combination with the modular door assembly described herein to form a modular door and track assembly.

Summary of the Invention

According to a first aspect of the present invention there is provided a modular door assembly comprising: (a) a first door module comprising a first door panel and a first frame comprising at least one stile, a first cross rail and a second cross rail, wherein the first frame may be configured to support the first door panel, and (b) a second door module comprising a second door panel and a second frame comprising at least one stile, a third cross rail and a fourth cross rail, wherein the second frame may be configured to support the second door panel wherein the first frame and the second frame are configured to engage with each other to form the modular door assembly.

The subject matter of the current invention seeks to solve one or more of the problems described herein with conventional fully assembled doors and disassembled door kits currently on the market.

The modular door assembly of the present invention provides a convenient solution to the aforementioned issues in relation to difficulty in transporting standard size doors as well as the shortcomings of existing disassembled door kits and modular door assemblies on the market. In particular, provision of a first door module and second door module according to the first aspect of the present invention provides the user with modular door assembly which can be quickly and efficiently transported and easily assembled by a single person.

Preferably, the first frame and the second frame may be configured to reversibly engage. This allows the user to easily disassemble the modular door assembly of the present invention thus allowing the user to repair, modify or clean the assembly during its lifetime.

Further preferably or alternatively, the first frame and the second frame may be configured to engage via an intermediate member. This provides a strong connection between the first and second frames. The intermediate member also overcomes problems associated with using complimentary connecting features formed on the first and second frames, for example, the need to replace whole frames when the complimentary connecting features are damaged or succumb to wear and tear. Whilst the intermediate member may be used as an alternative to complimentary connecting features it may also be used to supplement complimentary connecting features formed on the first and second frames to further strengthen the engagement between frames.

The intermediate member may be adapted to be fastenable to the first frame and/or to the second frame using a fastening means. This ensures that the first frame and second frame do not disengage or disconnect as a result of the intermediate member moving when in use.

The at least one stile of the first frame and/or second frame may be operable to receive the intermediate member. In particular, the at least one stile of the first frame and/or the second frame may comprise a longitudinal chamber to receive the intermediate member. This allows the intermediate member to be concealed when the first and second frames are engaged. Preferably, the fastening means may reversibly connect the intermediate member to the longitudinal chamber. This ensures that the intermediate member is tightly secured to the longitudinal chamber.

Beneficially, the intermediate member may be a connecting plate. The connecting plate provides an alternative to connecting pins, rods, screws etc. The connecting plate is quick and easy to manufacture and can be easily modified to receive a fastening means if necessary. In such circumstances, the connecting plate may comprise an aperture and the longitudinal chamber may comprise an aperture formed in a wall thereof, wherein the apertures formed in the connecting plate and the longitudinal chamber may be mutually positionable to receive the fastening means such that the fastening means may reversibly connect the intermediate member to the longitudinal chamber. This helps enhances engagement between the first and second door modules and improves the flexural strength and stability of the assembled modular door assembly. Moreover, this prevents pivoting of the first and second door modules against one another during assembly and when in use. The at least one stile of the first frame may further comprise a longitudinal channel formed on a first surface of the stile and may be configured to cooperate with the first and second cross rails to form the first frame; and/or wherein the at least one stile of the second frame may further comprise a longitudinal channel formed on a first surface of the stile and may be configured to cooperate with the third and fourth cross rails to form the second frame. This configuration of stiles and cross rails acts to securely form the door frames and support the door panel when modular door assembly is being assembled or when in use. The longitudinal channel may cooperate with the cross rails via an interference fit. This interference fit prevents movement of the cross rails within the stiles during manufacturing, assembly and in use.

Advantageously, the first cross rail of the first frame may engage with the third cross rail of the second frame. For example, the first cross rail may engage with the third cross rail directly. Furthermore, the first cross rail may engage with the third cross rail via complementary features. For example, the complementary features may comprise a tongue and groove. This provides the user with an easy to use push-fit mechanism for engaging and securing a first door module and a second door module together during assembly.

Preferably, the first door module and second door module may be pre-formed. This provides the user with an easy and quick to assemble modular door assembly.

For convenience, the modular door assembly of the present invention may be supplied as a kit of parts. Therefore, according to a second aspect of the present invention there is provided a kit of parts comprising a first pre-formed door module and a second pre- formed door module, wherein the first pre-formed door module and the second pre- formed door module are configured to engage with one another to form an assembled modular door assembly.

As used herein, the terms "engage", "engagement" and "cooperate" refers to the situation wherein a component or element, such as a door module or any part thereof, may be configured to directly connect to another component or element or indirectly connect to another component or element with one or more intermediate members interposed there between. Moreover, the components or elements may also be configured to permanently, semi-permanently or indeed reversibly connect or engage.

As used herein, the terms "interference fit", "friction fit" and "press fit" refers to a fastening or connecting of two or more parts which is achieved by friction once the parts are pushed together. As used herein, the term "intermediate member" may be any element or component suitable for causing engagement between separate components, such as door modules or parts thereof. For example, the intermediate member may include dowels, bolts, brackets, nail plates, connecting plates and/or any suitable intermediate member. As used herein, the term "fastening means" refers to any element or component that secures two or more parts together. For example, the fastening means may include, but is not limited to, screws, pins, rivets, dowels, adhesives or any other suitable fastening means. Detailed Description of the Invention

Some embodiments of the present invention are described more fully hereinafter with reference to accompanying drawings. In the drawing figures, dimensions may be exaggerated for clarity of illustration. Like reference numerals refer to like elements throughout.

Figure 1 depicts a perspective view of a first door module and second door module of a modular door assembly according to the present invention. Figure 2 depicts a partial perspective view of the first door module shown in Figure 1 receiving an intermediate member.

Figure 3 depicts a partial perspective view of the first door module shown in Figures 1 and 2 receiving an intermediate member and fastening means.

Figures 4A, 4B and 4C depict plan views of a stile of a modular door assembly according to the present invention in isolation (A), in engagement with a door panel (B) and in engagement with a door panel and cross rail (C).

Figure 5 depicts an end view of a lowermost cross rail of a modular door assembly according to the present invention in engagement with a door panel and bottom wheel.

Figure 6 depicts an end view of an uppermost cross rail of a modular door assembly according to the present invention in engagement with a door panel and top rollers.

Figures 7A and 7B depict side edge views of a partial first door module in engagement with a partial second door module wherein the cross rails engage via a tongue and groove.

Figure 8 depicts a front view of a fully assembled modular door assembly according to the present invention comprising a first door module, second door module and third door module. Figure 9 depicts a partial perspective view of a first door module and cover strip of a modular door assembly according to the present invention.

Figure 10 depicts a partial perspective view of a die cast component being attached to second door module of a modular door assembly of the present invention.

In the following detailed description, only certain embodiments of the present invention have been shown and described, simply by way of illustration. As those skilled in the art would realise, the described embodiments may preferably be modified in various different ways, all without departing from the spirit or scope of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive.

Specific Embodiments of the Invention

As illustrated in Figure 1 , a first door module (101 ) and second door module (201 ) are configured to engage with each other according to directional arrow (A). The first door module (101 ) includes a door panel (102) and frame (107) having stiles (103, 104) and cross rails (105, 106). The stiles (103, 104) and cross rails (105, 106) are constructed to form frame (107) and act to support and retain door panel (102). Similarly, the second door module (201 ) includes stiles (203, 204) and cross rails (205, 206) which are constructed to form frame (207) and act to support and retain door panel (202). The first frame (107) and second frame (207) are configured to engage with one another to form the assembled modular door.

Figures 1 depicts the first frame (107) of the first door module (101 ) configured to engage with the second frame (207) of the second door module (201 ) via a connecting plate (300). As shown in Figures 2 and 3, connecting plate (300) is fastened to stile (103) of first frame (107) using screws (302). Screws (302) secure the connecting plate (300) to stile (103) of the first door module (101 ). In particular, the connecting plate (300) is positioned within a longitudinal chamber (400) formed inside stile (103) of first frame (107). Longitudinal chamber (400) is shown more clearly in Figure 4A. When positioned in the longitudinal chamber (400), the connecting plate (300), which includes apertures (301 ) at either end of its length, is aligned such that a number of its apertures (301 ), in this case two, are aligned with apertures (401 ), formed in a wall of the longitudinal chamber (400). Once aligned, screws (302) are then threaded through apertures (401 ) and (301 ) to secure one end of the connecting plate (300) to the longitudinal chamber (400) of stile (103). As shown in Figure 3 and 4A, stile (103) may include a further longitudinal channel (404) formed on an opposite surface (405) to longitudinal channel (402). Longitudinal channel (404) also includes apertures (406) which are mutually positionable, or aligned when in use, with apertures (301 ) of the connecting plate (300) and apertures (401 ) of the longitudinal chamber (400). This is discussed in more detail below. The opposite end of the connecting plate (300) is position within a like longitudinal chamber formed inside stile (203) of the second frame (207) in an identical manner to that described above for stile (103). This secures the connecting plate (300) to both the first door module (101 ) and second door module (201 ) and provides engagement between the first frame (107) and second frame (207) to form the modular door assembly. A similar mechanism may be employed between stile (104) of the first frame (107) and stile (204) of the second frame (207), using a connecting plate similar or identical to connecting plate (300) to enhance engagement between the first and second door modules and improve the flexural strength and stability of the assembled modular door assembly. Moreover, this prevents pivoting of the first and second door modules against one another during assembly and when in use.

As shown in Figures 4A, 4B and 4C, stile (103) engages with both a door panel (102) and a cross rails (105). Figure 4A illustrates that stile (103) includes, in addition to the longitudinal chamber (400) for receiving a connecting plate (300), a longitudinal channel (402) formed on one surface of the stile. The stile (103) is configured to engage directly with door panel (102) via an interference fit as the door panel (102) extends towards the base of the longitudinal channel (402). This interference fit is enhanced by the presence of teeth (403) formed on the inner walls of the longitudinal channel (402) and prevents door panel (102) from moving within or along the length of longitudinal channel (402) when operating or constructing the modular door assembly. Stile (103) is also configured to engage with a cross rail (105) via an interference fit. This can occur whilst the cross rail (105) is either engaged with or connected to one edge of the door panel (102) or when the cross rail (105) is in isolation. Ordinarily, the door panel (102) is introduced into the longitudinal channel (402) and brought towards the base thereof before cross rail (105) is then brought into engagement. When assembled, the door panel (102) extends towards the base of the longitudinal channel (402) to engage with stile (103) via an interference fit and cross rail (105) extends into the longitudinal channel (402) as far as teeth (403) to engage with stile (103) via an interference fit. An upper region of the longitudinal channel (402) which accommodates the cross rail (105) is wider than a lower region of the channel (402) which accommodates the door panel (102) to allow door panel (102) to extend through the upper region and down in to the lower region. The interference fit formed between stile (103) and both door panel (102) and cross rail (105) provides a strong but reversible connection or engagement between the components. The interference fit also allows for the expansion of the door panel and cross rail components within the longitudinal channel (402), which (depending on the materials of the door panel/cross rail components) may occur due to environmental conditions. The reversibility of the interference fit also provides the user with the versatility to vary or replace door panel/cross rail components when needed. As it will be appreciated, other stiles (e.g. 203, 104, 204) also include longitudinal channels, as described above, into which associated cross rails and door panels may extend. Accordingly, a first frame and second frame may be constructed using such profiles and features.

As shown in Figure 4B, stile (103) may include a further longitudinal channel (404) formed on an opposite surface (405) to longitudinal channel (402). Longitudinal channel (404) also includes apertures (406) (not shown in Figures 4A-4C) which are mutually positionable, or aligned when in use, with apertures (301 ) of the connecting plate (300) and apertures (401 ) of the longitudinal chamber (400). Screws (302) are threaded through the aligned apertures (301 , 401 and 406) to secure one end of the connecting plate (300) to the longitudinal chamber (400). Once fully threaded, the head of screws (302) sit within the longitudinal channel (404) and below exterior surface (405) of the stile. This improves safety for the user when constructing or operating the assembled modular door assembly since naked, and potentially hazardous screw heads, are not exposed. In addition and as shown in Figure 9, a flexible cover strip (901 ) may extend along the length of the longitudinal channel (404) to cover the head of screws (302) thus providing an extra layer of protection between the user and the screw head. The flexible cover strip (901 ) also prevents the user from coming into contact with hazardous edges or other profile features, for example the lips of the longitudinal channel (404), whilst operating or assembling the modular door assembly. Moreover, the cover strip may be used as any other functional or decorative element. As it will be appreciated, other stiles (e.g. 203, 104, 204) may also include further longitudinal channels, as described above, to hide screw heads when an associated stile- connecting plate mechanism is assembled. Moreover, further flexible cover strips may be utilised to extend along such longitudinal channels. In some embodiments, longitudinal channel (404) may be mutually positionable, aligned when in use, with a corresponding channel formed on stile (104) such that a single cover strip may extend along the length of both longitudinal channel (404) and the longitudinal channel formed on stile (104) when the door module assembly is assembled. In some embodiments of the present invention, the longitudinal channel (402) may cooperate with the cross rails via a suitable mechanical fastening means. For example, longitudinal channel (402) may cooperate with a cross rail using a screw extending through mutually positionable apertures formed in longitudinal channel (402) and the cross rail. In either case, the interference fit and/or the mechanical fastening means may be supplemented with adhesives to enhance the strength and durability of the stile-cross rail connection.

Referring now to Figure 5, a lowermost cross rail (501 ) is shown with a wheel (502) positioned within and connected to a recess (504) formed within the lowermost cross rail (501 ). The lowermost cross rail (501 ) also includes a channel (505) formed on an opposite surface to recess (504) for receiving and supporting the door panel (503).

Teeth (506) formed within channel (505) allow the lowermost cross rail (501 ) to friction grip the door panel (503). This prevents movement and thus damage of the door panel during operation or assembly. When in use the wheel (502) contacts a bottom track

(not shown) thus providing a movement means for the modular door assembly to slidably move along a length of the bottom track.

Referring now to Figure 6, an uppermost cross rail (601 ) is shown with rollers (602) positioned within and connected to a recess (605) formed within the uppermost cross rail (601 ). This connection may be formed using a fastening means, such as a screw (not shown). The uppermost cross rail (601 ) also includes a channel (606) formed on an opposite surface to the recess (605) for receiving a supporting the door panel (603). Lips (604) formed at the opening of the channel (606) retain and secure the door panel (603). This prevents movement and damage of the door panel (603) during operation or assembly. Rollers (602) are adapted and designed to feed into a top track (not shown) when in use thus providing a movement means for the modular door assembly to slidably move along a length of the top track. By way of example, lower cross rail (501 ) and upper cross rail (601 ) may replace the cross rails (105) and (206), illustrated in Figure 1 , respectively such that when oriented in an upright position the fully assembled door assembly of Figure 1 is able to move along top and bottom tracks. As it will be appreciated, an uppermost cross rail and lowermost cross rail of the present invention may be configured to engage with at least one stile and and door panel of the present invention in a similar manner to that described for cross rails (105, 106) and stile (103) illustrated in Figure 4 and described above.

As illustrated in Figure 7A and 7B, cross rails of adjacent door modules may be configured to engage with one another. Cross rail (106) of a first door module (101 ) engages with the cross rail (205) of a second door module (201 ). In this example, the cross rails (106) and (205) engage via tongue and groove features formed on the cross rails. This provides the user with an easy to use push-fit mechanism for engaging and securing the first door module (101 ) and second door module (201 ) together during assembly. It is also shown that door panel (102) extends into a longitudinal channel (701 ) formed on a surface of the cross rail (106) opposite to tongue and groove features. The door panel (102) is supported in the longitudinal channel (701 ) and may also engage there with via an interference fit. Door panel (202) is supported in a similar manner within longitudinal channel (702) formed within cross rail (205). Figure 7A also illustrates connecting plate (300) in use on the opposite side (i.e. the side furthest away and set into the page) of the door modules (101 ) and (201 ), In addition, Figures 7A and B show die cast member (1 10) positioned between stile (103) and (203). This is described in more detail below with reference to Figure 10.

In other embodiments of the present invention, the tongue and groove features formed on cross rails of adjacent door modules may be replaced by any other suitable engagement means. For example, an adhesive material or a mechanical bolt connection may be used to provide engagement between cross rails of adjacent door modules.

It will also be appreciated that at least one additional door module may be disposed between or adjacent to at least one of the first and second door modules of the present invention using similar engaging means and connecting mechanisms as described herein to provide an alternative modular door assembly according to the present invention. In this situation, a stile-connecting plate mechanism (similar to that as described for Figures 1 -3) may be utilised to engage and connect the at least one additional door module with/to the first door module and second door module in series. For example, Figure 8 shows a fully assembled modular door assembly (800) (in an upright position) comprising a first door module (801 ) having an upper cross rail (805), second door module (802) and third door module (803) having a lower cross rail (804) engaged and connected in series using the stile-connecting plate mechanism described above. In some embodiments, cross rails for each door module in series are also engaged using the tongue and groove features shown in Figure 7.

It is envisaged that by incorporating at least one additional door module between or adjacent to at least one of the first and second door modules, the user is able to easily modify the dimensions, functional properties, aesthetic properties or any other property of the modular door assembly.

As illustrated in Figure 10, a die cast component (1 10) is positioned at one end of stile (203) and is disposed between stiles (203) and (103) of the second and first door modules respectively when the stiles are engaged. The die cast component (1 10) aids alignment of the stiles during assembly and also conceals visible joint lines formed between stiles (103) and (203) when the stiles are engaged. The die cast component (1 10) is profiled to allow for the optional cover strip (901 ) and connecting plates (300), mentioned above, to function as described above. In particular, the die cast component (1 10) includes an aperture (1 12) mutually positionable with a longitudinal chamber (400) formed in stile (103) (not shown) and the corresponding longitudinal chamber (400) formed in stile (203) through which a connecting plate (300) can extend. Moreover, the die cast component (1 10) includes a cavity (1 13) which is mutually positionable with the longitudinal channel (404) formed on stile (103) (not shown) and the corresponding longitudinal channel (404) formed in stile (203) through which a cover strip (901 ) can extend. Moreover, the die cast component (1 10) includes a cavity (1 14) which is mutually positionable with the longitudinal channel (402) formed in stile (103) (not shown) and the corresponding longitudinal channel (402) formed in stile (203). Cavity (1 14) is configured to engage with a cross rail (205) and door panel (202) via an interference fit, in a similar manner to that as described for stile (103), door panel (102) and cross rail (105) above (see Figure 4A-C). The die cast component (1 10) is connected to one of the cross rails (205) and one of the stiles (203) using a screw (1 1 1 ) extending through mutually positionable apertures formed in the die cast component (1 10), longitudinal channel (402), longitudinal chamber (400), longitudinal channel (404) and cross rail (205). More specifically, die cast component (1 10) includes a hooped protrusion (1 15) extending out from one face of the die cast component (1 10) and into the longitudinal chamber (400) of stile (203). The hooped protrusion (1 15) forms an aperture (1 16) which is mutually positionable with apertures formed in longitudinal channel (402), longitudinal chamber (400), longitudinal channel (404) and cross rail (205).

It will be appreciated that a modular door assembly of the present invention may be a moving structure used as a barrier which prevents access to an entrance or an enclosed space when closed and allow access to the entrance or the enclosed space when open. In some embodiments of the present invention the modular door assembly may be a hinged door, slidable door, rotatable door, automatic door or any other type of door.

In some embodiments of the present invention the modular door assembly may be a slidable door mounted on, or suspended from, a bottom track or top track respectively. Such tracks are useful for guiding of the slidable door and thereby ensuring that the door follows a set path (corresponding to the track). For convenience, such a track may be provided together with a modular door assembly as a kit of parts for installation into a doorway. Where the modular door assembly of the present invention is a slidable door, the slidable door may include an uppermost cross rail adapted to move along the length of a top track when the door is suspended from the top track. Moreover, the slidable may include lowermost cross rail adapted to move along the length of a bottom track when the door is mounted on the bottom track. In particular, the uppermost cross rail and the lower most cross rail may include a suitable movement means for moving along the length of a top or bottom track to open and close an opening in a doorway. Suitable movement means may include, but are not necessarily limited to, rollers, wheels, skates and or caterpillar tracks. In some embodiments, the modular door assembly may include multiple movement means which may be the same as one another or different.

As referred to herein an uppermost cross rail refers to a cross rail located at the top of a modular door assembly of the present invention when upstanding and vertical. Likewise, a lowermost cross rail refers to a cross rail located at the bottom of a modular door assembly of the present invention when upstanding and vertical. By way of example, Figure 8 illustrates an uppermost cross rail (805) and lowermost cross rail (804).

In some embodiments, a modular door assembly according to the present invention may include an uppermost cross rail including rollers (as shown in Figure 6) to move along a top track and/or a lowermost cross rail including wheels to move along a bottom track (as shown in Figure 5). In yet further embodiments, uppermost cross rail and lowermost cross rail of the present invention may be configured to engage with at least one stile and/or door panel of the present invention in a similar manner to that described for cross rails (105, 106), stile (103) and door panel (102) illustrated in Figure 4 and described above.

As noted above, the modular door assembly of the present invention may be supplied as a kit of parts. As it will be appreciated a stile-connecting plate mechanism (similar to that as described for Figures 1 -3) may be utilised to engage and connect the first preformed door module and the second pre-formed door module to form the assembled modular door assembly. In some embodiments, cross rails for each of the pre-formed door modules may also engage using the tongue and groove features shown in Figure 7.

Moreover, the kit of parts according to the second aspect of the present invention may further include at least one additional pre-formed door module configured to be disposed between the first pre-formed door module and the second pre-formed door module using similar mechanisms as described in the present Figures. Like components, such as connecting plates, screws, cover strips, die casts, wheels, rollers, as described in the context of Figures 1 -9 may also be included in the kit of parts.

According to some embodiments of the present invention, a door module may include a door panel and frame. Typically, a frame of the present invention may include stile and cross rail components which may be formed of any suitable material. In some embodiments, the frame or any of its components may be formed of a suitable metal material, alloy material, plastic material, wood material, glass material or a combination thereof. Suitable metals and alloys may include aluminium, brass, copper stainless steel and wrought iron. More preferably, the frame or any of its components may be formed of extruded aluminium, for example the alloy 5050 T6. In some embodiments of the present invention, the thickness of the extruded aluminium may be from 0.9mm to 2.0mm, for example 1 .2mm, 1 .3mm or 1.8mm. In other embodiments, the stiles may be formed of extruded Aluminium alloy 5050 T6 having thickness of 1 .3mm. In further embodiments, the cross rails may be formed of extruded Aluminium alloy 5050 T6 having a thickness of 1 .2mm or 1 .8mm.

A door panel of the present invention may be formed of any suitable material. Such materials may include a metal material, an alloy material, a plastic material, a wood material, a glass material or a combination thereof.

In still further embodiments of the present invention the modular assembly may be adapted to include various conventional door features such as door handles and door locking mechanisms.

Claims

A modular door assembly comprising: a first door module comprising a first door panel and a first frame comprising at least one stile, a first cross rail and a second cross rail, wherein the first frame is configured to support the first door panel; a second door module comprising a second door panel and a second frame comprising at least one stile, a third cross rail and a fourth cross rail, wherein the second frame is configured to support the second door panel; wherein the first frame and the second frame are configured to engage with each other to form the modular door assembly.

A modular door assembly as claimed in claim 1 , wherein the first frame and the second frame are configured to reversibly engage.

A modular door assembly as claimed in claim 1 or 2, wherein the first frame and the second frame are configured to engage via an intermediate member.

A modular door assembly as claimed in claim 3, wherein the intermediate member is adapted to be fastenable to the first frame and/or to the second frame using a fastening means.

A modular door assembly as claimed in claim 3 or 4, wherein the at least one stile of the first frame and/or second frame is operable to receive the intermediate member.

A modular door assembly as claimed in claim 5, wherein the at least one stile of the first frame and/or the second frame comprises a longitudinal chamber to receive the intermediate member.

7. A modular door assembly as claimed in claim 6, wherein the fastening means reversibly connects the intermediate member to the longitudinal chamber.

8. A modular door assembly as claimed in claim 7, wherein the intermediate member is a connecting plate. 9. A modular door assembly as claimed in claim 8, wherein the connecting plate comprises an aperture, the longitudinal chamber comprises an aperture formed in a wall thereof, and wherein the apertures formed in the connecting plate and the longitudinal chamber are mutually positionable to receive the fastening means such that the fastening means reversibly connects the intermediate member to the chamber.

10. A modular door assembly as claimed in any one of claims 2 to 9, wherein the at least one stile of the first frame further comprises a longitudinal channel formed on a first surface of the stile and configured to cooperate with the first and second cross rails to form the first frame; and/or wherein the at least one stile of the second frame further comprises a longitudinal channel formed on a first surface of the stile and configured to cooperate with the third and fourth cross rails to form the second frame

1 1. A modular door assembly as claimed in claim 10, wherein the longitudinal channel cooperates with the cross rails via an interference fit.

12. A modular door assembly as claimed in any one of the preceding claims, wherein the first cross rail engages with the third cross rail.

13. A modular door assembly as claimed in any one of the preceding claims, wherein the first cross rail engages with the third cross rail of directly. 14. A modular door assembly as claimed in claim 13, wherein the first cross rail engages with the third cross rail via complementary features.

15. A modular door assembly as claimed in claim 14, wherein the complementary features comprise a tongue and groove.

16. A modular door assembly as claimed in claim 15, wherein the first door module and second door module are pre-formed.