Note: Descriptions are shown in the official language in which they were submitted.
CA 02743870 2011-06-21
DOOR AND METHOD OF MANUFACTURING THEREOF
BACKGROUND OF THE INVENTION
1. TECHNICAL FIELD
The invention relates generally to hinged door assemblies which are mounted in
an entry way. More particularly, the invention relates to a door assembly
having skins
secured to a frame. Specifically, the invention relates to a door assembly
with multi-
piece stiles composed of different materials and secured together with
dovetail joints.
2. BACKGROUND INFORMATION
Doors are movable barriers used to cover an opening. A traditional household
door can come in a variety of shapes and sizes depending on the desired look.
However, the inner and outer skins of a door share the same profile, meaning
that
the design on the outside is the same as the design on the inside.
A traditional hinged door is secured on one side to a door frame opening with
hinges and secured to the other side with a locking mechanism. The frame may
be
comprised of four pieces, including a top and bottom rail secured between a
hinge stile
and a lock stile. The connection points of the frame may have dovetail joints
machined in them so that the frame is a sturdy assembly. Skins are then
secured to
each face of the door frame assembly with an internal core separating these
skins.
The skins may be composed of fiberglass, wood, or any other suitable material,
while
the core may also be solid wood or a spray foam composite material.
Traditionally,
the back side of each skin is flush and adapted to receive an adhesive to
secure the
skin to the frame assembly. In order to assemble the door, the frame is
assembled
and one of the skins is secured to one side of the frame. Next, a foam core is
inserted
between the frame assembly and against the installed skin. Finally, the
opposing skin
is then glued to the open side of the door frame.
BRIEF SUMMARY OF THE INVENTION
The present invention broadly comprises a door including a frame having a lock
stile, a hinge stile, a front side, and a back side, the lock stile having an
outer member
connected to an inner member with a dovetail joint, the hinge stile having an
outer
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member connected to an inner member with a dovetail joint, a first skin
secured to the
front side, and a second skin secured to the back side.
The present invention also broadly comprises a method of manufacturing a
door comprising the steps of forming a lock stile outer member with a dovetail
protrusion along substantially an entire length of the lock stile outer
member, forming a
lock stile inner member with a dovetail slot along an entire length of the
lock stile inner
member, forming a hinge stile outer member with a dovetail protrusion along
substantially an entire length of the hinge stile outer member, forming a
hinge stile
inner member with a dovetail slot along an entire length of the hinge stile
inner
member, joining the lock stile outer member dovetail protrusion and the lock
stile inner
member dovetail slot with an adhesive; joining the hinge stile outer member
dovetail
protrusion and the hinge stile inner member dovetail slot with an adhesive,
connecting
a top rail and a bottom rail to the lock stile and the hinge stile, and
securing a front skin
and a rear skin to the lock stile and the hinge stile.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
A preferred embodiment of the invention, illustrated of the best mode in which
Applicant contemplates applying the principles, is set forth in the following
description
and is shown in the drawings and is particularly and distinctly pointed out
and set forth
in the appended claims.
Fig. 1 is a front elevational view of the door assembly with a first skin
mounted
thereon;
Fig. 2 is an exploded view of a preferred embodiment door assembly with the
skins rotated in order to view the inside surface of each skin;
Fig. 3 is a top plan view of the lock stile disconnected from the bottom and
top
rails;
Fig. 4 is a front view of the lock stile showing vertical slots therein;
Fig. 5 is a top plan view of the hinge lock stile disconnected from the top
and
bottom rails;
Fig. 6 is a front view of the lock stile with vertical slots therein;
Fig. 7 is a bottom view of a bottom rail with horizontal slots therein;
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Fig. 8 is a perspective view of a portion of the back side of a skin with a
plurality
of vertical protrusions extending from the back side of the skin;
Fig. 9 is a front view of a portion of the top rail being slid downward and
installed on the lock stile dovetail connection;
Fig. 10 is a top view of a portion of the top rail secured to the lock stile
with an
adhesive;
Fig. 11 is a top view of a preferred embodiment door assembly taken generally
about line 11-11 in Fig. 9 with the door skins removed;
Fig. 12 is an assembled view of a preferred embodiment door assembly
illustrated in Fig. 11 with the door skins attached to the frame;
Fig. 13 is an enlarged view of the section labeled Fig. 13 in Fig. 12;
Fig. 14 is a perspective view of the top stile side of a preferred embodiment
door in the fully assembled state;
Fig. 15 is an exploded view of a second preferred embodiment door frame
assembly with the skins rotated to show the door skin inner surfaces and a
dual
composite wood frame;
Fig. 16 is a top cross-sectional view of a second preferred embodiment door
with a dual composite frame;
Fig. 17 is an exploded view of a third preferred embodiment door assembly with
the skins rotated to show the inner surfaces of each skin;
Fig. 18 is a cross-sectional view of a third preferred embodiment door frame
assembly with door skins separated from the frame;
Fig. 19 is a cross-sectional view of the door assembly in Fig. 18 with the
skins
attached;
Fig. 20 is an exploded view of a preferred embodiment door with the second
skin rotated to illustrate the back side;
Fig. 21 is an enlarged view of a preferred embodiment lock stile inner member
illustrating a dovetail slot in dashed lines;
Fig. 22 is an enlarged view of a preferred embodiment hinge stile inner member
illustrating a dovetail slot in dashed lines;
Fig. 23 is a sectional view of the preferred embodiment lock stile taken
generally about line 23-23 in Fig. 20;
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Fig. 23A is sectional view of a second preferred embodiment lock stile taken
generally about line 23-23 in Fig. 20;
Fig. 24 is a sectional view of the preferred embodiment hinge stile taken
generally about line 24-24 in Fig. 20; and,
Fig. 24A is a sectional view of a second preferred embodiment hinge stile
taken
generally about line 24-24 in Fig. 20.
Similar numbers refer to similar parts throughout the drawings.
DETAILED DESCRIPTION OF THE INVENTION
At the outset, it should be appreciated that like drawing numbers on different
drawing views identify identical, or functionally similar, structural elements
of the
invention. While the present invention is described with respect to what is
presently
considered to be the preferred embodiments, it is to be understood that the
invention
as claimed is not limited to the disclosed aspects.
Unless defined otherwise, all technical and scientific terms used herein have
the same meaning as commonly understood to one of the ordinary skill in the
art to
which this invention belongs. Although any methods, devices or materials
similar or
equivalent to those described herein can be used in the practice or testing of
the
invention, the preferred methods, devices, and materials are now described.
The door assembly of the present invention is indicated generally at 20, and
is
particularly shown in Figs. 1-19. As specifically seen in Fig. 1, a preferred
embodiment door assembly 20 includes a first skin 22 with a variety of panels
24. As
seen in Fig. 2, door assembly 20 also includes a second skin 26 which is
secured to
the door frame 28 opposite first skin 22 and will be described in further
detail below.
Door frame 28 includes four components in a preferred embodiment. A lock
stile 30 is parallel and spaced apart from a hinge stile 32. The hinge and
lock stiles
define the vertical perimeter of the door and are preferably spaced apart
approximately the same distance as the length of a top rail 34 and a bottom
rail 36.
Lock stile 30 includes dovetail joints 38 extending from a top end 39 and a
bottom end
41 to ensure a secure engagement with the top and bottom rails. Hinge stile 32
also
includes dovetail joints 38 extending from a top end 45 and a bottom end 47.
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In accordance with one of the main features of the present invention, a
plurality
of slots 40 is formed in both a front side 42 and a back side 44 of lock stile
body 46. In
a preferred embodiment, slots 40 are formed in body 46 and extend vertically
the full
length of body 46, however, it is within the spirit in the scope of the
present invention
as claimed that the slots extend for merely 25% of the height of the frame,
50% of the
height of the frame, or any other suitable length. As seen in Figs. 3 and 4,
slots 40
include sidewalls 48 and a bottom wall 50 which define a generally rectangular
opening. While the protrusion is preferably defined with a rectangular cross-
section,
any suitable cross-section may be incorporated, including semi-circular,
square or any
other shape.
Moving on to Figs. 5 and 6 and in accordance with yet another main feature of
the present invention, hinge stile 32 is arranged similar to lock stile 30.
Hinge stile 32
includes a plurality of slots 40 arranged vertically throughout the length of
body 52 of
hinge stile 32.
Fig. 7 is a bottom view of bottom rail 36. Bottom rail 36 includes a pair of
bottom slots 54 extending along the length of bottom rail 36. Bottom slots 54
are
preferably arranged to receive a door sill seal. Further, bottom rail 36
includes
receiving portions 56 which are complimentary shaped to and arranged to
contact the
dovetail joint of the hinge and lock stiles.
Referring to Figs. 2 through 6, lock stile body 46 includes an inner wall 43
and
hinge stile body 52 includes an inner wall 49. Further, top rail 34 and bottom
rail 36
each include inner walls 35 and 37 respectively. Advantageously, inner walls
35, 37,
43 and 49 define an internal cavity 75.
In accordance with yet another main feature of the present invention, Fig. 8
illustrates first skin 22 with a back side 58 having a plurality of
protrusions 60
extending therefrom. In a preferred embodiment, protrusions 60 are spaced a
distance A from a top edge 62 of skin 22. Further, a similar distance is
incorporated
for the bottom end of the skin (not shown). Advantageously, this arrangement
allows
the second skin back side 58 to be flush against top rail 34 and bottom rail
36 while
allowing protrusion 60 to engage slots 40. While a preferred embodiment second
skin
includes five protrusions, any number or arrangement of protrusions may be
incorporated without departing from the spirit and scope of the present
invention as
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claimed. Further, protrusions 60 are illustrated with generally square walls
extending
from the back side of the skin and a rounded top end. Protrusion 60 may have a
varying width as well as any suitable shape so long as they mate with slots
40. Finally,
protrusions 60 are also spaced apart a distance B which can also be varied so
long as
the requirements above are satisfied.
Fig. 9 illustrates top rail 34 being inserted in the direction of arrow 64 to
install
the top rail on frame 28 along top end 39. An adhesive 66 is placed on inner
wall 35
and receiving portion 56 to secure the top rail to lock stile 30. A similar
process is
completed with respect to hinge stile 32 to secure the other side of top rails
34 to the
hinge stile. While the adhesive is described as being placed on inner wall 35,
the
adhesive may also be placed directly on the hinge and lock stiles.
Fig. 10 is a top view of top rail 34 installed on dovetail joint 38 of lock
stile 30.
In particular, dovetail joint 38 is slidingly engaged with receiving portion
56 of top rail
34. Advantageously, this arrangement allows top rail 34 to be secured on lock
stile 30
and permit movement only in an upward direction.
Figs. 11-13 illustrate the attachment of first skin 22 and second skin 26 to
lock
stile 30 as well as locating a foam core 68 between the skins in cavity 75.
Fig. 11
illustrates skins 22 and 26 prepared for installation on lock stile 30, while
a similar
arrangement is found at hinge stile 32, but not shown. As discussed above,
skin 22
includes a back side 58 with protrusions 60 extending away from the skin. The
first
skin 22 also has a front side 70 which includes a variety of panels as
discussed above.
Second skin 26 includes a back side 72 having a
plurality of protrusions 60 extending therefrom and a front side 74 opposite
back side
72 and also including a plurality of panels.
Fig. 12 illustrates first skin 22 and second skin 26 in the installed position
after
forcing protrusions 60 within slots 40. Specifically, skin 22 is forced in the
direction
associated with arrow 76 while skin 26 is forced in the direction associated
with arrow
78. In a preferred embodiment and seen in Figs. 12 and 13, adhesive is located
along
the back side 58 of skin 22 and back side 72 of skin 26 such that adhesive
bonds
between the back sides 58, 72 and lock stile 30 and a top rail outer surfaces
29A and
29B. Further adhesive is also located within slots 40 and on protrusions 60
such that
there is an increased adhesive area at the protrusions. During the
installation, skins
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22 and 26 are forced in their respective directions until protrusions 60 are
fully seated
within slots 40. Protrusions 60 and slots 40 may also be arranged such that
there is a
slight interference fit to ensure that the skins do not become separated from
the frame
while the adhesive is curing.
Fig. 14 illustrates the top corner of a preferred embodiment door assembly 20.
Top rail 34 is adhesively secured to lock stile 30, while skins 22 and 26 are
each
adhesively secured to top rail 34 and lock stile 30. Accordingly, the present
invention
creates a sounder and more secure bound between door skins 22 and 26 and lock
stile 30 and hinge stile 32 (not shown) while retaining the traditional look
of a standard
door.
Having described the structure of the first embodiment, only those portions of
the second embodiment which are different than the first embodiment are
described in
detail. Likewise, similar numerals refer to similar parts throughout the
various
embodiments.
Fig. 15 and 16 illustrate a second preferred embodiment, with a first skin 80
and
a second skin 82. In accordance with yet another main feature of the present
invention, skins 80 and 82 have distinct and different outer surfaces 84 and
86
respectively. Further, inner surfaces 85 and 87 of skins 80 and 82 are also
distinct
from each other. While the second preferred embodiment is shown with six
panels 24
on the first skin and two panels 83 on the second skin, any arrangement of
first and
second skins that have a distinct outer appearance may be utilized.
Advantageously,
this allows the purchaser to have a first skin which matches the exterior of
the
dwelling, while having a second skin facing the interior of the dwelling that
again
matches a completely different environment than the outside.
Another advantage of the preferred embodiments is the ability to selectively
size the door using protrusions 60 and slots 40. Specifically, protrusions 60
may align
with only a portion of slots 40, thereby having a portion of the skins hang
over the
frame. The skin can then be trimmed to reduce the side of the door. The hinge
and
lock stiles may then include an additional member bolted thereon to ensure a
proper
door size.
In a second preferred embodiment, frame 88 is composed of six pieces, top rail
34 and bottom rail 36 remaining the same as the previous embodiment. However,
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lock stile 90 includes a high quality outer piece 92 and a low quality
interior piece 94.
Hinge stile 96 also includes a high quality outer piece 98 and a low quality
inner piece
100. High quality pieces 92 and 98 both include dovetail joints at the top and
bottom
portions and define the outer most edges of the frame. High quality pieces 92
and 98
are also thin and incorporated at the ends to provide the appearance of a hard
wood
or high quality door throughout the frame construction, while reducing costs
by
incorporating low quality pieces 94 and 100. Further, low quality pieces 94
and 100
include protrusions 40 similar to the first embodiment throughout their
length.
Advantageously, incorporating low quality pieces 94 and 100 for the entire
length of
the slots ensures that machining of the slots is more readily accomplished
without a
waste of material.
Finally, high quality piece 92 is preferably adhesive secured to low quality
piece
94, while high quality piece 98 is also adhesively secured to low quality
piece 100.
Accordingly, when the high quality and low quality pieces are attached, they
form the
lock stile and hinge stile described in the first preferred embodiment in a
more cost
effective manner.
Having described the structure of the first two embodiments, only those
portions
of the third embodiment, which are different than the first two embodiments,
are
described in detail. Likewise, similar numerals refer to similar parts
throughout the
various embodiments.
Figs. 17-19 illustrate a third preferred embodiment with a first skin 102, a
second skin 104, and a frame 106. Frame 106 is generally shaped identical to
the first
preferred embodiment frame, however the incorporation of the second preferred
embodiment frame with high quality and low quality pieces is within the spirit
and the
scope of present invention as claimed. Further, first skin 102 is arranged
similar to
first skin 22 in that there are six panels 24. Second skin 104 has three
panels 108 in
the third preferred embodiment to provide a distinct and
different appearance than the first skin. Frame 106 includes a lock stile 110
and a
hinge stile 112.
In accordance with one of the main features of the present invention, lock
stile
110 and hinge stile 112 (not shown) include a plurality of protrusions 114
extending
from both sides of each stile. Further, skins 102 and 104 each include a back
side
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116 and 118 respectively. A plurality of slots 120 are formed within back
sides 116
and 118 so that slots 120 are arranged to receive protrusions 112 of lock
stile 110 and
hinge stile 112.
As discussed in the first preferred embodiment, installation of the third
preferred
embodiment skins is similar in that first skin 104 is forced in the direction
associated
with arrow 122 until protrusions 114 are inserted within slots 120, while the
second
skin is forced in the direction associated with arrow 124 until protrusions
114 are
inserted within slots 120. Once again, this arrangement provides for an
increased
adhesion contact area as well as an interference fit between the skins and the
stiles.
Having described the structure of the preferred embodiments, a preferred
method of manufacturing will be described in detail and should be read in
light of Figs.
1-19.
Initially, plurality of slots 40 are formed in frame 28, and preferably in
lock stile
30 and hinge stile 32. Next, a plurality of protrusions 40 are formed on back
side 58
and 72 of the skins. The slots may be formed by machining or any other
suitable
removable technique. Similarly, protrusions 60 may be formed by removing
material
with a machining apparatus or by adhesively securing preformed protrusions on
the
back side of each skin. Alternatively, slots 40 may be formed in the skins,
while
protrusions 60 may be formed on frame 28 without departing from the spirit of
the
invention.
Next, adhesive is located on either frame 28 or back side 58 and 72 of skins
22
and 26. The skins are then directed towards the frame such that the
protrusions 60
are inserted within the respective slots 40 of the frame. After one side has
been
inserted, foam core 68 is disposed within the frame or may be placed by
blowing foam
insulation within the frame.
Frame assembly 28 is formed by machining top rail 34 with receiving portions
56 on each end and bottom rail 36 with the same receiving portions 56. Lock
stile 30
and hinge stile 32 each include dovetail joints 38 on each end. The dovetail
joints and
receiving protrusions are complimentary shaped to ensure a tight and secure
fit as well
as provide increased contact surface for the adhesive to
cure. Frame 28 is finally formed by securing the dovetail joints and receiving
portions
of the lock stile, hinge stile, top rail and bottom rail with adhesive.
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Having described the structure and operation of the first three preferred
embodiments, only those portions of the fourth preferred embodiment which are
different from the previous embodiments are described in detail. Likewise,
similar
numerals refer to similar parts throughout the various embodiments.
Figures 20 through 24 illustrate a fourth preferred embodiment door assembly
130. Specifically, fourth preferred embodiment door assembly 130 is similar to
the
three prior embodiments, with the exception of the lock and hinge stiles. A
lock stile
132 includes an outer member 134 and an inner member 136. A hinge stile 138
includes an outer member 140 and an inner member 142.
Figures 21 and 22 illustrate enlarged views of lock stile inner member 136 and
hinge stile inner member 142 respectively. Both lock stile inner member 136
and
hinge stile inner member 142 include slots 40 extending the length of the
members at
least partially defining adhesive pockets. In accordance with another main
feature of
the present invention, lock stile inner member 136 includes a dovetail slot
144
extending the entire length of an outer side wall 146 of the lock stile inner
member.
Similarly, hinge stile inner member 142 includes a dovetail slot 148 extending
throughout the entire length of an outer side wall 150.
Figure 23 illustrates lock stile 132 with outer member 134 separated from
inner
member 136. In particular, outer member 134 includes a dovetail protrusion 152
extending inward toward inner member 136. Advantageously, dovetail protrusion
152
extends for at least the entire length of inner member 136 and preferably
extends the
entire length of outer member 134. Advantageously, this arrangement permits
outer
member 134 to be composed of a high quality material with a more expensive
appearance while the inner member 136 can be composed of a lower quality and
less
appealing material to reduce cost while still maintaining the door's
integrity.
Figure 23A illustrates an alternative embodiment for lock stile 132. In
particular,
outer member 134 again includes a dovetail protrusion 152, but inner member
136
may include a plurality of components. Specifically, inner member 136 may
include an
intermediate member 154 located next to an internal member 156. Still further,
a
secondary intermediate member 158 may be located between intermediate member
154 and internal member 156. In this arrangement, each piece may be composed
of
a different material and adhesively secured together, or the intermediate and
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secondary intermediate member may be a single unit and adhesively secured to
internal member 156. Advantageously, this arrangement again permits the
components to be manufactured of a lower quality or varying quality of
materials to
reduce the cost while maintaining the integrity of the door with a variety of
material
densities. Specifically, the intermediate member is preferably denser than the
inner
member or the internal member, while the outer members are even denser than
the
intermediate members in a preferred embodiment.
Figures 24 and 24A illustrate the hinge stile of the fourth preferred
embodiment.
Figure 24 illustrates hinge stile outer member 140 with a dovetail protrusion
160
extending the entire length of the outer member. As can be seen, the dovetail
protrusion 160 is axially aligned with dovetail slot 148 of the hinge stile
inner member
such that the two are mated along the longitudinal axes. In accordance with
another
main feature of the present invention, Figure 24A illustrates hinge stile
inner member
142 having an intermediate member 162 with the dovetail slot 148 and proximate
an
internal member 164. Preferably, the internal member 164 is secured to the
intermediate member 162 with an adhesive to form the hinge stile inner member
142.
Once again, hinge stile outer member 140 is preferably composed of a high
quality
material providing a more appealing fit and finish, while the inner members
142,
intermediate member 162, and internal member 164 are each composed of a lower
quality material. Still further, intermediate member 162 may be composed of a
higher
quality material than internal member 164 if desired.
Having described the structure of the fourth preferred embodiment, a method of
manufacturing will now be described in detail and should be viewed in light of
Figures
1 through 24A. Initially, a lock stile outer member is formed with a dovetail
protrusion
along the entire length of the lock stile outer member and a dovetail slot is
machined
along an entire length of the lock stile inner member. Further, the hinge
stile outer
member is formed with a dovetail protrusion along the entire length of the
inner portion
while the hinge stile inner member is formed with a dovetail slot along the
entire length
thereof. Next, the lock stile outer member protrusion in the lock stile inner
member
slot are joined together with an adhesive, while the hinge stile outer member
protrusion and the hinge stile inner member slot are joined together with an
adhesive.
Next, a top rail and a bottom rail are secured to the lock stile and the hinge
stile before
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a front skin and a rear skin are finally secured to the frame. Accordingly,
the
integration of protrusions and slots may still be incorporated in a manner
similar to the
procedures detailed above.
While the above method of manufacturing utilizes protrusions on the back side
of each skin, it is within the spirit of the scope of the present invention to
form
protrusions on both sides of the lock and hinge stiles and machine slots in
the back
side of each skin. Further, a combination of the two may also be used without
departing from the spirit of the scope of the invention as claimed. For
example, one
side of the lock stile may have protrusions, while the opposite side of the
same stile
may have slots therein. Still further, the lock stile may have protrusions on
both ends,
and a combination of protrusions and slots while the hinge stile only has
slots. Thus, it
is seen that any useful combination of slots and protrusions on the stiles and
skins
may be used without departing from the spirit and scope of the present
invention as
claimed.
Thus, door assembly 20 provides an increased contact surface area between a
door frame and the skins. The door skins are also arranged so that a first
skin may
have a unique and distinct outward appearance, while the opposing second skin
may
have a completely different appearance to enable the purchaser to custom fit
his/her
desired application. Further, a cheaper and more cost effective version of the
invention may be incorporated by providing both high quality and low quality
wood
strategically placed to provide the increased contact surface as well as
different skin
options. Still further, the outer members may include protrusions joined to
the inner
members to provide greater strength and integrity while reducing material
costs.
It will be evident to one skilled in the art that a variety of changes can be
made
that are within the spirit and scope of the present invention. For instance,
the
protrusions may be located on either the skin or the stile, while the slots
may also be
located on either the skin or stiles. Further, any suitable skin design may be
used in
combination with any other suitable skin design such that the purchaser has a
great
deal of flexibility in his/her door skins.
Accordingly, the door assembly is an effective, safe, inexpensive, and
efficient
device that achieves all of the desired objectives of the invention, provides
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for eliminating difficulties encountered with prior art devices, systems,
methods, and
solves problems and obtains new results in the art.
In the foregoing description, certain terms have been used for brevity,
clearness, and understanding; but no unnecessary limitations are to be implied
therefrom beyond the requirement of the prior art, because such terms are used
for
descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention is an example, and
the scope of the invention is not limited to the exact details shown or
described.
Having now described the features, discoveries, and principles of the
invention,
the manner in which the door frame is constructed and used, the
characteristics of the
construction, and the advantageous new and useful results obtained; the new
and
useful structures, devices, elements, arrangement, parts and combinations are
set
forth in the appended claims.
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