CA1068988A

CA1068988A - Door structure

Info

Publication number: CA1068988A
Application number: CA253,623A
Authority: CA
Inventors: Camille Richard; Helmut Schmidt
Original assignee: TRIGEX LTEE
Current assignee: TRIGEX LTEE
Priority date: 1976-05-28
Filing date: 1976-05-28
Publication date: 1980-01-01

Abstract

ABSTRACT OF THE DISCLOSURE

The disclosure herein describes a door structure having a rectangular-shaped body that comprises: a pair of parallel inner and outer metal facing panels, each panel having inwardly bent portions extending along each vertical side edge thereof, the bent portions of one panel being spaced from the oppositely facing bent portions of the other panel;
an upper rail member and a lower rail member respectively extending transversely along the upper edge and lower edge of the body; a pair of flexible moulding strips engagedly interconnecting the oppositely spaced bent portions of the panels; and an insulation filling material within the panels bonded to the moulding strips.

Description

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FIELD OF THE INVENTION
The present invention relates to door structures and, more particularly, to an improved door construction having inner and outer metal facing panels separated by insulating material.
BACKGROUND OF THE INVENTION
It is essential on such door structure having inner ; and outer metal panels that there be no direct contact between the panels so as to avoid any thermal conduction from one to the other side of the door. Such construction is particularly usefull when the temperature gradient on both sides of a door is of importance.
There are two well-known types of constructions which will prevent thermal conduction between the two metal skins of a door. A first type includes a frame consisting of vertical stiles and horizontal rails, both made of wood on which the metal skins are adhesively secured along their edges. This construction is subject to warpage. In a more recent type of construction, all the edges of the panels are interconnected to one another by means of a moulding strip which extends along all four edges of the rectangular door. However, these moulding strips must be connected to one another at the corners of the door with a 45 chamfer and one problem associated with this construction is that, under cold conditions, the moulding strips (which are usually made of plastic material) are subject to contraction thereby exposing the insulating material at the corners of the door.
OBJECTS AND STATEMENT OF THE PRESENT INVENTION
It is an object of this invention to provide a door structure which combines the advantages of prior art devices while avoiding their disadvantages. This is accomplished by ~ ~ , . . ., : ~ .
~ ' ' ,, , ,:; ' , ~ ;, ~, . ' . , ~6~g~8 using wooden members and plastic moulding strips in an efficient manner so that warpage and contraction of parts, which are unavoidable when the door is used in varying temperature conditions, are insignificant and will not affect the overall appearance and characteristic of the door.
The present invention is achieved by providing a :. .r door structure which has upper and lower rail members and two vertical side moulding strips, the length of the moulding strips being greater than the difference separating the rail :
members so that contraction of the strips will not leave a gap to expose the insulating material of the door. Furthermore, ~.^
the moulding strip is particularly constructed so that warpage :
of the metal skins which are interconnected at their opposite vertical edges by the moulding strip, may be taken up by the .
strip itself without deformation of the overall structure of the door. :
The present invention therefore relates to a door structure having a rectangular-shaped body which comprises: . ;
a pair of parallel inner and outer metal facing panels, each panel having inwardly bent portions extending along each vertical side edge thereof, the bent portions of one panel being spaced ~rom the oppositely facing bent portions of the other panel; an upper rail member and a lower rail member - respectively extending at the upper and lower edge of the body, the rail members being fixedly secured to the panels;
a pair of flexible moulding strips engagedly interconnecting the oppositely spaced bent portions of the panels; the length of the moulding strips being greater than the distance separating the rail members; the strips, rail members and panels defining therebetween an enclosed space; and an insulation material filling said space.

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In one form of the invention, the strip has a T-shaped configuration with a head portion lying flat with the side edge of the door, and a stem portion provided with flange portions to define channels to receive the bent edge portions of the panels.
A support member is provided in the lower face of the lower rail member and is adapted to receive a series oF
weather strips; the support member is further adapted to be vertically adjusted to fill the various separations between the lower edge of a door and the sill element.
The lower extremity of the moulding strips further includes side weather strips to prevent air circulation through the lower side corners of the door.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter; it should be understood, however, that the detailed description while indicating preferred embodiments of the invention is given by way of illustration only since various changes and modifications within the spirit and scope of the invention would become apparent to those skilled in the art from this detailed ;
description.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is an elevational view of a door structure made in accordance with the present inventioni Figure 2 is a cross-sectional view, shown broken in parts~ along lines 2-2 of Fig. 1, illustrating the door mounted in a door frame structure;
Figure 3 is a cross-s~ctional view, shown broken in parts, taken along lines 3-3 o-f Fig. 1, illustrating the door in a door frame structure;

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Figure 4 is a bottom perspective view showing one ~-lower side corner portion of the door of the present invention;
Figure 5 is an end view of the door portion illustrated in Fig. 4, showing parts broken away;
Figure 6 is an elevational front view of the door portion illustrated in Fig. 4, showing parts broken away; and Figure 7 is a plan view of the door portion illustrated in Fig. 4, showing parts broken away.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to Figs. 1-3, there is shown a door structure having a rectangular-shaped body 10 that includes -two parallel inner and outer metal facing panels 12 and 14.
Each panel has inwardly bent portions 16, 18 (see Figure 3) extending along each vertical side edge thereof. Each bent portion includes a first portion 16a, 18a which is perpen-dicular to the plane of its main panel portion and a second recess portion 16b,18b which terminates with an inwardly turned extremity 16c,18c. Extremities 16c,18c at each vertical side of the body 10 are spaced from one another so ;;
as to avoid thermal conduction from one metal skin to the other.
Referring more particularly to Fig. 2, panels 12 and 14 have upper and lower straight edges 20 and 22, 24 and 26 respectively. An upper rail 28 and a lower rail 30, both preferably made of wood, respectively, extend at the upper and lower edges of the panels and are fixedly secured, for example, by means of an adhesive, to the inner marginal edges of the metallic panels. As explained hereinafter, the rail members 20 and 30 do not extend the entire width of the panels and terminate short of the bent extremities 16 and 18 of both panels.

6~388 To assemble panels 12 and 14, a flexible moulding strip 32 is slid between the bent portions of the panel in order to interconnect them (see Figure 3). Each moulding strip has a T-shaped configuration with a head portion 34 and a stem portion 36. The free end of the stem portion further includes two outwardly projecting flange portions 38 and 40 which define with the adjacent face of the stem portion and the opposite face of the head portion, a channel 42, 44 in which are received the bent portions 16b and 16c, 18b and 18c of the panels. One example of a material used for the flexible moulding strip is a plastic material known under the trademark Geon.
The recess formed by portions 16b and 18b of the bent edges of the panels is shaped to receive the head portion 34 of the strip so that the outer face of the strip will be in the same plane as that of the outer face of portions 16a and 18a of the bent edges of the panels. For improved engagement of the bent portions in their respective channels 42 and 44, the inner faces of the head portion and of the stem portion may be provided with small lengthwise ribs 43 and 45. Moulding strips 32 extend for the entire height of the panels; hence, they abut the opposite extremities of rails 28, 30. This is an important feature of the present invention in that contraction of the plastic strip 32 under cold temperature conditions will not result in leaving a gap between the rails and the strips.
The rail members 28 and 30, the moulding strips 32 and the panels 12 and 14 define therebetween an enclosed space. This space is filled with an insulation material 46, such as formed-in-place polyurethane foam. An opening (not shown) is provided in the lower rail to allow foam injection G89~8 during assembly.
The door further includes a series of blocks 48,49, 50 and 52 which are adhesively secured to the inner marginal faces of the panels and serve to secure a handle 54 and hinges 56 (three having been shown). These blocks, which are prefer-ably made all of wood, include on the outside face thereof a I ~
a groove 58 (see Fig. 3) to receive the stem portion 36 and ;`
its flange portions 16c and 18c. The width of groove 58 is -preferably made smaller than the overall width of the flange portions 16c and 18c to provide a tight engagement on the flange portions in the groove.
Referring to Figs. 4-7, the lower rail member 30 includes a concave lower surface in which is adjustably received a support member 60. This support member extends lengthwise of the lower rail and includes a central channel `
62 and two side channels 64 and 66. A pair of weather strips 68 and 70 have their upper ends slidably engaged in channels 64 and 66, respectively. The support member 60 is adjustably secured to the rail member 30 by means of L-shaped elements 72 mounted at each extremity of the rail member 30. These elements 72 include a vertically extending portion 72a ~ abutting the edge of the rail and a horizontally extending ; portion 72b which is appropriately received in channel 62.
Vertical portion 72a includes a slot 74 through which a screw 76 extends to engage socket 78 fixedly received in the edge of rail member 30. As can be seen in Fig. 6, the height of support member 60 may be adjusted by untightening screw 76.
Further weather strip means are provided on each corner of the door beneath the moulding strips. These weather strips, generally denoted 80, extend perpendicularly to weather strips 68 and 70 and serve to prevent air circulation .: .
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~ G~39~38 along the sides of the door. In the embodiment described, these weather strips consist of a yoke-like member having two vertically extending strips 82 and 84 which are respectively received between the head portion 34 of the moulding strip and the recess portions 16b, 18b of the bent edge portions of the panels. Height adjustment of the weather strip 80 is also done by untightening screw 76 and releasing the pressure exerted by the head portion 34 of the moulding strip on the two vertical strips 82 and 84. A brush-like member 86 is supported in an appropriate channel 87 provided in the lower ~ ;
part of member 80. `~
Referring to Figs. 2 and 3, door 10 is shown mounted for use in a conventional door Frame having side members 88 and 90, a header 92 and sill plate 94. The sill plate 94 is usually made of metal and includes a portion 95 provided with series of transversely spaced openings 98 for water flow. Air entering through openings 98 are prevented from reaching the inside of a room due to weather strip 70 and side brushes 86. The other members 88,90 and 92 of the door frame may consist of claddings made of plastic material.
Referring to Figs. 2 and 3 these door frame members are each provided with extension means which allow the addition of further members 88a, 92a, 94a, 96a to suit various sizes of door frames.

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Claims

The embodiments of the invention in which an exclu-sive property or privilege is claimed are defined as follows:

1. A door structure having a rectangular-shaped body comprising: a pair of parallel inner and outer metal facing panels, each panel having inwardly bent portions extending along each vertical side edge thereof; the bent portions of one panel being spaced from the oppositely facing bent portions of the other panel; an upper rail member and a lower rail member respectively extending at the upper edge of the body and at the lower edge of said body, said rail members being fixedly secured to said panels; a pair of flexible moulding strips extending along the vertical side edges of said panels and engagedly interconnecting said oppositely spaced bent portions of said panels, said moulding strips having a length greater than the distance separating said rail members; said moulding strips, rail members and panels defining therebetween an enclosed space; and an insulation material filling said space and bonded to said moulding strips, rail members and panels.

2. A door structure as defined in Claim 1, wherein said interconnected bent portions define a recess along each vertical side of said body; each moulding strip having a generally T-shaped configuration with a head portion and a stem portion, said head portion being received in said recess.

3. A door structure as defined in Claim 2, wherein each bent portion includes a first portion extending perpendi-cular to the planes of said panels and a recessed second portion defining in part said recesses; said head portion of said moulding strip having an outer surface substantially aligned with said first portions to thereby define generally planar vertical side edges to said body.

4. A door structure as defined in Claim 3, wherein each moulding strip includes flange portions outwardly extending at the free end of said stem portion of said T-shaped configuration; said flange portions defining with said stem portion and said head portion opposite channels to engagedly receive therein said second portions of said bent portions.

5. A door structure as defined in claim 4, further comprising lengthwise ribs on the inner face of said head portion and of said stem portion for providing tight engagement of said bent portions in said channels.

6. A door structure as defined in claim 5, further comprising a series of blocks located in said space adjacent said vertical bent portions for securing handles and hinges thereto; said blocks being adhesively secured to said panels and each including a groove on one side thereof for receiving therein said interconnected strip and bent portions.

7. A door structure as defined in claim 6, wherein each said groove is slightly smaller in width than the overall width of said flange portions for providing a tight engagement of said flange portions in said groove.

8. A door structure as defined in claim 1, said lower rail member including a longitudinal recess in the lower face thereof; a support member adjustably received in said recess; first weather strip means having one end slidably received in said support member and the other end extending below the lower edge of said panels for contacting a door sill element.

9. A door structure as defined in claim 8, further comprising releasable attachment means for adjusting the height of said support member in said recess and, consequently, for adjusting the lower end of said weather strip means to said door sill element.

10. A door structure as defined in claim 9, wherein said releasable attachment means include a pair of L-shaped elements mounted at opposite ends of said lower rail member;
said L-shaped elements each including a first vertical portion having a slot therein and a second horizontal portion extending in a further channel provided in said support member; said releasable attachment means further including fastening means extending through said slot and being fixedly received in each said end of said lower rail.

11. A door structure as defined in claim 10, further comprising second weather strip means mounted adjacent the lower extremity of each said moulding strips; each said second weather strip means including a first upward portion secured between said bent portions of said panels and said moulding strip, and a lower sealing portion extending in a plane perpen-dicular to the plane of said first weather strip means and having its lower extremity adapted to contact said door sill element.

12. A door structure comprising: a rectangular-shaped body having two pairs of opposite side edges; a pair of parallel inner and outer metal facing panels, each panel having inwardly bent portions extending along a first pair of said side edges, the bent portions of one panel being spaced from the oppositely facing bent portions of the other panel; a pair of elongated members respectively extending at the other of said pairs of said side edges of said body, said members being fixedly secured to said panels; a pair of flexible moulding strips extending along and engagedly interconnecting said oppositely facing bent portions of said panels, said moulding strips having a length greater than the distance separating said members; said moulding strips, members and panels defining therebetween an enclosed space; and an insulation material filling said space and bonded to said moulding strips, members and panels.