Note: Descriptions are shown in the official language in which they were submitted.
CA 02802355 2014-02-27
DOOR SILL ASSEMBLIES WITH REPLACEABLE SILL DECKS
CROSS-REFERENCE TO RELATED APPLICATIONS
[001] This application is a continuation of U.S. Patent Application Serial No.
13/367,875,
filed on February 7, 2012, published as 20130091776, which is a continuation-
in-part of U.S.
Patent Application Serial No. 13/009,449, filed on January 19, 2011, now
Patent 8,490,332.
FIELD OF THE INVENTION
[002] The present invention relates generally to entry door sill
constructions, and more
particularly, to a door sill construction having a replaceable sill deck.
BACKGROUND OF THE INVENTION
[003] Door sills can be damaged during shipment from the manufacturer to the
construction
site, or more commonly during construction of a building. Common causes
include objects
dropped on the sill, excessive traffic within a relatively short time period,
or accidental
application of paint or stucco to the door sill. Left unrepaired, the door
sill will not function
as originally designed, i.e., the damaged door sill will not provide an
effective seal between
the frame and door, nor will the door sill manage water intrusion that
minimizes moisture
accumulation. Unrepaired door sills do not have the desirable aesthetics that
newly
manufactured and installed door sills have.
[004] There are solutions available to a building owner or contractor who
installs the door
systems. The damaged door sill can be completely cut out and replaced. While a
new door
sill may be aesthetically pleasing, this particular type of repair can damage
the surrounding
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mullions, doorjambs, astragals or other structures, compromising the entire
stability or
function of the entryway system. Replacing a door sill is also costly, and is
rarely done. An
alternative is to simply attach a metal cover patch to the exposed surface of
the existing
door sill. The metal patch is not aesthetically or functionally equivalent to
the original,
undamaged door sill. This repair can also be costly because it is cut and
notched on-site in
order to provide the proper fit to the door unit.
[005] There is a need, therefore, for a door sill system that retains
functionality, allows for
easy replacement of door sill components, and can address any damage arising
during
shipping, installation, or construction.
SUMMARY OF THE INVENTION
[006] The following presents a simplified summary of the invention in order to
provide a
basic understanding of some aspects of the invention. This summary is not an
extensive
overview of the invention and is not intended to identify key or critical
elements of the
invention or to delineate the scope of the invention. The purpose of this
section is to
present some concepts of the invention in a simplified form as a prelude to
the more
detailed description that is presented later.
[007] A door sill assembly for an entryway of a building can include a
substrate having a
nosing and a sill channel. A nosing cover can be attached to the substrate and
extending
over at least a portion of the nosing and over at least a portion of the sill
channel. A sill
deck can be on the substrate. The sill deck can include a deck and a clip. In
selected
embodiments, the sill deck and clip can be formed as a unitary construction.
The deck can
be engaged with a portion of the nosing cover. The clip can be operably
engaged with the
deck. The clip can be removably attachable to the substrate. The sill deck is
capable of
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. .
removable attachment from the door sill assembly before or after the door sill
assembly is
installed in the entryway.
BRIEF DESCRIPTION OF THE DRAWINGS
[008] Figure 1 is a front perspective view of a door sill assembly with a
replaceable sill
deck thereon according to an embodiment of the invention.
[009] Figure 2A is a side view of a door sill assembly with a replaceable sill
deck thereon
according to an embodiment of the invention.
[010] Figure 2B is a cut-away side view of the door sill assembly of Figure 2
illustrating an
alternative embodiment having an integrally-formed sill deck and clip.
[011] Figures 3A and 3B show front perspective and side views, respectively,
of optional
protective covers on a door sill assembly shown in Figures 1 and 2.
[012] Figure 4 is a front perspective view of a door sill assembly with a
replaceable sill
deck thereon according to an embodiment of the invention.
[013] Figure 5 is a side view of a door sill assembly with a replaceable sill
deck thereon
according to an embodiment of the invention.
[014] Figures 6A and 6B show front perspective and side views, respectively,
of optional
protective covers on the door sill assembly shown in Figures 4 and 5.
[015] Figure 7 is a front perspective view of a door sill assembly with a
replaceable sill
deck thereon according to an embodiment of the invention.
[016] Figure 8 is a side view of a door sill assembly with a replaceable sill
deck thereon
according to an embodiment of the invention.
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,
[017] Figures 9A and 9B show front perspective and side views, respectively,
of optional
protective covers on the door sill assembly shown in Figures 7 and 8.
[018] Figure 10 is a front perspective view of a door sill assembly with a
replaceable sill
deck thereon according to an embodiment of the invention.
[019] Figure 11 is a side view of a door sill assembly with a replaceable sill
deck thereon
according to an embodiment of the invention.
[020] Figures 12A and 12B show front perspective and side views, respectively,
of
optional protective covers on the door sill assembly shown in Figures 10 and
11.
[021] Figures 13A and 13B show side perspective and front perspective assembly
views,
respectively, of a door sill assembly installed in an entryway having a mull
and a sidelight
panel according to another embodiment of the invention.
[022] Figures 13C and 13D show a partial side assembly and partial front
views,
respectively, of a mull and mull riser used on a door sill assembly shown in
Figures 11A and
11B.
[023] Figures 14A and 14B show side perspective, and front perspective
assembly views,
respectively, of a door sill assembly installed in an entryway having a mull
and a sidelight
panel according to another embodiment of the invention.
[024] Figures 14C and 14D show a partial side assembly and partial front
views,
respectively, of a mull and mull riser used on the door sill assembly shown in
Figures 11A
and 11B.
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DETAILED DESCRIPTION
[025] Certain exemplary embodiments of the present invention are described
below and
illustrated in the accompanying figures. The embodiments described are only
for purposes
of illustrating the present invention and should not be interpreted as
limiting the scope of
the invention, which, of course, is limited only by the claims below. Other
embodiments of
the invention, and certain modifications and improvements of the described
embodiments,
will occur to those skilled in the art and all such alternate embodiments,
modifications, and
improvements are within the scope of the present invention.
[026] Figures 1 through 3B show door sill assemblies 10 and 11, and temporary
protective
covers 90 and 95, according to embodiments of the invention. As shown in
Figures 1 and
2A, the door sill assembly 10 includes a substrate 20 having an upwardly
extending nosing
22 and substrate dam 24 defining a sill channel 23. The assembly 10 also
includes a nosing
cover 60 on the substrate 20, a sill cap 80 received by the sill channel 23,
and a removable
sill deck 40 engaged with the nosing cover 60 and substrate 20. The sill deck
40 includes a
deck 42 connected to a clip 50. The clip 50 is on the substrate 20, and can
pivot to allow
removal of sill deck 40 from the door sill assembly 10 before or after
installation of the door
assembly in the building.
[027] A conventional, e.g., 4-9/16 inch width, door sill assembly is shown in
Figures 1
through 3B that can be used with single in-swing doors typical of entryways in
residential
homes. The door sill assembly, however, may have any particular width as the
need may
arise. Figures 4 through 9B show embodiments of a 5-5/8 inch wide door sill
assembly with
a replaceable sill deck and temporary protective covers. The embodiments shown
in Figures
4 through 9B can also be used with single in-swing doors. In other
embodiments, the door
sill assemblies as described herein may be used with double in-swing doors,
sliding door
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constructions, or outswing doors. Figures 10A through 11D show yet another
embodiment
of the invention wherein the door sill assembly comprises one or more mullions
and one or
more sidelight panels.
[028] Figure 2A shows how the substrate 20 can engage the nosing cover 60 and
sill deck
40. The substrate 20 has a first end 21 near the inside of the building, the
first end 21
including the nosing 22 and sill channel 23. A nosing lip 28 is located at the
underside of
the nosing 22 near the undersurface of the substrate 20. The nosing lip 28
receives a
portion of the nosing cover 60, as will be further discussed below. The
substrate second
end 31 is opposite the first end 21 and can include a ledge 32 configured to
receive the clip
50. In particular, the ledge 32 can have upper and lower surfaces 33 and 34,
respectively,
and a lip 35 to engage the clip 50.
[029] The substrate 20 can be any material, including, but not limited to,
wood, composite,
polymeric or other rigid material. Additional fillers can be included in the
substrates as
needed, e.g., wood flour and/or materials other than the primary material. In
one
embodiment, the substrate can be integrally formed. For example, the substrate
can be
integrally formed as described in U.S. Patent No. 6,789,358, the entirety of
which is herein
incorporated by reference. In another embodiment, the substrate can be
integrally formed
for the entirety of its length. In yet another embodiment, several substrate
sections of the
substrate can abut one another or connect together to form the support
structure for the
door sill.
[030] As shown in Figure 2A, the nosing cover 60 includes lower portion 61,
nosing
portion 62 covering the upper surface of the nosing 22, sill channel portion
64, and a dam
portion 66 having first and second projections 67 and 68. The nosing cover
lower portion
61 engages the nosing lip 28 on the undersides of the substrate 20 to secure
the nosing
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cover 60 to the first end 21 of the substrate 20. The nosing portion 62
extends over the
nosing 22 and turns down toward the substrate 20 to cover at least a portion
of the surface
of the sill channel 23 forming the sill channel portion 64. In the embodiment
shown, sill
channel portion 64 covers all of the surface of the sill channel 23.
[031] The dam portion 66 can extend upwardly from the sill channel portion 64.
In an
embodiment, the dam portion 66 is adjacent to, and can extend vertically past
the top of the
substrate dam 24. First and second projections 67 and 68 respectively can
extend over the
substrate dam 24 and engage the deck 42 and the substrate 20, respectively.
More
specifically, the first projection 67 can be received by a deck channel 44,
and the second
projection 68 can be received within an opening 26 on the substrate 20. The
second
projection 68 is shown with multiple sealing fins that help form a water and
vapor seal when
second projection 68 is placed in the opening 26. In another embodiment, the
first
projection 67 can have sealing fins also. The first projection 67 and second
projection 68
can extend from dam portion 66 along the length (along the Z-axis as shown in
Figure 1) of
the nosing cover 60. In alternate embodiments, however, the first and second
projections
67 and 68 can be formed by several spaced-apart segments. Although two
projections 67
and 68 are shown in Figure 2, more or less than two projections can be used to
engage with
the sill deck 40 and substrate 20.
[032] In alternate embodiments, the nosing cover 60 can include a nosing
portion 62 and
sill channel portion 64 in the sill channel 23, but not extend to or cover the
dam portion 66.
The nosing cover, nosing portion and sill channel portion 64 can extend the
length of the
sill.
[033] Continuing with Figures 1 and 2A, the nosing cover 60 can extend down
the length
(Z-direction) of the door sill assembly. So configured, the nosing cover 60
helps form a
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, .
water and vapor barrier and can help lirnit water seeping into the substrate
20. The nosing
cover 60 allows water to drain into and seep through drain channels (not
shown) at
opposing sides of the door sill. Further, if one or more substrate portions
are combined to
form the substrate, the nosing cover 60 spans across the seams formed between
adjacent
substrate segments. Having a barrier over such seams can also help limit water
intrusion.
[034] Figures 2A and 2B show an adjustable sill cap 80 disposed in the sill
channel 23 and
on the nosing cover 60. The sill cap 80 includes an adjustable element 82 in
the body 86,
cap plug 84 and a leg 87. The leg 87 extends in the Y-direction and then down
toward the
sill deck 40. A flexible fin 88 on the distal end of leg 87 can contact the
nosing cover dam
portion 66 and deck 42 to form a seal. The seal can be an additional barrier
to water
intruding through the door sill assembly 10. In another embodiment for
outswing type
doors, the sill cap can have a leg extending in the Y-direction down toward
the deck, and
contain a bulb at the distal end of the leg to form a seal with the dam or the
deck.
[035] An installer, resident, or homeowner can remove cap plug 84 from the
sill cap 80
and access the adjustment element 82. The adjustment element 82 can be rotated
to cause
adjustment of the sill cap 80 between a raised position (not shown) elevated
above the
substrate 20 and a lowered position as shown in Figures 2A and 2B. In other
embodiments,
non-adjustable sill caps can be used.
[036] As stated, the sill deck 40 includes a deck 42 and a clip 50, the clip
50 being pivotally
connected to the deck 42 in a preferred embodiment. The deck 42 and clip 50
together
form the tread portion of door sill assembly 10. The deck 42 and clip 50
typically are
formed of aluminum, or other material that is durable for use in an entryway.
[037] As shown in Figures 2A and 2B, the deck 42 can include a channel 44,
support leg
46, and a clip engaging end 45. The channel 44 receives the first projection
67 extending
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from the nosing cover 60. The support leg 46 can extend from the undersurface
of the deck
42 to rest atop the substrate 20. One or more support legs can be used to
support the deck
42, as needed. As shown in Figure 2A, the clip engaging end 45 can include a
knuckle joint
47 and a curvilinear slot 48 that engages the clip 50. The slot 48 can receive
a curved clip
leg 52 that is slidable in the Z direction therein.
[038] The sill deck 40 removal is accomplished by taking advantage of the
design of the
deck 42 and clip 50. As shown in Figure 2A, the clip 50 has a clip end 54
configured to
engage a lip 35 on the undersurface on substrate ledge 32. More specifically,
the clip end 54
can have a first engagement point 55, and a second engagement point 56 that
releaseably
extends over the lip 35. The clip engaging end 45, resting on ledge upper
surface 33, and
the clip engagement points 55 and 56 engage with the second end 31 of the
substrate 20 to
limit vertical (Y-direction) and horizontal (X-direction) displacement of the
clip 50. Because
the clip 50 is also connected to the deck 42 at the knuckle joint 47, the deck
42 is pressed
into engagement with the projection 67 of the nosing cover 60, vertical and
horizontal
displacement of the sill deck 40 is minimized. To facilitate removal, a slot
58 can be
positioned proximate to the clip end 54 and can be designed to receive a tool,
e.g., a screw
driver, flat edged tool or the like. A user inserts the tool into the slot 58
and by pivoting the
tool to force the clip end 54 from beneath the substrate ledge 32 so that the
clip leg 52
pivots about the knuckle joint 47. In this manner, the clip 50 is pivoted
about the deck 42
in the direction of arrow A as shown.
[039] As shown in the cut-away view of Figure 2B, in another embodiment, the
deck 42
and clip 50 may be formed as a unitary piece, with the clip engaging the
substrate second
end 31 in similar fashion as the embodiment of Figure 2A. As shown, at the end
of the
deck 42, where the deck 42 intersects with the clip 50, a score line, groove,
or weakened area
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of decreased thickness 53 can be formed. Constructed in this manner, a user
inserts the tool
into the slot 58 and can force the clip end 54 from beneath the substrate
ledge 32 so that the
front edge of the sill deck 42 flexes or breaks along the score line 53,
allowing the clip leg 52
to pivotally disengage in the direction of the arrow A as shown.
[040] Under either of the embodiments shown in Figures 2A or 2B, once the clip
50 is
removed from the substrate 20, the deck 42 can be disengaged from the
projection 67 by
sliding the deck 42 in the X-direction, thereby allowing the entire sill deck
40 to be
completely removed from the door sill assembly 10 and frame structure. Sill
deck 40
removal occurs without modification or damage to the frame structure, and
without
disassembly of the remaining portions of the door sill 10. A new sill deck
with a deck and
clip can then be removeably attached onto the substrate 20 by reversing the
above steps,
thereby preserving the originally designed functionality and aesthetics of the
installed door
sill.
[041] The scope of this invention also includes the use of optional temporary
protective
covers, which can later be removed and discarded, and replaced with a sill
deck upon
completion of the construction. Temporary protective covers can be placed on
door sill
assembly 10 during door assembly manufacture, or during installation of the
door sill
assembly in the building. The temporary protective covers allow a pre-hung
door to be
assembled and shipped to the job site without the final sill deck and sill cap
assembly
attached, thus minimizing damage risk to these door sill components. In the
embodiment
shown in Figures 3A and 3B, a door sill assembly 11 can include a temporary
deck
protective cover 90 and temporary sill cap protective cover 95. The temporary
deck
protective cover 90 includes a deck surface 91 and a plurality of supports 92
extending
therefrom to rest on the substrate 20. A channel 94 receives one of the
projections
extending from the nosing cover 60. The protective sill cap cover 95 can be
placed over the
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. ,
nosing cover 60 to protect the sill channel 23. The sill cap protective cover
95 includes a
first leg 96 and a second leg 97 that can provide support and contact the
nosing 22 and sill
channel 23. An extension leg 98 engages a channel 93 in the deck surface 91,
securing the
deck protective cover 90 in place. The temporary protective covers 90 and 95
can be
removed once construction of the building is complete and discarded as waste.
A
replaceable sill deck as described above can then be installed.
[042] Figures 4 through 6B show another door sill assembly, according to
another
embodiment. While the embodiment shown can be used with doors of various
widths, in
one embodiment the door sill assembly is a 5-5/8 inch wide door sill. As shown
in Figures
4 and 5, the door sill assembly 110 includes a substrate 120, nosing 122 and
substrate dam
124. Also shown is a sill channel 123, nosing cover 160, sill cap 180 in the
channel 123, and
a replaceable sill deck 140. The nosing cover 160, sill channel 123, sill cap
180, and the first
end 121 of the substrate 120 are constructed and function similar to the
equivalent
components of the embodiment described above and shown in Figures 1 and 2A,
2B. As
shown best in Figure 5, however, the second (or outside-facing) end 131 of the
substrate
120 includes an indentation 133 near the ridge 134, and a slot 135 positioned
at the end 131
of the substrate 120. The indentation 133 can receive a first clip leg 159
while the slot
135 receives a second clip leg 153. Details of the clip 150 are discussed
below.
[043] As shown in Figures 4 and 5, the sill deck 140 includes a deck 142 and
an
interconnected clip 150. The deck 142 can include a channel 144 for engaging
the nosing
cover 160, at least one support leg 146, and a clip engaging end 145 shown in
this
embodiment as pivotally connecting to the clip 150. The channel 144 receives a
first
projection 167 extending from the nosing cover 160. The support leg 146
extends from the
undersurface of the deck 142 to rest atop the substrate 120. One or more
support legs can
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be used to support the deck 142, as needed. The clip engaging end 145 includes
a knuckle
joint 147 and a curved slot 148 that receives a portion of the clip 150. The
lower surface of
the clip engaging end 145 can rest on the upper surface 125 of the substrate
120.
[044] As shown in Figure 5, the clip 150 includes a curved clip leg 152, first
and second
clip legs 159 and 153, and a slot 158 for receiving a tool. The curved clip
leg 152 slidably (in
the Z-direction) fits within the slot 148, connecting the clip 150 to the deck
42. The first
clip leg 159 extends from the knuckle joint 147 into the indentation 133,
while the second
leg 153 is received in the substrate slot 135. The clip legs 153 and 159 when
engaged with
the second end 131 of the substrate 120 limit vertical (Y-direction) and
horizontal (X-
direction) displacement of the clip 150. Because the clip 150 is also
connected to the deck
142 at the knuckle joint 147, the deck 142 is pressed into engagement with the
projection
167 of the nosing cover 160, vertical and horizontal displacement of the sill
deck 140 is
minimized. A tool can be inserted into the slot 158 and pivoted to release the
clip leg 153
out of the slot 135. The clip 150 can pivot in the direction of arrow B to
disengage from
the substrate 120 and nosing cover 160. This allows the sill deck 140 to be
completely
removable from the door sill assembly 110 without cutting, modifying, or
damaging the
surrounding frame structure of the door sill assembly, or disassembling the
door sill. A new
sill deck can be placed on the substrate and nosing cover as needed.
[045] Figures 6A and 6B show a door sill assembly 211 with optional temporary
protective
covers that fit the substrate described in Figures 4 and 5 above. The covers
190 and 195
function similarly to the protective covers described above and shown in
Figures 3A and
3B. The deck protective cover 190 includes a deck surface 191 and a plurality
of supports
192 extending therefrom to rest on the substrate 120. A channel 194 receives
one of the
projections extending from the nosing cover 160. The temporary protective sill
cap cover
195 can be placed over the nosing cover 160 to protect the sill channel 123.
The sill cap
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protective cover 195 includes a first leg 196 and a second leg 197 that can be
placed upon
the nosing 122 and sill channel 123. An extension leg 198 engages a channel
193 in the deck
surface 191, securing the deck protective cover 190 in place. In an
embodiment, the
temporary covers 190 and 195 can be installed on door sill assembly 111 and
shipped to the
construction site. The door sill assembly 111 can be installed in the building
entryway. The
protective covers 190 and 195 can be removed once construction of the building
is
complete and discarded. A replaceable sill deck as described above can be
installed.
[046] Figures 7 through 9B show a door sill assembly 210 according to another
embodiment of the invention. Turning to Figures 7 and 8, the door sill
assembly 210
includes a substrate 220 having an upwardly extending nosing 222 and dam 224,
a nosing
cover 260 attached to the substrate 220, and a sill cap 280 in the sill
channel 223.
[047] Figure 8 shows how the substrate 220 engages the nosing cover 260 and
sill deck
240. The substrate 220 includes a first end (or inside facing end) 221, and an
opposite
second end 231. The first end 221 includes an upwardly extending nosing 222
and a dam
224 forming a sill channel 223 therebetween that is sized to receive the sill
cap 280 as
shown. A projection 227 extends in the X-direction from the dam 224 to receive
the deck
242. While one projection is shown, one or more projections can be used.
Further, other
configurations could be employed for securing the deck 242 to the substrate
220, preferably
in the X-and Y-directions.
[048] The second end 231 of the substrate 220 includes a ledge 232, an
indentation 233,
and an undersurface 234 that represents in this embodiment a cutaway or relief
in this
portion of the substrate 220. The ledge 232 is configured to receive a clip
250, as described
below.
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[049] The substrate 220 shown in Figure 8 can be integrally formed to include
the nosing,
dam, and projections. Further, the substrate 220 can be formed similarly to
the substrates as
described in the embodiments above and shown in Figures 1 through 6B.
[050] As shown in Figures 7 and 8, the nosing cover 260 includes a lower ledge
261
secured to a lower lip 228 of the substrate 220. The nosing cover 260 extends
just over the
top of nosing 222 and extending but not reaching the bottom of the sill
channel 223. In
other embodiments, however, a nosing cover 260 can include a nosing portion,
sill channel
cover portion, and an upwardly extending dam, as described above and shown in
Figures 2
and 5.
[051] Figures 7 and 8 show an adjustable sill cap 280 disposed on the sill
channel 223.
The sill cap 280 includes a body 286 having an adjustment element 282 disposed
thereon
and resting atop substrate 220. A leg 287 extends downwardly toward the sill
deck 250 from
the body 286 and spaced therefrom to receive the dam 224. The sill cap 280
function
similar to embodiments described above. For outswing doors, however, the sill
cap leg 287
can include a bulb (not shown) at its distal end to seal with deck 242.
Further, other
features typical of outswing sill caps can be used with replaceable sill decks
and nosing
covers as described herein.
[052] As shown in Figures 7 and 8, the sill deck 240 includes a deck 242 and
clip 250. The
deck 242 engages both the substrate 220 and clip 250, while the clip 250
engages the second
end 231 of the substrate 220. The deck 242 includes a channel 244, a support
leg 246, and a
deck platform 247 for positioning with the clip 250. The channel 244 is sized
to receive the
projection 227 extending from the dam 224. A support leg 246 extends from the
deck 242
and rests atop the substrate 220 to support the deck 242. More than one
support leg can be
used as needed.
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[053] As best shown in Figure 8, the clip 250 has a top 252, bottom 255, and
inner surface
256 that fits around the substrate ledge 232. A plurality of legs 253 and 254
extended from
the inner surface 256 to removeably engage the substrate ledge 232. The first
leg 253, as
described above, is received within the indentation 233. The second leg 254
extends
inwardly in the X-direction to contact the distal end of the substrate ledge
232. The top 252
rests upon a deck platform 247 and the bottom 255 is received on the
undersurface 234 of
the ledge 232.
[054] When the clip 250 engages the deck 242, the clip top 252 rests on the
deck platform
247. The legs 253 and 254 limit horizontal (X-direction) displacement of the
clip 250 about
the substrate 220 while the top 252 and bottom 255 limit vertical (Y-
direction) displacement
of the clip 250 about the substrate. Because vertical and horizontal
displacement of the clip
250 is minimized, the deck 240 is pressed into engagement with the dam
projection 227,
vertical and horizontal displacement of the sill deck 240 about the door sill
assembly 210 is
minimized.
[055] A tool can be used to separate the clip 250 from the deck 242 and
substrate 220. A
tool can be inserted (see arrow marked TOOL) proximate the clip top 252 and
pivoted to
move the clip top 252 away from the deck ledge 247. This movement will raise
the leg 253
out of the indentation 233. This can then allow the clip 250 to slide in the X-
direction of
arrow C away from the deck 242. With the clip 250 removed from the substrate
220, the
deck 242 can be removed from engagement with the dam projection 227 by moving
the
deck 242 in the same X-direction of arrow C. A new sill deck including a new
deck and clip
can be replaced on the door sill assembly by reversing these steps.
[056] Figures 9A and 9B show a door sill assembly 211 with optional temporary
protective
sill deck covers, suitable for use with the substrate 220 described above. A
deck protective
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=
cover 290 includes a deck surface 291 and a plurality of supports 292
extending therefrom
to rest on the substrate 220. A channel 294 receives one of the projections
extending from
the dam 224. A protective sill cap cover 295 can be placed over the nosing
cover 260 to
protect the sill channel 223. The sill cap protective cover 295 includes a
first leg 296 and a
second leg 297 that can contact the nosing 222 and sill channel 223. An
extension leg 298
engages a channel 293 in the deck surface 291, securing the deck protective
cover 290 in
place. The protective covers 290 and 295 can be removed once construction of
building is
complete and the replaceable sill deck as described above can be installed.
[057] Figures 10 through 12B show another door sill assembly, according to
another
embodiment. While the embodiment shown can be used with doors of various
widths, in
one embodiment the door sill assembly is a 5-5/8 inch wide door sill. As shown
in Figures
and 11, the door sill assembly 310 includes a substrate 320, nosing 322 and
substrate dam
324. Also shown is a sill channel 323, nosing cover 360, sill cap 380 in the
channel 323, and
a replaceable sill deck 340. The nosing cover 360, sill channel 323, sill cap
380, and the first
end 321 of the substrate 320 are constructed and function similar to the
equivalent
components of the embodiment described above and shown in Figures 1 and 2A. As
shown best in Figure 11, the second (or outside-facing) end 331 of the
substrate 320
includes a ledge 332, including a lip 335 for engaging a clip 350, as
discussed in detail below.
[058] As shown in Figures 10 and 11, the sill deck 340 includes a deck 342 and
clip 350.
The deck 342 includes a channel 344 for engaging the nosing cover 360, at
least one support
leg 346, and a clip engaging end 345. The channel 344 receives a first
projection 367
extending from the nosing cover 360. The support leg 346 extends from the
undersurface
of the deck 342 to rest atop the substrate 320. One or more support legs can
be used to
support the deck 342, as needed.
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[059] As shown in Figure 11, the clip 350 is integrally formed with and
connected to the
deck 342 at the end 352 of the deck 342. A first clip leg 353 extends
substantially vertically
downwardly. As explained in greater detail below, located at the intersection
between the
deck 342 and the clip 350 is a score line, groove, or weakened area 343. In
the embodiment
shown in Figure 11, the score line 343 is V-shaped. A second clip leg 355
extends inwardly
and at a slight downward angle from the bottom edge of the first clip leg 353.
A third clip
leg 357 extends downwardly substantially vertically downwardly from the edge
of second
clip leg 355. Lastly, a fourth clip leg 359 extends outwardly from the edge of
the third clip
leg 357, and substantially parallel with the second clip leg 355, forming a
shit 358 for
receiving a tool. Extending upwardly and slightly inwardly from the top of the
third clip leg
357 is a projection 356 for engaging the lip 335 on the outermost surface of
ledge 332.
When the deck 342 is slidably installed (by sliding inwardly in the negative X-
direction) on
the substrate 320, the second clip leg 355 will resistantly bow slightly to
allow the projection
356 to snap over lip 335.. The clip is so formed that the second clip leg 355
will be caused
to flex slightly downwardly. As the deck 342 is fully seated, the second clip
leg 355 will
return to its normal position and the projection 356 will engage the lip 335
on the outermost
surface of channel 332. When the deck 342 is fully seated, the second clip leg
355 and the
projection 356 limit vertical (Y-direction) and horizontal (X-direction)
displacement of the
clip 350. A tool can be inserted into the slot 358 and pivoted in the
direction of arrow D,
which will cause the second clip leg 355 to flex downwardly, disengaging the
projection 356.
Continued pivotal movement of the tool in the direction of arrow D will cause
the first clip
leg 353 to pivot about the weakened area of the score line 343, wherein the
clip is
completely disengaged. If desired, continued pivotal movement can cause the
clip 350 to
break at the score line 343, separating the clip 350 from the deck 342. In
either case, this
allows the deck 340 to be completely removable from the door sill assembly 310
without
cutting, modifying, or damaging the surrounding frame structure or door jambs
of the door
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sill assembly, or disassembling the door sill. A new sill deck can be placed
on the substrate
and nosing cover as needed.
[060] Figures 12A and 12B show a door sill assembly 311 with optional
temporary
protective covers that fit the substrate described in Figures 10 and 11 above.
The covers 390
and 395 function similarly to the protective covers described above and shown
in Figures
3A and 3B. The deck protective cover 390 includes a deck surface 391 and a
plurality of
supports 392 extending therefrom to rest on the substrate 320. A channel 394
receives one
of the projections extending from the nosing cover 360. The temporary
protective sill cap
cover 395 can be placed over the nosing cover 360 to protect the sill channel
323. The sill
cap protective cover 395 includes a first leg 396 and a second leg 397 that
can be placed
upon the nosing 322 and sill channel 323. An extension leg 398 engages a
channel 393 in
the deck surface 391, securing the deck protective cover 390 in place. In an
embodiment,
the temporary covers 390 and 395 can be installed on door sill assembly 311
and shipped to
the construction site. The door sill assembly 311 can be installed in the
building entryway.
The protective covers 390 and 395 can be removed once construction of the
building is
complete and discarded. A replaceable sill deck as described above then can be
installed.
[061] Figures 13A through 13B show yet another embodiment of a door sill
assembly 410
with a replaceable sill deck 440 for installation in an entryway with a side
light 400.
Sidelight-type entryways include mullion or mull 415 engaged with the door
sill assembly
410. As shown in Figure 13A, the door sill assembly 410 includes a substrate
420, a nosing
cover 460, sill channel 423 and a replaceable sill deck 440. A sill cap 480
can be used in the
door sill assembly on one side of mull 415 (the sill deck 440 is removed from
Figure 13B for
illustrative purposes). A sidelight cap 410 is disposed on the other side of
the mull 415 in
sill channel 423. The replaceable sill deck 440 can engage the nosing cover
460 and
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substrate 420 as described in the embodiments above and shown in Figures 1
through 12B,
although Figures 13A show the embodiment of Figures 4-5.
[062] Figures 13B, 13C and 13D illustrate how the mull 415, mull boot 470 and
mull riser
475 cooperate to allow the mull 415 to engage the door sill assembly 410, yet
permit sill
deck 440 replacement when needed. In particular, the mull boot 470 includes a
sill channel
engaging end 473, and a sill deck engaging end 474, each having a bottom that
fits the
profile of the nosing cover 460 and sill deck 440.
[063] As shown in Figures 13B, 13C and 13D, a mull riser 475 can be placed on
(and
optionally secured) to the bottom surface of the mull boot 470. The mull riser
475 elevates
the mull boot 470 above the substrate 420 so that the sill deck 442 can slide
partially
between the mull 415 and substrate 420 and engage the nosing cover 460 and
substrate 420.
The mull riser 475 includes an opening (not shown) for a mechanical fastener
to be placed
therethrough to secure the substrate 420, mull boot 470 and mull 415 together.
As shown
in Figure 13C, the lower surface 477 of the mull riser 475 has a cut out 476
for engaging to
nosing cover 460. The mull riser can be separate from the mull boot as shown.
In other
embodiments, the mull riser can be formed directly onto the bottom surface of
the mull
boot.
[064] As shown in Figure 13B, the deck 442 can have a notch 441 to receive the
mull riser
475 as the deck 442 is placed on the substrate 420 and nosing cover 460. The
notch 441
allows the deck 442 to engage the substrate 420 while allowing mull boot 470
to rest on the
sill deck 440 and nosing cover 460. The door sill remains stable and the frame
structure
remains unaffected by removal of the sill deck 440. The installer or user may
form the
notch 441 on the deck 442 prior to installation. In other embodiments, the
notch 441 may
be formed in the deck 442 during manufacture of the sill deck 440. Further,
the deck 442
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can include a longitudinal score line (not shown) that provides visual
indication of where the
terminal end of the notch 441 should be. This score-line allows for easy
construction-site
modification of the deck 442 during installation of the door sill assembly.
[065] Figures 14A through 14C show another embodiment of a mull riser 575 for
use with
a mull 515 and a door sill assembly 510 installed an entryway having a
sidelight 500 and
sidelight cap 510. In the embodiment shown in Figures 14A through 14C, the
mull riser
575 is secured to the bottom surface of the mull 515 and does not include a
mull boot. The
mull riser 575, as described above, elevates the mull 515 above the substrate
520 so that the
sill deck 542 can slide between the mull 515 and the substrate 520 to engage
the nosing
cover 560 and sidelight cap 510. As shown in Figure 14C, the mull riser lower
surface 577
has a cut out 576 for engaging the nosing cover 560.
[066] As described above, a notch 541 in the deck 542 receives the mull riser
575. While
the mull riser 575 is shown as a separate component from the mull, in an
alternate
embodiment, the mull riser can be integrally formed onto the bottom surface of
the mull.
In addition, any of the temporary sill deck protective covers described above
may include a
suitable notch for receiving the mull risers.
[067] Another embodiment of the invention is a method of using a replaceable
sill deck.
A door sill assembly can be provided that includes a substrate having a nosing
and a sill
channel. A nosing cover can be attached to the substrate and extending over at
least a
portion of the nosing and over at least a portion of the sill channel. A sill
deck having a
deck and a clip can be provided for removable attachment to the substrate and
nosing
cover. The deck can be placed onto and receive a portion of the nosing cover.
The clip
can be removably engaged with the substrate. To remove the sill deck, a tool
can be used to
position the clip out of engagement with the substrate and/or deck. The deck
can then be
CA 02802355 2013-01-18
removed from engagement with the nosing cover. Another sill deck can be
replaced by
reversing the above steps.
[068] In another embodiment, the door sill assembly can include one or more
temporary
protective covers placed over a portion of the substrate engaged with the
nosing cover. A
first temporary protective cover can be placed on the sill channel and nosing
cover. A
second temporary protective cover can be placed on the substrate and engage
the nosing
cover or a substrate dam. The door sill assembly with one or more temporary
protective
covers can be installed in an entryway. When construction of the building is
complete, the
temporary protective covers can be removed from the door sill assembly. The
replaceable
sill deck having a deck and clip connected to the deck can be removeably
attached to the
substrate as discussed above.
[069] The replaceable sill deck and temporary protective covers as described
herein can be
used with selectively positionable sill and panel caps in entryways having one
or more fixed
sidelight panels. Selectively positionable sill and panel caps are described
in U.S. Patent No.
5,426,894, the entirety of which is herein incorporated by reference.
Entryways with fixed
sidelight panels can have a continuous sidelight threshold and door sill
assembly. A channel
(similar to 23, 123 or 223 shown in Figures 2, 5, 8, and 11 respectively),
nosing cover
(similar to 60, 160, 260, or 360 in Figures 2, 5, 8, and 11 respectively), can
extend the length
of the continuous threshold. The sill and panel caps can have a length (in the
Z-direction as
shown in the Figures) that is smaller than the length of the channel. A panel
cap can be
selectively positioned in the channel to underlie the fixed sidelight panel.
The sill cap can
also be selectively positionable in a sill channel to underlie the hinged
door. Both the sill
cap and panel cap can engage the replaceable sill deck as described in the
embodiments
above and shown in Figures 1 through 14D.
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[070] The replaceable sill deck and temporary protective covers as described
herein can be
used with substrates formed of two or more substrate sections attached and
interlocked
together end-to-end (not shown). Such interlocking substrates are described in
U.S. Patent
No. 7,350,336. In an embodiment, the substrate can be comprised of at least
first and
second substrate sections. The first substrate section can have dovetail
tongues on one end
thereof, and dovetail grooves on the other end thereof. The dovetail tongue of
the first
substrate section can be received with an interlocked with the dovetail groove
of second
substrate section. In another embodiment, the substrate can have first
substrate section
having at least one protruding element along one end of the substrate section.
A second
substrate section can have at least one slot at one end of the second
substrate section. The
protruding elements of the first substrate section can slidingly engage in an
end-to-end
relationship with the slot of the second substrate section. The interlocking
substrates can
engage a nosing cover and replaceable sill deck as described in the
embodiments above and
shown in Figures 1 through 14D.
[071] Although the present invention has been described with exemplary
embodiments,
the scope of the claims should not be limited by the preferred embodiments set
forth in the
examples, but should be given the broadest interpretation consistent with the
description as a
whole.
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