Note: Descriptions are shown in the official language in which they were submitted.
. CA 02211279 1997-07-24
A DOOR SLAB ASSEMBLE STRUCTURE FOR THE PARTLY
HOLLOW DOOR SKIN AND GLASS
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a door slab assemble structure for the partly
10 hollow door skin and glass, which consists of glass and a Sheet Molding
Compound's (SMC) embossed grain door skin with double-layer grooves. There
are three type of assembly: two, four and eight sheet door skins.
2. Description of Prior Arts
The prior arts include US Patent No. 4,850,168, Patent No, 4,720,951, Patent
No.4,546,585, and Patent No. 4,327,535.
At present there are two types of assemble structures for existing partly
hollow door skins: two sheet and eight sheet door skins. The former structure is20 described in US Patent No. 4,327,535. Two sheet door skins are made using thefollowing steps. First, the perimeter of the door skin is assembled with sealingstuffs. Second, the sealing stuffs and the glass are assembled together on the
hollow area, then inserted into the convex part of the door skin to form a hollow
and close space inside the door skin. Finally it is filled with polyurethane foam
25 plastics to form a partly hollow door skin with glass.
The other type, eight sheet door skins (US Patent No.4,720,951), involve
taking a pair of door skins which are produced using Sheet Molding Compound
(SMC) and by fixing the hollow area's long rib to the insulating glass during the
compression process to replace the hollow area's sealing stuffs disclosed in US
30 Patent No. 4,327,535. Thus the process of assembly saves time and materials.
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This patent's perimeter is still assembled through the insertion of four sealingstuff. The inner part is also filled with foam plastics to form a door skin. Thefollowing describes in detail the drawbacks of the patents mentioned above:
5 1. The insulating glass is inserted with the door skin during production and can
not be replaced. If the glass breaks during production or transport, the whole
door skin will be rendered useless.
2. To fix the glass with the convex rib as in US Patent No.4,720,951 is
problematic as well. The one specific glass size can not satisfy the various
needs of customers which now include single, double and triple layers. US
Patent No. 4,850,168 has improved somewhat in this area; however, the
addition of sealing stuff in the convex area has aesthetic drawbacks.
3. US Patent No.4,850,168 replaces the perimeter sealing stuffs assembly with
the integral edge structure. This fixes the height of the door skin which thus
cannot be changed.
4. The length and width of glass can not be modified. This limits the possible
widths of the door skin.
There is another existing eight sheets door skin assembly that is similar to
20 US Patent No.4,546,585. This technique adopts two up and down cross stuffs and
two left and right vertical stuffs to be assembled together for the formation of a
partly hollow door slab. The advantage of this structure is that door slabs of
different widths can be produced to meet the customer's requirements, by
ch~nging the length of the up and down crossed stuffs. However, this structure
25 also has some drawbacks. This type of assembly is time consuming. Also, as a
result of the lock action between the vertical and crossed stuffs it is weaker than
the door skin. Furthermore, if the size is not precisely accurate, a gap may appear
at the connecting part between the vertical stuff and the crossed stuff.
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SUMMARY OF THE INVENTION
This invention focuses on the improvement of the existing partly hollow door
5 slab assembly, Through research and tests, we created a novel assemble mode
including two sheets, four sheets and eight sheets assembly. Below is a
description of this invention's feature.
The feature of the two sheet door slabs are two partly hollow door skins
which have the left-right integral edge glued together with the reinforcement
10 wood inside the door left and right, in addition to the top and bottom rail and the
hollow area's sealing stuffs. Another feather is the insertion of glass between the
glaze beads and the hollow area's sealing stuffs. The sealing stuffs for joining the
door skins could be made out of wood, polyvinyl chloride (PVC), polyethylene,
(PE), polypropylene (PP), resin, particle board or foam plastics. The insides of15 the door are filled with polyurethane foam plastics. Its assembly with glass
together create a glazed door with glass in the middle.
The feature of the four sheet door slabs structure involves setting two
crossed convex ribs on each of the long ribs and short ribs lying at the end of the
four sheet "L" type door skin, and through the connection between the metal
20 sheet of corning fixing and crossed ribs, to fix two "L" type slabs, and to thus
forrn a partly hollow door skin. A further feature involves gluing together the
reinforcement wood inside both the left and right part of the door, the top and
bottom rail and the hollow, area's sealing stuffs, to form a partly hollow door
slab. The door width of this invention is changeable by cutting the length of the
2s "L" type short rib. This concept is taken from the structure of two sheet door
skins.
The feature of the right sheet door slab's structure is to use 4 crossed and 4
vertical door skins which all have flush skins on the edge to form a rectangularframe. On the left and right side of the frame is a metal sheet inserted with
30 sealing stuffs There are a total of sixteen (16) metal sheets on the two sides. The
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crossed and the vertical door skin are then glued on the rectangular frame to form
a partly hollow door skin. In the same way the hollow area's sealing stuffs can be
fixed with glass and a PVC foam profile.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of this invention will be readily
apparent from the followinng description of certain preferred embodiments
hereof taken in conjunction with the accompanying drawings although variations
10 and modifications may be affected without departing from the spirit and scope of
the novel concepts of the disclosure and in which:
FIG. 1 is a perspective view of a door slab assemble having door skins.
15 FIG. 2 is a vertical sectional view of the door skin shown in FIG. 1.
FIG. 3is a cross sectional view of the door skins show in FIG. 1.
FIG. 4 is a perspective sectional view of the structure of the door skin shown in
FIG. 1.
FIG. 5 is a perspective explosive drawing of a door slab assemble having four
sheet door skins.
25 FIG. 6 is a vertical sectional view of the door skin shown in FIG. 5.
FIG. 7is a cross sectional view of the door skin shown in FIG.5.
FIG. 8 is a perspective sectional view of the door skin shown in FIG. 5.
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FIG. 9 is a perspective drawing of a door slab assemble having eight sheet door
skins.
FIG. 10 is a vertical sectional view of the door skin shown in FIG.9.
FIG. 11 is a cross sectional view of the door skin shown in FIG. 9.
FIG. 12 is an assembling view of the metal sheet and scaling stuff of the door skin
shown in FIG.9.
FIG.13 is a perspective sectional view of the door skin shown in FIG. 9.
DESCRIPTION OFTHE PREFERRED EMBODIMENTS
15 1. Two sheet door skin assembly (FIGS. 1 through 4) comprising of SMC door
skins 1, 2 whose center is a hollow rectangle land which has a convex integral
edge 3, 4 on the left and right skin edges as a feature. While the two sheet door
skins insert with each other from left to right there is also a corner sealing stuff
23 on both the left and right side, glued together with the top and bottom rail 6
20 and hollow area's sealing stuffs 5 of the door skin to form a partly hollow door
slab with a closed space. The inner part is filled with PU foam plastics 7 and afiller is put on the inlet to create a solid core door skin, wherein the opposite
corner stuff 23 and door skins integral edge 3, 4 is departed by 3mm to
strengthen the whole door skin and to reinforce the strength for installment of a
25 hinge.
The hollow, area's sealing stuff 5 of the solid door skin with partly hollow
assembly can be set to glass 9 and fixed by glass bead 8. At the bottom of glazebead 8 there is a plug-in convex rib which can be inserted in the groove of the
hollow area's sealing stuff 5 for tight jointing. Then with the same structure,
30 glass fixed to the glaze bead to complete assembly of a new ffinctional door
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slab with partly hollow sheet and glass. The features of two sheet door skin
assembly are as follows:
(1) Assembly is easy using the integral edge and using the most popular door size.
Also, this assembly saves left and right side stiles.
(2) The top and bottom rail can be cut to change the door slab height.
(3) The glaze bead can be replaced. Also, if the insulating glass is fragile or
breaks, it can be replaced as well. Different size glaze beads can fit with
different glass thicknesses to meet the diverse needs of the market.
2. Four sheet door skin assembly (FIGS. 5 through 8) consist of: four "L" type
sheets, N0. 10, 11, 12 and 13 of the SMC door skin. Both the long and the short
rib edges of the oak wood grain door skin have two crossed convex ribs each,
whereupon the two crossed convex ribs 17 of "L" short rib and the two convex
ribs 16 of "L" long rib are fixed tightly with the two grooves of the corner
fixing metal sheet 15 to form a partly hollw door skin. The left and right side
edges of the four sheet "L" door skins, each is designed with a pair of inserting
convex ribs 37 4 to be glued and inserted together during assembly of the door
skin.
Both the left and right part of the inner door skin is glued with corner stuff
23 whose integral edge is 3 mm departed so as not to be too close to each other.The door slab's top and bottom rail 6, hollow area's sealing stuff 5 and the
preceding four sheet "L" door skins are glued together to form a partly hollow
door slab. PU foamed plastics are filled into the door skin and the inlet is sealed
to form a door slab. The function of this invention is door skin width that is
changeable by following the concept of two sheet door skin assembly and
cutting the length of the "L" short of the "L" door skin. The inserting fixed
mode of insulating glass of the four sheet door skin assembly is similar to those
of the two sheet door skin and functions in the same way. The advantages are as
follows:
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(1) "L" type structure can be reassembled by cutting the "L" short rib to change the door skin width and thus fulfill the customer's needs.
(2) The metal sheet fixed on the corner can increase the door skin's strength and
5 reduce the angle matching error.
3. Eight sheets door skin assembly (FIGS. 9 through 13) has a corner fixing
metal sheet 22 with 90 degree edge, which can be inserted into the left and right
side stiles 14, the top and bottom rail 6, and the grooves of the hollow area's
10 sealing stuffs 5, for the door skin. In total there are 16 metal sheets, both sides of
which are used for fixing a door frame. Then, the four sheet door skins are
made with a long strip of oak wood grain and flush skin edges, which consists
of two sheet crossed stuff 18, 19 and two sheet vertical stuffs, to be glued on
the door frame to form a partly hollow door skin. The inside of the door is
15 filled with PU foam plastics and is sealed on the inlet with sealing stuff. The
hollow area's sealing stuff can be laid in and the glass tightly inserted between
the plug-in convex rib of the glaze bead and the groove of the hollow area's
sealing stuff. The glass just described can be of single, double or triple layers.
Different size glaze beads can be fixed to the glass by the same structure,
20 forming a novel and functional door slab assemble structure with partly hollow
door skin and glass. The advantages of the eight sheet door skin assembly
include:
(l) The eight sheets of vertical and crossed stuffs can be cut using different
25 widths and lengths to meet various requirements.
(2) The metal sheets of the door skin body provide strength and will not deform
over time.
(3) It is easier to assemble than previous, more traditional ways and thus can save
labor costs.
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Although the invention has been described with respect to preferred
embodiments, it is not to be so limited as changes and modifications may be
made therein which are within the full intended scope as defined by the appendedclaims.
