Note: Descriptions are shown in the official language in which they were submitted.
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TIT~B OF THB INVENTION
An insulated door assembly.
FIELD OF THB lNv~..lON
The present invention relates to an insulated
door assembly having an insert, such as a window unit,
and, more particularly, to the type of door assemblies
having an insulating core for providing thermal and sound
insulating characteristics.
DE8CRIPTION OF THE PRIOR ART
In typical door assemblies in which is inserted
a window unit, such insert is usually locked into the
door opening by means of screws or other type of
fastening devices.
However, such doors are constructed in
accordance with the manner in which they are to be
installed to a door frame, i.e. to open from the right or
to open to the left. At present, a door cannot be
mounted for both installations as, in one of the two
situations, the fastening devices would be visible.
Hence, this lack of versatility in door constructions is
a problem for inventories where both types of doors must
be kept before being installed.
There are various methods of fabricating foam
filled door assemblies having inserts. For example, such
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doors are described in U.S. patent No. 4,327,535 issued
May 4, 1982 to Governale, in U.S. patent No. 4,546,585
issued October 15, 1985 to Governale and in laid-open
Canadian patent application No. 2,044,331 filed June 11,
1991.
However, none of these methods avoid the above
described problem of lack of versatility.
OBJECT8 AND STATEMENT OF THE lNv~N.ION
In accordance with the present invention, there
is provided a unique construction of a door assembly
wherein a single foam filled wind~w structure is formed
for both above described situations of installation and
wherein a window unit may be inserted to the structure,
either at the door manufacturing plant or at the window
assembling plant.
This is achieved by providing a door assembly
formed of spacers, stiles, cross pieces and moldings so
assembled as to form a structural door filled with
insulation. The assembled parts define an opening into
which a window unit may be subsequently inserted and
secured in place by means of a window molding frame.
In accordance with the present invention, the
door assembly comprises:
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a first side consisting of a pair of opposite
metallic stiles and upper and lower metallic cross pieces
extending between the stiles;
an opposite second side consisting of a pair of
opposite metallic stiles and upper and lower metallic
cross pieces extending between these stiles;
the upper cross pieces of the first and second
sides being spaced from the lower cross pieces of the
first and second sides to define, between the stiles, a
rectangular opening in the door; each stile and each
cross piece having outer edges and flanged inner edges
facing the opening; each cross piece including flanged
side edges;
a rectangular frame peripherally received in
the~opening;
a pair of non metallic stile spacers disposed
peripherally between the outer edges of the stiles of the
first and second sides;
a pair of non metallic cross spacers disposed
peripherally between the outer edges of the cross pieces
of the first and second sides;
a pair of opposite first stile moldings having
means engaging the flanged inner edges of the stiles and
the flanged side edges of the cross pieces;
a pair of opposite second stile moldings having
means engaging the flanged inner edges of the stiles and
the flanged side edges of the cross pieces;
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a pair of opposite first cross moldings having
means engaging the flanged inner edges of the cross
pieces;
a pair of opposite second cross moldings having
S means engaging the flanged inner edges of the cross
pieces;
a core of rigid foam filling the interior space
defined between the spacers, the stiles, the cross pieces
and the moldings and adhering to the inner faces of the
spacers, stiles, cross pieces and mouldings to form a
bonded structure; and
window molding means peripherally received in
the opening opposite to the rectangular frame; the
molding means and the frame each having cooperating
inter-engaging means so that, after a window unit has
been inserted in the opening, the inter-engaging means
cooperate to secure the window unit in the opening of the
bonded structure.
In one form of the invention, the moldings are
M-shaped in cross-section with a pair of recesses, one
recess receiving the flanged inner edges, the other
recess receiving the flanged sides edges or the frames,
or both.
In another form of the invention, the window
molding means define a second rectangular peripheral
frame.
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In another form of the invention, some flanged
inner edges and the side edges have C-shaped resilient
extremities which are forcingly insertable in the
recesses of the M-shaped moldings.
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 this 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 will become apparent to those
skilled in the art.
8RIEF DE8CRIPTION OF THE DRAWING8
Figure 1 is an elevational view showing the
front side of a door assembly according to the present
invention;
Figure 2 is an exploded perspective view
thereof;
Figure 3 is a cross-sectional view taken along
lines 3-3 of figure 1;
Figure 4 is a cross-sectional view taken along
lines 4-4 of figure 1;
Figure 5 is a cross-sectional view taken along
lines 5-5 of figure 1;
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Figure 6 is an enlarged cross-sectional view
showing the connection of a molding with one of the non
metallic cross pieces of the door assembly.
Figure 7 is a cross-sectional view similar to
that of figure 3 showing another embodiment of the
present invention; and
Figure 8 is a cross-sectional view similar to
that of figure 4 showing this other embodiment.
DE8CRIPTION OF PREFERRED EMBODIMENTS
The following description will refer to front
and rear sides of a door assembly; however, these words
have been used to simplify the description and to avoid
confusion if words such as first and second sides were
employed. It is understood that either side of the door
may be the front or the rear.
Hence, figure 1 shows the front side of a door
assembly 10 consisting of a pair of opposite metallic
stiles 12 and 14 and upper and lower metallic cross
pieces 16 and 18 extending between the front side stiles.
Referring to figure 2, the rear side of the
door assembly consists of a pair of opposite metallic
stiles 20 and 22 and upper and lower metallic cross
pieces 24 and 26 extending between the rear side stiles.
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The upper cross pieces 16 and 24 are spaced
from the lower cross pieces 18 and 26 to define, between
themselves and the stiles, a rectangular opening in which
is subsequently received a window unit 28, such as a
single glass panel or a pair of guillotine-type windows.
A pair of non metallic stile spacers 30 and 32 are
disposed at the periphery of the stiles terminating at
the outer edges thereof. Also, a pair of non metallic
cross spacers 34 and 36 are disposed at the periphery of
the cross pieces terminating at the outer edges thereof.
A pair of opposite front stile moldings 38 and
40 extends along the inner edges of the stiles 12 and 14
while another pair of rear stile moldings 42 and 44
extends along the inner edges of the stiles 20 and 22.
A pair of opposite front cross moldings 46 and 48 extends
along the inner edges of the cross pieces 16 and 18 while
another pair of opposite rear cross moldings 50 and 52
extends along the inner edges of the opposite cross
pieces 24 and 26. These moldings are made of resilient
plastic material.
The door assembly 10 comprises also front and
rear rectangular frames 54 and 56 to which is fixed the
window unit 28 as explained hereinbelow. These frames
are made of rigid plastic material.
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Figures 3, 4 and 5 are cross sections at
different areas of the door assembly of figure 1 when all
the components shown in figure 2 are assembled. All
moldings 38, 40, 42, 44, 46, 48, S0 and 52 are M-shaped
in cross sections, each defining a pair of recesses.
However, it will be noted that the cross section of
moldings 46 and 50 (figure 3) as well as that of moldings
48 and 52 is somewhat different from the cross section of
moldings 40 and 44 (figures 4 and 5) and of moldings 38
10and 42. Indeed, moldings 46, 48, 50, 52 display a pair
of slotted recesses while moldings 38, 40, 42, 44 display
a pair of rectangular grooves having a restricted
entrance.
As can be seen in figure 2, the longitudinal
15rectangular stiles 12, 14, 20 and 22 have flanged inner
and outer edges while the cross pieces 16, 18, 24 and 26
are rectangular shaped panels, each having a flanged
inner edge, a linear outer edge and opposite flanged side
edges. The flanged inner edges of the stiles and the
flanged side edges of the cross pieces are C-shaped, as
illustrated in figures 4, 5 and 6. This configuration
allows them to be resilient so that they may be forced by
the restricted entrance of the longitudinal grooves of
moldings 38, 40, 42, 44 into securement in these grooves.
25As can be seen in figure 3, the recesses of
moldings 46 and 50 are in the form of longitudinal slots
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having a width adapted to receive the straight flanged
inner edges 16a, 24a of the cross pieces 16 and 24 and
portions 54a, 56a of frames 54, 56, respectively.
Frame 56 has a web portion 56b extending across
the width of the door assembly and defining a stop wall
for polyurethane foam 57 injected in the space defined by
the spacers, the stiles, the cross pieces and the
moldings to form an insulation for the assembly. Again
when the door is fully assembled, as described
hereinbelow, the free extremity of web 56b is squeezed
between an inner projection 54b of frame 54 and the side
wall of the molding 46. The frames 54 and 56 each have
a longitudinal window contacting lip portion 54c, 56c,
between which is secured the peripheral edge of the
window unit 28.
It can be seen that, should it be required to
remove the unit 28 from its opening, frame 54 is slid out
of its engagement with the web 56b and the slotted recess
of the molding 46.
To assemble the door assembly of the present
invention, the metallic members 12, 14, 16 and 18 are
placed within a first hollow rectangular assembling frame
(not shown). The cross moldings 46 and 48 are properly
positioned as well as the longitudinal moldings 38 and
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40. Thereafter, the wood spacers 30, 32, 34 and 36 are
placed thereover.
In a second hollow rectangular assembling frame
(not shown), metallic members 20, 22, 24 and 26 are
positioned and frame 56 placed thereover. This is
followed by the installation of the cross moldings 50 and
52 and the longitudinal moldings 42 and 44.
Then, the second frame with its components is
flipped over the first frame in a face-to-face
arrangement. Thereafter, the assembly is pressed so that
all the interconnecting edges may engage their
corresponding recesses of the moldings. Finally, an
injection of foam is made through a proper opening (not
shown) in one of the wood spacers 30, 32, 34 and 36 so
that the entire space defined between the various
components is filled with insulation. The foam
thereafter solidifies to form as rigid core that bonds
the assembled components together. Hence, in this
embodiment, no fastening devices are required for the
assembly of the door.
The outer edges of the stiles have recesses 60,
62 (see figure 4) to receive the flanged outer edges 64,
66 of the stiles. The outer edges 68, 70 (see figure 3)
of the cross-pieces terminate flush with the end wall 72
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of the cross spacers 34; the peripheral edges of the
cross pieces may be glued to the wood spacers.
The above described door may be manufactured
and assembled at the plant. However, if the window unit
is assembled elsewhere, frame 54 is shipped separately
with the other assembled parts to the window installation
plant where a window unit is placed in the opening of the
bonded door structure and secured therein by forcing the
engaging parts of frame 54 to interconnect with the
corresponding parts of the bonded door structure
Referring to figures 7 and 8, a variant is
illustrated; however, only those parts which are
different from that of the embodiment illustrated in
figures 1-6 will be described. The rectangular frame 156
lS includes a web portion lS6b which lies in contact over a
web portion 146a of the molding 146. To further ensure
bonding of the web portion 146a to the foam 57, a series
of fastening elements 200 secures the web portions lS6b
and 146a together (see figure 7). Similarly, molding 140
is modified to include a web portion 140a which lies
under and contacts web portion 156b of frame 156, both
being secured together by means of fastening elements 200
(see figures 8). These elements, however, are not
visible in the assembled door. In this embodiment, the
frame lS4 has an inner hook wall 160 that engages the
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protruding edge 14Ob of the molding 140 and the
protruding edge 146b of molding 146.
. Although the invention has been described above
with respect with one specific form, it will be evident
to a person skilled in the art that it may be modified
and refined in various ways. It is therefore wished to
have it understood that the present invention should not
be limited in scope, except by the terms of the following
claims.
