Note: Descriptions are shown in the official language in which they were submitted.
CA 02842214 2015-06-22
DOOR ENTRYWAY SYSTEM
TECHNICAL FIELD
10021 The present disclosure relates generally to entryway systems for
residential and
commercial buildings and more particularly to threshold assemblies of entryway
systems.
BACKGROUND OF THE DISCLOSURE
[003] Entryway systems used in building construction generally include a pair
of
vertically extending door jambs and a head jamb that frame the entryway and
receive a
hinged door panel. An elongated threshold assembly is attached at its ends to
the
bottoms of the door jambs and spans the bottom of the entryway. Many modern
threshold assemblies include a frame defining an upwardly-open channel from
which a
sill slopes outwardly and downwardly. A threshold cap is disposed in the
upwardly open
channel and underlies a closed door mounted in the entryway. The threshold cap
usually
is manually adjustable (using, for example, screw mechanisms) in a vertical
direction to
engage and form a seal with the bottom of the door panel or a flexible sweep
attached
thereto.
[004] For years, manufacturers of threshold assemblies for entryway systems
have
struggled with preventing the leakage of incidental rain water beneath the
threshold, in
order to avoid rainwater causing rot to the underlying sub floor. One location
where
such incidental leakage is a problem is between the threshold cap and the
underside of a
door panel or door sweep. In this regard, houses can settle after
construction, thus
compromising the weathersealing of the door panel due to movement of the
mating
components from their intended position. Homeowners must then be able to
vertically
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adjust The threshold cap manually in order to correct this issue, which can be
difficult to
properly achieve. Furthermore, cap plugs used to address these issues placed
in
adjustment hardware holes can interfere with the sealing of the threshold cap
to the
underside (e.g., the bottom of the door) of the door panel.
10051 Another location where such incidental leakage is a problem is along the
gap
between a forward wall of the upwardly open channel of the frame and the
threshold cap
that rides in the channel. This region poses a particular leakage problem
because it is
exposed to the elements on the outside of the entryway and, in a blowing rain
for
example, rainwater can be forced by several hydrodynamic mechanisms into the
gap.
When this happens, water can collect in the channel under the threshold cap,
from where
it flows to the ends of the threshold assembly and onto the sub floor below.
10061 A variety of attempts to stem leakage along the gap between the
threshold cap
and its channel have been made over the years. For example, some threshold
assemblies
include an upstanding dam that forms the upper part of the outside channel
wall. It is
also common where plastic threshold caps are used to form the threshold cap
with an
overlapping tongue along its outside edge that overlaps the dam to prevent
leakage of
rainwater from the top of the threshold cap directly into the gap between the
forward
edge of the cap and its channel.
10071 The various techniques used in the past to seal the gap between a
threshold cap
and its channel have generally been less than successful. For example,
flexible bellows-
type seals tend to harden, shrink and crack over time, allowing water to seep
directly
through the bellows and into the channel. Where flexible fins are used to
create the seal,
dirt can accumulate between the fin and the surface of the threshold cap,
breaking the
seal. In addition, in cases where the entryway system may not be installed on
a perfectly
level surface, the threshold assembly can be racked to the extent that the fin
separates
from the threshold cap, resulting in severe leaks and an unsightly appearance.
The seal
also can be affected by the natural differential thermal expansion and
contraction
experienced by the various different materials of the assembly. Even with
plastic
threshold caps with dams and overlapping tongues, leakage still can occur due
to the
capillary effect between the tongues and the dams.
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10081 Accordingly, a need exists for an entryway system that includes a door
entryway
system and threshold assembly that improves management of water, both
incidental and
non-incidental, entering the threshold assembly.
BRIEF SUMMARY OF THE DISCLOSURE
10091 In one embodiment, a door entryway system can include a door sweep
capable of
attachment to a bottom of a door panel. The door entryway system can also
include a
threshold assembly having a self-articulating threshold cap configured to be
biased
toward the door sweep and interact therewith to form a sealing barrier when
the door
panel is in a closed position.
10101 The door entryway system can also include a threshold assembly that can
be
configured to sealingly interact with the door sweep. The threshold assembly
can
include a threshold substrate having a nosing defining one side of an open-
ended sill
channel. Also included in the threshold assembly is a self-articulating
threshold cap that
can be received within the open-ended sill channel. The self-articulating
threshold cap
can be configured to be biased toward the door sweep and interact therewith to
form a
sealing barrier when the door panel is in a closed position. A nosing strip
also can be
secured to the nosing and configured to sealingly engage the self-articulating
threshold
cap.
10111 An additional embodiment of a door entryway system can include a door
sweep
capable of being attached to a bottom of a door panel and a threshold assembly
configured to sealingly interact with the door sweep. The threshold assembly
can
include a threshold substrate defining an open-ended sill channel, and further
comprising
a threshold cap disposed within the sill channel. The threshold assembly can
also
include a self-articulating means for maintaining a sealing barrier between
the door
sweep and the threshold cap when the door panel is in a closed position.
10121 An additional embodiment of a door entryway system can include a door
sweep
capable of being attached to a bottom of a door panel. The door entryway
system can
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also iriclude a'threshold assembly having a self-articulating threshold cap
configured to
be biased toward the door sweep and interact therewith to form a sealing
barrier when
the door panel is in a closed position. The self-articulating threshold cap
can include a
rigid articulating top portion and at least one support base, preferably at
least a support
base disposed at each end of the rigid articulating top portion. The support
bases can be
disposed within an upwardly open sill channel defined by a threshold substrate
or nosing.
10131 Another embodiment of the invention is a threshold assembly for a door
entryway system of a building structure. The threshold assembly can include a
threshold
substrate having a forward end adapted to be disposed exterior to a building
structure.
The forward end can include at least one drain hole configured to allow water
to exit the
threshold substrate. In addition, the threshold assembly can include at least
one air inlet
configured to allow air to enter the threshold substrate. The air inlet can be
separate
from the drain hole. Further, the air inlet can be in an elevated arrangement
with respect
to the drain hole such that water exits the threshold substrate through the at
least one
drain hole.
10141 In the embodiment of the threshold assembly for a door entryway
described
above, the forward end of the threshold substrate can optionally include a
forward edge
with the drain hole and the air inlet can be at least partially defined by the
forward edge.
10151 In the embodiment of the threshold assembly for a door entryway
described
above, the forward edge of the threshold substrate can optionally define a
pair of drain
holes positioned at opposing ends thereof. In such an embodiment, a plurality
of the air
inlets can be disposed between the pair of drain holes along the forward edge.
10161 In the embodiment of the threshold assembly for a door entryway
described
above, the forward edge can define a recess forming the one or more air
inlets.
10171 In the embodiment of the threshold assembly for a door entryway
described
above, the forward edge can optionally include a wall extending substantially
perpendicular to a floor of the threshold substrate. In addition, the forward
edge can
optionally include a lip extending substantially perpendicular from the wall.
The
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forwat'd edge 'can define a recess extending from the wall and about the lip
to form an air
inlet.
[0181 In the embodiment of the threshold assembly for a door entryway
described
above, optionally included thereon is a decking cover plate configured to
extend about
the threshold substrate to form an upper surface thereof. The decking cover
plate can
extend about the lip so as to cooperate with the forward edge to form the at
least one air
inlet.
[019] In the embodiment of the threshold assembly for a door entryway
described
above, the forward edge can include a top surface defining a recess. The
decking cover
plate can extend about the threshold substrate to form an upper surface
thereof. The
optionally decking cover plate can be in abutting contact with the top surface
of the
forward edge to enclose the recess so as to cooperate therewith to form the at
least one
air inlet.
10201 In the embodiment of the threshold assembly for a door entryway
described
above, the threshold substrate is constructed from an injection molded plastic
material.
Other materials can be used to form the threshold substrate.
10211 An additional, second embodiment of a threshold assembly for a door
entryway
system can include a threshold substrate having a nosing defining one side of
an open-
ended sill channel. The threshold substrate can also include a self-
articulating threshold
cap received within the open-ended sill channel. The self-articulating
threshold cap can
be configured to be biased toward one of a door panel and a door sweep and
being
capable of interacting therewith so as to form a sealing barrier therebetween
when the
door panel is in a closed position. In addition, a nosing strip can be secured
to the nosing
and is configured to sealingly engage the self-articulating threshold cap.
Optionally, the
nosing strip can include a resilient fin configured to sealingly engage the
self-articulating
threshold cap.
[022j In the second embodiment of the threshold assembly described above, the
self-
articulating threshold cap can optionally include a rigid top articulating
portion having a
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top will and a' locking wall extending substantially perpendicularly from the
top wall.
The resilient fin can interact with the locking wall to form a sealing barrier
along a length
of the threshold substrate.
10231 In the second embodiment of the threshold assembly described above, the
self-
articulating threshold cap can further optionally include a bottom support
wall disposed
adjacent to a floor of the sill channel. The self-articulating threshold cap
can have a rear
wall operably engaged with and extending substantially perpendicularly from
the bottom
support wall so as to be substantially parallel with an inside surface of the
nosing.
Further, the rear wall can have a projection configured to interact with the
nosing strip to
form a sealing barrier.
[0241 In the second embodiment of the threshold assembly described above,
optionally
included therein is a biasing mechanism configured to interact with the
threshold cap and
to bias the threshold cap against the door sweep when the door panel is in the
closed
position. The biasing mechanism can be disposed within a cavity defined by the
threshold cap.
[025] In the second embodiment of the threshold assembly described above, the
threshold cap can optionally include a rigid articulating top portion capable
of being
deflected by the door panel or door sweep when the door panel is moved toward
the
closed position. The articulating top portion of the threshold cap is capable
of biasing
toward the door panel or the door sweep when the door panel is in the closed
position.
[026] In the second embodiment of the threshold assembly described above, the
threshold cap is optionally an integrally-formed and unitary workpiece
constructed from,
for example, a polymer material.
10271 In the second embodiment of the threshold assembly described above, the
threshold cap can include a bottom support wall capable of engaging a floor of
the sill
channel, a front wall operably engaged with the bottom support wall, a rigid
articulating
top portion extending from the front wall, a rear wall operably engaged with
the bottom
support wall, and an intermediate wall extending from the bottom support wall.
The
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rigid top articUlating portion can include a top wall and a locking wall
extending
substantially perpendicularly from the top wall. The locking wall can extend
between
the rear wall and intermediate wall. The locking wall can have a hook portion
configured to interact with the intermediate wall to prevent the locking wall
from entirely
advancing therepast.
10281 In the second embodiment of the threshold assembly described above, the
threshold substrate is optionally constructed from an injection molded plastic
material.
10291 Yet another embodiment of the invention is a threshold cap capable of
being
received within a sill channel of a threshold assembly for a door entryway.
The
threshold cap can include a bottom support wall capable of engaging a floor of
the sill
channel. A front wall can be operably engaged with the bottom support wall and
has at
least a portion thereof being substantially perpendicular to the bottom
support wall. The
threshold cap can also include a rigid articulating top portion extending from
the front
wall. The articulating top portion can be configured to bias against one of a
door sweep
mounted to a door panel when the door panel is in a closed position.
10301 In the embodiment of the threshold cap describe above, the rigid
articulating top
portion can be biased upwardly toward the door sweep by a resilient hinge
disposed
between the articulating top portion and the front wall.
10311 In the embodiment of the threshold cap described above, optionally
included is a
dam sealing projection extending from the front wall in a direction opposite
to the rigid
articulating top portion. The dam sealing projection is capable of extending
over and
around the front of the sill channel dam to provide a sealing engagement with
the dam.
10321 In the embodiment of the threshold cap described above, optionally
included is a
rear wall operably engaged with and extending substantially perpendicularly
from the
bottom support wall so as to be substantially parallel with the front wall.
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10331 In the embodiment of the threshold cap described above, the rear wall
optionally
includes a longitudinally extending projection configured to interact with the
threshold
assembly to form a sealing barrier along the sill channel.
[034] In the embodiment of the threshold cap described above, optionally
included on
the rigid top articulating portion is a top wall and a locking wall extending
substantially
perpendicularly from the top wall.
[035] In the embodiment of the threshold cap described above, optionally
included is an
intermediate wall having a first leg and a second leg. The first leg can
extend
perpendicularly from the bottom support wall and the second leg can depend
perpendicularly from the first leg toward the rear wall. The locking wall can
extend
between the rear wall and the second leg and can have a hook portion
configured to
interact with the second leg to prevent the locking wall from advancing
entirely
therepast.
[036] In the embodiment of the threshold cap described above, optionally
included is a
biasing mechanism adapted to bias the top portion toward the one or both of
the door
panel and the door sweep assembly. Such biasing allows sealing contact
therewith when
the door panel is in the closed position. The biasing mechanism can be
disposed within a
cavity at least partially defined by the bottom support wall, the front wall
and the
articulating top portion.
[037] In the embodiment of the threshold cap described above, the threshold
cap can
optionally be an integrally-formed and unitary workpiece constructed from a
polymer
material.
[038] In the embodiment of the threshold cap described above, optionally the
front wall
includes a cap leg capable of being received within a spacer of the threshold
assembly.
10391 An additional embodiment of the invention is a door sweep for a door
entryway
system. The door sweep can include a support wall capable of attachment to a
bottom of
a door panel. The support wall can have a first edge and a second edge. The
door sweep
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can alto include a resilient sealing provision disposed at the first edge of
the support
wall. The resilient sealing provision is capable of sealingly engaging a self-
articulating
threshold cap of the door entryway system when the door panel is in a closed
position.
Included in the door sweep can be a rigid arm, extending from the support wall
and being
capable of interacting with the self-articulating threshold cap to deflect a
top portion
thereof downward when the door panel is moving toward the closed position. The
rigid
arm is capable of sealingly engaging the self-articulating threshold cap when
the door
panel is in a closed position.
[0401 In an embodiment of the door sweep described above, optionally included
is a
resilient fin disposed at the second edge of the support wall and extending
outwardly
therefrom. The resilient sealing provision can be a resilient bulb capable of
interacting
with the self-articulating threshold cap when the door panel is in a closed
position.
10411 In the embodiment of the door sweep described above, the rigid arm can
optionally be integrally formed with the support wall.
10421 In the embodiment of the door sweep described above, optionally the
rigid arm
and the resilient sealing provision are separate and discrete components.
10431 In the embodiment of the door sweep described above, the rigid arm can
optionally include an inclined portion angularly extending from the support
wall. The
rigid arm can also include an arcuate portion extending from the inclined
portion. Both
the arcuate portion and the inclined portion can be configured to interact
with the self-
articulating threshold cap such that the threshold cap is initially deflected
away from the
support wall by the inclined portion and then maintained in sealing contact
with arcuate
portion when the door panel is in the closed position.
10441 In the embodiment of the door sweep described above, optionally the
rigid arm is
a plastic material.
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10451 In the embodiment of the door sweep described above, optionally included
therein is at least one rigid mounting leg with flexible barbs for matingly
engaging at
least one slot in the door panel bottom face.
[046] An additional embodiment of a door sweep can include a support wall
capable of
attachment to a bottom of a door panel. The support wall can have a first edge
and a
second edge. The door sweep can also include a resilient sealing provision
disposed at
the first, interior, edge of the support wall. The resilient sealing provision
is capable of
sealingly engaging a self-articulating threshold cap of the door entryway
system when
the door panel is in a closed position. Included in the door sweep can be a
rigid arm
extending obliquely from the support wall in close proximity to the resilient
sealing
provision, and being capable of interacting with the self-articulating
threshold cap to
deflect a top portion thereof into proper engagement with the resilient
sealing provision.
Included in the door sweep can be a second rigid member extending downwardly
from
the support wall near the second, exterior, edge of the support wall. The
second rigid
member is positioned to initially deflect the top portion of the self-
articulating cap while
the door panel is being closed.
[047] Another embodiment of the invention is a water management system for a
door
entryway system. The water management system can include a threshold assembly
adapted to span a door entryway along a length thereof The threshold assembly
can
include a threshold substrate defining an open-ended sill channel between a
first wall and
a second wall. A threshold cap can be positioned within the sill channel and
can have a
front wall facing and spaced apart from the first wall so as to form a gap
therebetween,
in the absence of at least one sealing provision provided along the length of
the gap for
sealing thereof
[048] In the embodiment of the water management system described above,
optionally
included therein is at least one spacer that is at least partially disposed
between the front
wall and the first wall so as to maintain the gap formed therebetween. The
spacer can
extend partially along a length of the gap corresponding to the length of the
door
entryway such that water is capable of entering the threshold assembly via the
gap.
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[049] = In the embodiment of the water management system described above, the
first
wall can be a substrate dam and the second wall can be a nosing.
10501 In the embodiment of the water management system described above,
optionally
included therein are a plurality of the spacers. The spacers can be spaced
apart along the
length of the gap and each spacer can be at least partially disposed between
the front wall
and the first wall so as to maintain the gap formed therebetween. The spacing
between
adjacent spacers allows water to enter the threshold assembly via the gap.
[051] In the embodiment of the water management system described above, the
gap
distance between the front wall and the first wall can be about 2.0 mm to
about 5.0 mm.
In other embodiments, however, the gap distance can be smaller than 2.0 mm or
larger
than 5.0 mm.
[052] In the embodiment of the water management system described above,
optionally
one spacer can define a spacer channel and a portion of the threshold cap can
be received
within the spacer channel for securing thereto.
[053] In the embodiment of the water management system described above, the
threshold substrate can optionally define at least one chamber in fluid
communication
with the sill channel via a drain channel defined by the first wall and
extending
therethrough.
10541 In the embodiment of the water management system described above, the
threshold substrate optionally includes at least one drain hole in
communication with the
at least one chamber. The drain hole (or holes) can be disposed about an
exterior edge of
the threshold substrate and configured to allow water contained within the
chamber to
exit the threshold substrate.
[055] In an embodiment of the water management system described above,
optionally
included in the threshold assembly can be a decking cover plate positioned
adjacent to
the threshold substrate. The decking cover plate can have a decking dam
disposed in
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planaerelatioil to the first wall such that the decking dam forms an extension
thereof with
respect to the sill channel.
10561 The invention can include yet an additional, second, embodiment of a
water
management system for a door entryway system. The water management system can
include a threshold assembly adapted to span a door entryway along a length
thereof.
The threshold assembly can define an open-ended sill channel for at least part
of the
entryway length. Also included is a water management means for directing water
received within the open-ended sill channel out of the threshold assembly. In
addition, a
gap means can ensure that a gap is provided at the open-ended sill channel
such that
water is capable of flowing therein.
[057] The second embodiment of the water management system described above can
optionally include a drain path means for directing water received within the
open-ended
sill channel out of the threshold assembly.
[058] The second embodiment of the water management system described above can
include an optional chambering means for directing water received within the
open-
ended sill channel out of the threshold assembly. Also included is an air
pressure
equalization means for improving water exit flow from the threshold assembly
and air
flow into the threshold assembly. The air pressure equalization means can
include a
drain means for draining water from the threshold assembly and air inlet means
for
allowing air to flow into the threshold assembly separate from the drain
means.
10591 These and other features, aspects, and advantages of the disclosure will
be
apparent from a reading of the following detailed description together with
the
accompanying drawings, which are briefly described below.
BRIEF DESCRIPTION OF THE DRAWINGS
10601 Having thus described the disclosure in general terms, reference will
now be
made to the accompanying drawings, wherein:
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[061] FIG. Y is a cross-sectional side elevation view of an entryway system
having a
threshold assembly with a self-articulating threshold cap, and implementing a
water
management system in accordance with the present disclosure;
[0621 FIGS. 2-6 are cross-sectional side elevation views of various entryway
systems
having a threshold assembly with one of a fixed threshold cap and a manually
adjustable
threshold cap, and implementing a water management system in accordance with
the
present disclosure;
[063] FIGS. 7-11 are various views of a threshold assembly having a plurality
of
spacers disposed between a threshold base substrate and a threshold cap for
implementing a water management system in accordance with the present
disclosure;
10641 FIGS. 12 and 13 are perspective views of a threshold base substrate for
use in
accordance with various aspects of the present disclosure;
10651 FIGS. 14-16 are perspective views of a threshold assembly having drain
holes
and separate air inlets, according to one aspect of the present disclosure;
[066] FIG. 17 is a perspective view a threshold assembly having a self-
articulating
threshold cap, according to one aspect of the present disclosure;
[067] FIG. 18 is a side elevation view of a threshold assembly having a self-
articulating
threshold cap in an unbiased position, according to one aspect of the present
disclosure;
10681 FIG. 19 is a side elevation view of a threshold assembly having a self-
articulating
threshold cap in a biased position, according to one aspect of the present
disclosure;
[069] FIGS. 20 and 21 are perspective views of a self-articulating threshold
cap,
according to one aspect of the present disclosure;
[070] FIG. 22 is a perspective view of a door sweep, according to one aspect
of the
present disclosure;
[071] FIG. 23 is a cross-sectional side elevation view of a threshold assembly
having a
self-articulating threshold cap not interacting with a door panel in an open
position,
according to one aspect of the present disclosure; and
[0721 FIG. 24 is a cross-sectional side elevation view of a threshold assembly
having a
self-articulating threshold cap interacting with a door sweep of a door panel
between a
closed and an open position.
[073] FIG. 25A is a perspective view of another embodiment of the threshold of
the
present disclosure with door jamb elements shown.
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10741 FIG. 25B is a perspective view of the threshold of FIG. 25A with the
door jamb
elements removed.
10751 FIG. 26 is an exploded view of the threshold of FIG. 25A.
10761 FIG. 27 is a cross-sectional side elevation view of the threshold of
FIG. 25 in use
with another embodiment of a door sweep according to the present disclosure.
DETAILED DESCRIPTION OF THE DISCLOSURE
10771 The present disclosure now will be described more fully hereinafter with
reference to certain preferred aspects. These aspects are provided so that
this disclosure
will be thorough and complete, and will fully convey the scope of the
disclosure to those
skilled in the art. Indeed, the disclosure may be embodied in many different
forms and
should not be construed as limited to the aspects set forth herein; rather,
these aspects are
provided so that this disclosure will satisfy applicable legal requirements.
As used in the
specification, and in the appended claims, the singular forms "a", "an",
"the", include
plural referents unless the context clearly dictates otherwise.
10781 FIGS. 1-6 each illustrate an entryway system 10 having a threshold
assembly 11
including a threshold substrate 12, which, in some instances, may be a
unitarily molded
plastic workpiece. The threshold substrate 12 may be configured to define a
longitudinally extending, upwardly open, sill channel 13. The sill channel 13
is flanked
along its outside edge by a first channel wall 14 and along its inside edge by
a second
channel wall, i.e. nosing 15. The first channel wall 14 and the nosing 15 form
the
outside and inside walls, respectively, of the sill channel 13. The sill
channel 13 can be
sized to receive a threshold cap 100 (self-adjustable (see FIG. 1); non-
adjustable (see
FIG. 3); or vertically adjustable (see FIGS. 2 and 4-6)) for underlying a door
panel 200
in a closed position. The threshold substrate 12 preferably is made of a
deterioration
resistant material, but may be made of any other material with appropriate
support such
as, for example, wood. In some instances, the threshold substrate 12 may be
formed by a
traditional injection molding process, or by an extrusion process.
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1079] ' As usdd herein, the term "threshold cap" refers to any element that
substantially
underlies the end of a door panel, when the door is closed. In embodiments
that include
a nosing and a dam, the threshold cap bridges the gap between the nosing and
the dam of
a threshold. Also, a threshold cap is formed of a rigid material providing a
portion of the
tread (the portion that is walked on and over) of the threshold, and is not
made from
covered foam as commonly found in weatherstrips.
10801 In some instances, a nosing strip 16 may be attached to an inside edge
17 of the
sill channel 13 so as to extend upwardly therefrom over the nosing 15.
According to
some aspects, the nosing strip 16 may extend across the sill channel 13 to
cover a floor
18 thereof A downwardly projecting nosing barbed tab 19 can be positioned and
configured to be snapped into place within a nosing attachment slot 20 to hold
the nosing
strip 16 securely in place within the sill channel 13.
[081] A decking cover plate 21 may be attached with appropriate means (e.g.,
mechanical, adhesive, etc.) to the threshold substrate 12 and forms an upper
tread surface
22 of the threshold assembly 11. According to some aspects, the decking cover
plate 21
may include an upstanding decking dam 23 that extends upward from the first
channel
wall 14 to provide a water entry barrier that reduces the amount of water
directly
entering the sill channel 13. The decking cover plate 21 may have a contoured
outside
edge portion 24 (see FIGS. 14-19) configured to fit over the compatibly
contoured
forward edge 25 of the threshold substrate 12. A downwardly projecting barbed
decking
tab 26 may be formed along an underside surface 27 of the decking cover plate
21 and
may be positioned and configured to be snapped into place within a decking
attachment
slot 28 to hold the decking cover plate 21 securely in place on the threshold
substrate 12.
[082] While the threshold assemblies 11 of FIGS. 1-6 have discrete components
(e.g.,
the threshold substrate 12, the decking cover plate 21, and the nosing strip
16), it will be
understood that this is not a limitation of the disclosure. That is, in some
embodiments,
the threshold assembly I lean be formed completely from an aluminum extrusion,
can be
formed completely from an extruded or injection molded plastic material, or
may be a
combination thereof. The particular construction of the threshold assembly 11
illustrated
in FIGS. 1-6 is chosen because it is a common construction and because it
serves well to
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illustrate the present disclosure. Those of skill in the art will understand,
however, that a
variety of threshold assembly constructions may well be used without departing
from the
spirit of the present disclosure.
[083] The elongated threshold cap 100 is disposed in and projects upwardly
from the
upwardly open sill channel 13. The threshold cap 100 may be formed of single
or
multiple materials or components, wherein such suitable materials may include
wood,
plastic, a composite, or another appropriate material. The threshold cap 100
is
positioned to underlie a closed door panel 200 mounted in an entryway that
includes the
threshold assembly 11. In some instances, as shown in FIGS. 2 and 4-6, an
array of
vertical adjustment screw mechanisms 29 may be provided for selectively and
manually
adjusting the height of the threshold cap 100 such that the threshold cap 100
sealingly
engages a door sweep 300 mounted to a bottom edge 201 of a closed door panel
200 to
form a seal between the bottom edge 201 of the door panel 200 and the
threshold cap
100. A door sweep 300 can be formed of multiple components.
10841 According to aspects of the present disclosure, a gap 30 may be formed
between
the forward cap edge 31 of the threshold cap 100 and an inside surface 32 of
the first
channel wall 14 that defines an outside wall of the sill channel 13. The gap
30 may be in
the range of about 0.08 inches (2.03 mm) to about 0.20 inches (5.08 mm)
between the
forward cap edge 31 and the inside surface 32. For instance, a common
dimension of the
gap 30 in the threshold assembly 11 may be about 0.14 inches (3.55 mm). Since
the gap
30 is exposed to the elements on the outside of a building structure, it can
afford the
opportunity for rainwater to leak or seep into the upwardly open sill channel
13 and
ultimately to the sub floor upon which the threshold assembly 11 rests. In
this regard,
prior threshold assemblies have attempted to provide a watertight barrier
within or
otherwise about the gap 30, using sealing provisions, such as, for example,
weatherstripping, flexible foam tape, etc., to prevent water from entering the
sill channel
13. Accordingly, prior threshold assemblies intend to prevent water from
entering the
interior of the building structure by attempting to plug all possible water
entry points.
However, this is difficult to achieve and such sealing provisions typically
allow at least
some incidental water to seep or otherwise leak into the sill channel 13.
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10851 ' Such prior threshold assemblies may thus provide drain systems that
attempt to
remove the incidental water from the sill channel 13. However, such prior
drain systems
may only be capable of handling minimal amounts of water (i.e., incidental
water that
has leaked through the seal and into the sill channel). In this regard, prior
threshold
assemblies may not be equipped to handle non-incidental water (i.e., water
that is
naturally allowed to flow or otherwise enter the sill channel, rather than
just minimally
leak or seep into the sill channel). Moreover, such prior threshold assemblies
may have
not envisioned allowing such non-incidental water to enter the threshold
assembly.
10861 Accordingly, aspects of the present disclosure seek to allow non-
incidental water
to enter the threshold assembly 11 and then appropriately manage such non-
incidental
water. That is, the entryway system 10 of the present disclosure is configured
to allow
water to enter the sill channel 13 on the exterior of any sealing provisions
and then
manages the water and provides an avenue for water drainage out of the
threshold
assembly 11. As such, the gap 30 is not entirely filled or otherwise entirely
protected
with a sealing mechanism(s) and is, instead, allowed to remain at least
partially open-
ended to receive non-incidental water therein.
10871 In this regard, the present disclosure accepts that at least some water
will enter
the threshold assembly 11 regardless of the attempted sealing of the gap 30,
and, as such,
the present disclosure provides a water management system that allows non-
incidental
water into the threshold assembly 11 and then appropriately manages the water
out
thereof. To that end, some aspects of the present disclosure are directed to
providing an
unobstructed water entry path from the gap 30 to the exterior of a building
structure. In
some instances, water entry barrier provisions (e.g., flange 304, decking dam
23, fin 301
(see FIG. 6)) may be provided in which such provisions help define the water
entry path.
But, such provisions do not obstruct the water entry path and instead may, in
some
instances, only assist in defining the water entry path. In other instances,
sealing
provisions (e.g., fin 301 (see FIGS. 2-4)) may be provided wherein the water
leaks or
otherwise seeps through the sealing provision and into the sill channel 13 via
the gap 30.
10881 Accordingly, aspects of the present disclosure may provide the gap 30 as
partially
or entirely unobstructed such that water may flow directly into the sill
channel 13. For
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exam*, in sOme instances, the threshold cap 100 may be positioned or secured
toward
the nosing 15 such that the gap 30 is provided between the threshold cap 100
and the first
channel wall 14. Appropriate securement or fastening mechanisms may be
provided for
ensuring that the threshold cap 100 maintains its spacing from the first
channel wall 14 to
maintain the gap 30. That is, the threshold cap 100 may be secured toward the
nosing 15
so as to maintain the gap 30.
[089] In other instances, one or more spacers 33 may be positioned within the
gap 30 to
maintain the gap 30 between the forward cap edge 31 of the threshold cap 100
and an
inside surface 32 of the first channel wall 14. When a plurality of the
spacers 33 is
provided, the spacers 33 are spaced apart from each other along a length of
the sill
channel 13 spanning an entryway, as shown in FIGS. 7-11. In some instances,
the
spacers 33 may define a spacer channel 34 (FIGS. 1-6) configured to receive a
portion of
the threshold cap 100 (e.g., a cap leg 101 of a front wall 106 of the
threshold cap 100) for
securing the spacers 33 within the sill channel 13. The spacers 33 may be
disposed
between the forward cap edge 31 of the threshold cap 100 and the inside
surface 32 of
the first channel wall 14 to maintain the gap 30. As such, water may enter the
sill
channel 13 between the spacers 33. That is, since the spacers 33 do not extend
along the
length of the sill channel 13 to fully fill the gap 30, there are formed
openings 35
between the spacers 33 that allow water to enter the sill channel 13. In this
regard,
portions of the gap 30 may be left unfilled such that no sealing mechanism is
provided
between the threshold cap 100 and the first channel wall 14.
[090] However, in some instances, a sealing provision (e.g., a fin 301) may be
provided
on the door sweep 300 to limit the amount of water allowed to unimpededly
enter the sill
channel 13, as shown in FIGS. 2-4. Further, in some instances, the decking dam
23 may
provide a similar function (i.e., providing at least some impedance to water
entry into the
threshold assembly 11).
[091] In some instances, a single spacer 33 of unitary construction may be
provided and
extended partially or entirely along the length of the threshold assembly 11,
wherein the
spacer 33 itself may define one or more vertical slots (not shown) extending
therethrough
or otherwise defined thereby that allow the water to enter the sill channel
13.
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[092] The spacers 33 may be of various configurations, as illustrated in FIGS.
1-6. The
specific configuration of the spacer 33 may typically depend upon the type of
threshold
cap 100 incorporated into the threshold assembly 11. Preferably, the spacer 33
may
interlock or otherwise securely engage the threshold cap 100 in an
interference or snap
fit. For example, the spacer 33 may define a spacer channel 34 configured to
receive a
portion of the threshold cap 100 such as, for example, the cap leg 101. In
some
instances, the spacer 33 may be configured to accommodate the vertical
adjustment
screw mechanisms 29 associated with the vertically adjustable threshold cap
100 (FIGS.
2 and 4-6). In other instances, as shown in FIG. 3, the spacer 33 may include
one or
more spacer walls 56 capable of interacting with various portions of the
threshold cap
100. Furthermore, in some instances, the spacer 33 may extend substantially
entirely
along the floor 18 of the sill channel 13 between the first channel wall 14
and the nosing
15.
10931 Upon entering the gap 30 and flowing into the sill channel 13, the water
is
managed and directed out of the threshold assembly 11 through the threshold
substrate
12. As shown in FIGS. 10-13, the threshold substrate 12 is configured to
direct the water
from the sill channel 13 out of the threshold assembly 11 via a path that
causes the water
to eventually exit via one or more drain holes 36 (i.e., weep holes). More
specifically,
the water is directed out of the sill channel 13 through one or more drain
channels 37
defined by the first channel wall 14. The spacers 33 may be offset from the
drain
channels 37 such that the water can flow from the sill channel 13 into the
drain channels
37 according to the corresponding drain path. The water may then be directed
out of the
drain holes 36 via gravity flow due to a substrate floor 38 of the threshold
substrate 12
being downwardly sloped from the sill channel 13 toward the forward edge 25 of
the
threshold substrate 12.
[094] FIGS. 10-13 illustrate a threshold substrate 12 for installation in a
threshold
assembly 11 according to the present disclosure, where the threshold substrate
12 may
comprise molded plastic. The threshold substrate 12 is formed with the forward
edge 25,
a back edge 39, and a pair of side edges 40, 41. The sill channel 13 is
defined adjacent
and along the back edge 39 of the threshold substrate 12 for receiving and
holding the
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threshold cap '100. The sill channel 13 is bounded along the back edge 39 of
the
threshold substrate 12 by the nosing 15. An array of spaced apart support
walls 42
extend from the first channel wall 14 proximate to the forward edge 25 of the
threshold
substrate 12. In this regard, the decking cover plate 21 may be snapped or
otherwise
secured in place on the threshold substrate 12 covering and being supported by
the
support walls 42 thereof. The first channel wall 14, the support walls 42, the
forward
edge 25, and the side edges 40, 41 cooperate to form a plurality of chambers
43 that, in
some instances, may be continuously connected. That is, as shown in FIG. 10,
the
support walls 42 do not extend to the forward edge 25 of the threshold
substrate 12. In
this manner, the drain holes 36 may be positioned at opposing side ends of the
threshold
substrate 12. In some instances, the chambers 43 may be closed such that water
cannot
flow from one chamber 43 to another. In such instances, each chamber 43 may
include a
corresponding drain hole 36 for permitting removal of water therefrom. A
deflector wall
44 may be provided so as to direct water toward the drain holes 36. Additional
back
pressure walls 42A, 42B assist in preventing water inflow caused by back
exterior
pressure.
10951 Accordingly, the drain channels 37, which communicate with the sill
channel 13
and the drain holes 36, form a water management system for the threshold
assembly 11.
More specifically, rain water that may collect in the sill channel 13 via the
gap 30 is
channeled away from the sill channel 13 by flowing to the forward edge 25 of
the
threshold substrate 12, into the drain channels 37, through the chambers 43,
and out the
drain holes 36. In this manner, the non-incidental rainwater is appropriately
managed
such that there is no path for water to leak beneath the threshold assembly
and rot or
otherwise deteriorate the subfloor upon which it rests and all water is
drained to the
forward edge 25 of the threshold assembly 11 and out thereof.
[0961 As shown in FIGS. 14-16, according to one aspect of the present
disclosure, the
outside edge portion 24 of the decking cover plate 21 fits over the forward
edge 25 of the
threshold substrate 12. In some instances, the forward edge 25 of the
threshold substrate
12 may define a lip 45 extending beyond a forward wall 46 of the threshold
substrate 12,
which may be substantially perpendicular to the substrate floor 38 (FIGS. 11-
12). In this
regard, the outside edge portion 24 of the decking cover plate 21 may be
correspondingly
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configured to'mate with the lip 45, such as, for example, the outside edge
portion 24
having a U-shaped profiled configured to wrap about the lip 45. In such a
configuration,
the decking cover plate 21 terminates above the ground surface such that the
drain holes
36 (as defined by the forward wall 46 of the threshold substrate 12) are not
covered
thereby. That is, the outside edge portion 24 does not extend the entire
height of the
forward wall 46 so as to leave a portion thereof uncovered. Such a
configuration
eliminates the need to provide or otherwise define corresponding drain holes
36 in the
decking cover plate 21.
[0971 As shown in FIGS. 10-12, 14 and 15, according to further aspects of the
present
disclosure, one or more air inlets 50 may be provided in addition to and
separate from the
drain holes 36. The air inlets 50 allow air to enter the chambers 43 defined,
for example,
between the threshold substrate 12 and the decking cover plate 21. According
to one
particular aspect, the forward wall 46 of the threshold substrate 12 may at
least partially
define the air inlets 50 (e.g., slots) at an upper end 47 thereof for allowing
air to enter the
chambers 43. In this regard, the one or more air inlets 50 may be provided in
an elevated
arrangement with respect to the drain holes 36. In such a configuration, the
water may
exit the threshold assembly 11 through the drain holes 36 and not through the
air inlet(s)
50.
[098] In instances where the threshold substrate 12 is injection molded, the
forward
wall 46 may be injection molded with recesses that define the air inlets 50.
Further, the
air inlets 50 may extend from a vertical surface 48 of the forward wall 46 and
over a
chamfered portion 55 and a top surface 49 of the forward edge 25, such that
the decking
cover plate 21 is flush against the top surface 49 of the forward edge 25
except at the
recessed air inlets 50. That is, the decking cover plate 21 cooperates with
the forward
wall 46 and forward edge 25 of the threshold substrate 12 to form the air
inlets 50,
wherein the decking cover plate 21 provides an upper barrier. Such separate
air inlets 50
and drain holes 36 provide advantages over prior art threshold assemblies,
which have
drain holes that provide both an exit for water and an inlet for air to enter
the threshold
assembly 11 for equalizing air pressure therein.
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10991 That i , in prior threshold assemblies, the drain holes typically are
used not only
to provide an exit for water, but to also allow air to enter the threshold
assembly for
equalizing air pressure therein. However, such configurations typically allow
air to enter
the drain holes to the detriment of allowing water to exit therefrom. In this
regard,
allowing air to enter only through the drain holes can create a bubbling
effect. As such,
aspects of the present disclosure provide air inlets 50 separate from the
drain holes 36,
which allows air to enter the chambers 43 via a mechanism other than the drain
holes 36.
101001 According to further aspects of the present disclosure, as particularly
shown in
FIGS. 1, 17-19, 23 and 24, the threshold assembly 11 may include a self-
articulating or
self-adjusting threshold cap 100. That is, one aspect of the present
disclosure is a self-
articulating threshold cap 100 capable of self-adjusting to sealingly interact
with the
underside of the door panel 200 or otherwise with the door sweep 300 attached
to the
underside of the door panel 200. Self-adjusting refers to the ability for the
threshold cap
100 to change height without manual intervention. In most cases, this self
adjustment
provides a change in the vertical displacement of the threshold cap 100
relative to the
threshold assembly 11. In other words, the threshold cap 100 may self-bias
against the
door panel 200 to maintain contact therewith, regardless of settling of a
building or other
cause that creates additional or reduced space between the threshold cap 100
and the
door panel 200 or door sweep 300. As used herein, "bias" or "biasing" is
defined as
exerting force in a particular direction. In this embodiment, the bias of the
threshold cap
100 causes the forming of a sealing barrier when door is closed. This barrier
is formed
regardless of the differences in spacing that might occur between these two
elements.
Such a configuration is contrasted with prior threshold caps that are fixed or
otherwise
manually adjustable in a vertical direction using, for example, vertical
adjustment screw
mechanisms 29 (see FIGS. 2-6). The threshold cap 100 may be configured for
removal
and replacement within a threshold assembly 11 either before or after
installation thereof
in an entryway. In some instances, the threshold cap 100 may include a
mechanism,
integral or otherwise, causing it to remain in contact with the door panel 200
as intended.
In this regard, the threshold cap 100 is not manually adjusted, but instead
may be
displaced by the movement of the mating door panel 200 or the door sweep 300.
The
threshold cap 100 may be integrally formed and may be constructed from a
plastic or
polymeric material using, for example, an extrusion process. The material of
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constrktion Of the threshold cap 100 may have a hinge feature that allows the
threshold
cap 100 to inherently bias against the door panel 200 when in contact
therewith. That is,
the threshold cap 100 may be formed of a polymeric material that permits at
least a
portion thereof to flex or otherwise deflect in accordance with the structural
aspects of
the present disclosure. In this regard, the threshold cap 100 may include an
integral
feature causing a portion thereof to tend to stay in a position biased toward
the door
panel 200 or the door sweep 300. According to some aspects, the threshold cap
100 may
include supplemental biasing mechanisms used to assist a portion of the
threshold cap
100 to tend to stay in an upward position (e.g., a biasing spring 51).
101011 As shown in FIGS. 17-21, according to one particular aspect of the
present
disclosure, the threshold cap 100 may include a rigid articulating top portion
102 having
a continuous surface 103 capable of interacting with the door panel 200 or the
door
sweep 300. The threshold cap 100 may include a stationary body comprising a
bottom
support wall 104, a rear wall 105 and a bottom support wall 106 in a hinged
relationship
with the rigid articulating top portion 102. The bottom support wall 104 is
capable of
being disposed within the sill channel 13 to engage the floor 18 thereof. The
rear wall
105 may extend perpendicularly from the bottom support wall 104. The rear wall
105
may include a projection 114 capable of interacting with the nosing 15 or the
nosing strip
16 (when provided) to form a sealing barrier therewith. The front wall 106 may
depend
from the bottom support wall 104 or otherwise be connected thereto via, for
example, an
arcuate portion 113, and at least a portion of the front wall 106 may be
substantially
perpendicular to the bottom support wall 104. In some instances, the front
wall 106 may
include an extension, such as, for example, the cap leg 101, configured to be
securely
received within the spacer channel 34. The articulating top portion 102
extends from the
front wall 106. The articulating top portion 102 is configured to self-bias
against the
underside of the door panel 200 or the door sweep 300 when the door panel 200
is in the
closed position. The articulating top portion 102 may include a top wall 107
and a
locking wall 108 extending substantially perpendicular to the top wall 107.
The area of
the articulating top portion 102 that is proximate to the intersection of the
top wall 107
and the locking wall 108 forming the uppermost portion.
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101021 The threshold cap 100 may further include an intermediate wall 109
disposed
between the rear wall 105 and the front wall 106. The intermediate wall 109
acts to
constrain the articulating top portion 102. The intermediate wall 109 may
include a first
leg 110 and a second leg 111. The first leg 110 may extend perpendicularly
from the
bottom support wall 104. The second leg 111 may depend perpendicularly from
the first
leg 110 toward the rear wall 105. The locking wall 108 may extend between the
rear
wall 105 and the second leg 111. In some instances, the locking wall 108 may
have a
hook portion 112 configured to interact with the second leg 111 to prevent the
locking
wall 108 from advancing therepast, thereby limiting the upward travel of the
articulating
top portion 102. A cap leg 101 may be provided for being received within the
spacer
channel 34 such that each spacer 33 is maintained within the sill channel 13.
It is noted
that the described legs, walls, and portions of the threshold cap 100
substantially extend
along the entire length thereof.
101031 FIG. 23 illustrates one aspect of a threshold assembly 11 according to
the present
disclosure in which the door panel 200 is in an open position, wherein the
threshold cap
100 is not interacting with the door sweep 300. In some instances, the self-
articulating
threshold cap 100 may include the biasing spring 51 or other biasing mechanism
configured to bias the articulating top portion 102 of the threshold cap 100
in an
upwardly position for interacting with the door sweep 300. In some instances,
the
biasing spring 51 or other biasing mechanism may be disposed within a cavity
115
generally defined by the threshold cap 100 and extending along the length
thereof. In
some instances, the cavity 115 may be defined by the bottom support wall 104,
the
arcuate portion 113, the front wall 106, the intermediate wall 109, and the
articulating
top portion 102.
101041 FIG. 24 illustrates the door panel 200 in a partially closed position,
wherein the
door sweep 300 has started to engage and interact with the threshold cap 100.
As shown,
the door sweep 300 interacts with the threshold cap 100 so as to force the top
portion 102
thereof downward such that at least a portion of the door sweep 300 can
advance
therepast. More particularly, the door sweep 300 interacts with the top
portion 102 to
force the top wall 107 downward from an inclined position to an orientation
substantially
parallel to the bottom support wall 104. In this manner, the top portion 102
may move
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from d biased'position to an unbiased position when interacting with the door
panel 200
or the door sweep 300.
101051 FIG. 1 illustrates the door panel 200 in a closed position, wherein the
door sweep
300 is entirely engaged with the threshold cap 100 along the length of the
threshold
assembly 11. In this regard, the rigid articulating top portion 102 of the
threshold cap
100 is biased upward toward the door panel 200 to sealingly interact with a
resilient bulb
302 of the door sweep 300 to form a sealing barrier. As used herein, an
element is
resilient when, upon compression, the structure changes shape, and upon
removal of
compression, the structure substantially returns back to its original shape.
Further, at
least one portion of the nosing strip 16 may be configured to contact the
threshold cap
100 along the length of the threshold assembly 11 so as to form an additional
seal
therewith. In some instances, both the door sweep 300 and the nosing strip 16
may be
configured to contact the threshold cap 100 upon closing of the door panel 200
such that
multiple sealing barriers are formed along the length of the threshold
assembly 11.
[01061 The nosing strip 16, which may be of extruded plastic with a wood grain
or other
appropriate appearance, may be snapped or otherwise attached into place
covering the
nosing 15 of the threshold substrate 12. The nosing strip 16, which is visible
from the
inside of a building structure, covers the nosing 15 of the threshold
substrate 12 and
hides any junctions between adjacent threshold substrates 12. According to
some
aspects, the nosing strip 16 may include a nosing portion 52, a nosing fin 53,
and a sill
channel cover portion 54. The nosing portion 52 may extend about the nosing 15
of the
threshold substrate 12, from within the sill channel 13 to the back edge 39 of
the
threshold substrate 12. A barbed tab 19 of the nosing strip 16 may be
configured to be
received within the nosing attachment slot 20 so as to engage the threshold
substrate 12
for anchoring thereto. The nosing fin 53 may be flexible and capable of
interacting with
the locking wall 108 of the threshold cap 100 to form an additional seal along
the length
of the threshold assembly 11. Further, in some instances, a resilient sealing
provision
(e.g., resilient bulb 302) of the door sweep 300 may sealingly contact the
nosing strip 16,
and top wall 107. As previously mentioned, the nosing strip 16 may extend
across the
floor 18 of the sill channel 13. In such instances, the nosing strip 16 may be
used to
extend across adjacent threshold substrates 12, which interlock, for covering
a seam
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formed between the adjacent threshold substrates 12, as disclosed in U.S.
Patent No.
7,350,336 to Bennett, which is assigned to Endura Products, Inc. (also the
assignee of the
present disclosure), and which is hereby incorporated herein by reference in
its entirety.
[0107] As shown in FIGs. 1 and 24, the door sweep 300 may be integral with or
otherwise attached, secured or fixed to a bottom portion of the door panel
200. In some
instances, the door panel 200 includes an underside or bottom edge 201 with
the door
sweep 300 flush thereagainst. According to some aspects, the door sweep 300
may
include a support wall 303 secured to the bottom edge 201 of the door panel
200 and
extending along the width thereof. The door sweep 300 may be attached to the
door
panel 200 using, for example, one or more door sweep barbs 306 (as shown in
FIG. 22)
capable of being received within corresponding door slots (not shown) defined
by the
door panel 200. A flange 304, an arm 305, and the resilient bulb 302 depend
from the
support wall 303. The flange 304 and resilient bulb 302 are preferably
flexible, while
arm 305 is preferably rigid. In some instances, all three may be integrally
formed with
the support wall 303. While it is preferred that resilient bulb 302 be
generally ovoid,
other suitable shapes are possible, such as resilient fins. It should be
understood that
resilient bulb 302 extends the length of the door sweep 300, but since the
cross-sectional
shape is bulb-like, it is described as a bulb.
101081 The flange 304 may include a flexible seal fin 307 that fits between
the door
panel 200 and support wall 303 for sealing the joint between the door panel
200 and door
sweep 300, thus preventing water penetration along the joint.
101091 The, preferably rigid, arm 305 can be configured to interact with the
threshold
cap 100 so as to force the articulating top portion 102 thereof in a
substantially
downward direction (toward the floor 18 of the sill channel 13) as the door
panel 200 is
moved to the closed position. The arm 305 continues to maintain contact with
the
threshold cap 100 due to the upward biasing thereof by, for example, the
biasing spring
51, thereby forming a first seal along the length of the entryway system 10.
In this
regard, the arm 305 interacts with the continuous surface 103 and compresses
the
articulating top portion 102 of the threshold cap 100 into an unbiased
position. The arm
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305 m'ay be constructed of any suitable material, such as, for example, a
plastic material,
and may be integrally formed with the support wall 303.
101101 The arm 305 may include an arm arcuate portion 308 and an inclined
portion 309,
both configured to interact with the threshold cap 100 such that the threshold
cap 100 is
initially forced downward and then allowed to bias against the door sweep 300.
In this
regard, the inclined portion 309 may be in a sloped configuration with respect
to the
support wall 303 such that the inclined portion 309 provides the initial
contact between
the door sweep 300 and the threshold cap 100. Upon contact, the top portion
102 of the
threshold cap 100 then rides along the inclined portion 309, towards the arm
arcuate
portion 308, so as to maintain contact therewith as the door panel 200 is
moved to the
closed position. Continuing, as the door panel 200 is closed, the arm arcuate
portion 308
eventually contacts the top portion 102 and forces the top portion 102
downward to a
lower position. As the arm arcuate portion 308 moves along the top wall 107,
while
maintaining contact therewith due to the upward biasing of the threshold cap
100, the top
portion 102 moves upward away from the floor 18 and into sealing contact with
the door
sweep 300 upon the door being in a fully closed position.
[01111 As shown in FIG. 1, the resilient bulb 302 may be configured to
sealingly interact
with the threshold cap 100, thereby forming a second seal along the length of
the
entryway system 10. In some instances, the resilient bulb 302 may also be
capable of
contacting the nosing strip 16 to form an additional sealing barrier along the
length of the
entryway system 10, as shown in FIG. 1. Thus, the door sweep 300 and the
threshold
cap 100, when used together, provide a strong positive seal between the door
panel 200
and the threshold assembly II.
101121 FIG. 25A shows an entry system 10 disposed between door jambs 90 and
below a
door panel 200. The bottom of the door panel 200 includes one embodiment of a
door
sweep 600. The entryway system 10 includes one embodiment of a self
articulating
threshold cap 100.
101131 FIG. 25B shows the entryway system 10 of FIG. 25A having an exemplary
embodiment of a threshold cap 100 comprising an upper cap 400 and at least one
cap
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base 5'00. Disposed adjacent to the ends of the upper cap 400 may be side
gaskets 700.
The side gaskets 700 are sized to be accepted into the sill channel 13. The
side gaskets
700 may be held in sealing contact with the ends of the upper cap 400 by a
respective
cap base 500. In some embodiments, the cap base 500 is provided with an end
wall 530
for supporting the side gasket 700. The side gasket 700 may be adhered to the
end wall
530. The end wall 530 provides both a connection surface for the side gasket
700 but
also provides a rigid structure capable of supplying the side gasket 700 and
end of the
upper cap 400 with constant pressure. The upper cap 400 includes a rigid
articulating
top portion 402, supported and biased upwardly by a hinge 420. The upper cap
400 also
includes a dam cover 430 configured to seal with decking dam 23 (see FIG. 26)
of
decking cover plate 21. A similar dam sealing portion 730 may extend from the
side
gasket 700 to also cover the decking dam 23 and help prevent water intrusion.
101141 FIG. 26 shows an exploded view of the elements of FIG. 25A. As best
seen in
the exploded view of FIG. 26, the upper cap 400 in this embodiment extends
substantially the full width of the entryway system 10. The upper cap 400 is
then
supported by at least one cap base 500 disposed along the length of the upper
cap 400.
In a preferred embodiment, a cap base 500, 501 is disposed proximate to each
distal end
of the upper cap 400. In a more preferred embodiment, at least one additional
cap base
502 is disposed along the central portion of the upper cap 400 to provide
support thereto.
The number of cap bases 500, 501, 502 can be adjusted to provide sufficient
support
based on the length of the entryway system 10. The use of separate cap bases
500, 501,
502 at intervals along the upper cap 400 provides a cap base 500 and upper cap
400
combination that is less expensive to produce relative to threshold cap 100
due to a
reduction in the amount of material used. Some of the cap bases 500, 501 may
be
formed with an end wall 530 to support a side gasket 700 as discussed above.
Other cap
bases 502 may have the side wall omitted in order to allow the cap base 502 to
support
the central portion of the upper cap 400. In some embodiments, the cap base
500 is
configured to house a biasing spring 451 configured to provide an additional
upward
biasing force to the rigid articulating top portion 402.
101151 FIG. 27 shows a cross sectional view of FIG. 26 through the cap base
500, in
combination with another embodiment of a door sweep 600. The upper cap 400 may
be
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configured to'interact with the door sweep 600 as shown in FIG. 27 or may
alternatively
interact with the door sweep 300 of FIG. 1. The upper cap 400 may include a
rigid
articulating top portion 402 capable of interacting with the door panel 200, a
first
embodiment of a door sweep 300 (see FIG. 1), or a second embodiment of a door
sweep
600. The articulating top portion 402 may include a top wall 407 and a locking
wall 408
extending substantially perpendicular to the top wall 407. The area of the
articulating top
portion 402 that is proximate to the intersection of the top wall 407 and the
locking wall
408 forming the uppermost portion.
[0116] The upper cap 400 may include a front wall 406. At least a portion of
the front
wall 406 is configured to be substantially parallel, and disposed adjacent to
the first
channel wall 14 and decking dam 23. Extending outwardly and downwardly from
near
the top of the front wall 406 is a dam cover 430. The dam cover 430 and the
front wall
406 combine to form a first slot 432. The first slot 432 is configured to
accept the
decking dam 23 therein, and for forming a sealing engagement therewith, to
reduce or
eliminate water intrusion between the decking dam 23 and the upper cap 400.
Extending
inwardly and downwardly from the front wall 406 is a substantially L-shaped
projection
434. The L-shaped projection 434 includes a projection first leg 436 extending
in the
interior direction and a projection second leg 438 extending downwardly from
the
projection first leg 436, substantially parallel with the front wall 406. The
projection
second leg 438 may include one or more flexible barbs 440.
[0117] The rigid articulating top portion 402 extends from the inner surface
of the front
wall 406 at a position above the L-shaped projection 434. The articulating top
portion
402, particularly top wall 407, connects to the front wall 406 with a
resilient hinge 420.
The hinge 420 provides the mechanism by which the top portion 402 is biased
upwardly
toward the door panel 200 or door sweep 300, 600. The hinge 420 may be a
living hinge
comprised of an area of reduced thickness of the same polymeric material as
the top
portion 402, the front wall 406, the 1-shaped projection 434 and dam cover
430. In order
to help the upward bias of the articulating top portion 402, an optional
biasing spring 451
may be disposed under the articulating top portion 402.
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101181 Alternatively, the hinge 420 may be comprised of a separate resilient
material
disposed between the top wall 407 and the front wall 406 as shown in FIG. 27.
The
resilient material can be extruded and set to bias the articulating top
portion 402
upwardly relative to the front wall 406. In a preferred embodiment, the
resilient material
can be co-extruded with the articulating top portion 402 and the front wall
406 to form
the self-articulating upper cap 400. It should be noted that the hinge 420 of
FIG. 25B can
also apply to the self-articulating threshold cap 100 of FIGS. 1, 23 and 24.
Providing the
resilient material of the hinge 420 along the full length of the upper cap 400
is preferred.
This is because the resilient material will be able to provide a biasing force
across the
entire length of the rigid articulating top portion 402. Some prior art caps
have discrete
springs spaced along the cap and providing discrete point forces to the cap.
Application
of only point forces means the prior art cap is less able to compensate for
differences in
spacing between the door panel and the cap, at locations between point force
locations.
As a result of using resilient material along the full length of the upper cap
400, the top
portion 402 will have an increased ability to maintain a seal with the door
sweep 600
even if the gap between the door bottom edge 201 and the threshold assembly 11
is
inconsistent along the length of the upper cap 400.
101191 As best seen in FIG. 27, each of the cap bases 500, 501(see FIG. 26),
502 (see
FIG. 26) is capable of being disposed within the sill channel 13 to reside on
the floor 18
thereof. Each cap base 500, 501, 502 comprises a bottom wall 504 to be
disposed along
the floor 18 of the sill channel 13. Where the nosing strip 16 extends along
the floor 18
of the sill channel 13, as shown in FIG. 1, the cap bases 500, 501, 502 can be
set upon
the nosing strip 16. The bottom wall 504 connects to a back wall 505 to be
disposed
adjacent to the nosing 15 or nosing strip 16.
101201 Each cap base 500, 501, 502 defines a cavity 510 with an upward opening
511.
For the embodiments shown, a portion of said opening 511 is covered by a stop
wall 512.
The cavity 510 of each cap base 500, 501, 502 is configured to accept the
locking wall
408 of the upper cap 400. The locking wall 408 may further include a hook
portion 412
configured to interact with the stop wall 512 to prevent the locking wall 408
from
advancing upwardly therepast, thereby limiting the upward travel of the
articulating top
portion 402 of the upper cap 400.
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101211 The stop wall 512 acts as a vertical adjustment limiter for the rigid
articulating
top portion 402. Providing the stop wall 512 properly positions the top
portion 402 when
the door panel 200 is in the open position. If this vertical limiter were
removed, the top
portion 402 would relax to a height that would impede the ability to close the
door panel
200 since the top portion 402 would likely strike the door panel 200, instead
of first
enacting with the door sweep 300, 600. If the top portion 402 alone had a
relaxed
position equal to the height of engagement with the stop wall 512, the
relative biasing
force applied to the top portion 402 would decrease, reducing the available
sealing force
between the upper cap 400 and the door sweep 300, 600.
101221 Cap bases 500, 501, 502 can be provided with stop walls 512 disposed at
various
heights relative to the bottom wall 504. The stop walls 512 may be provided
with
various thicknesses to achieve the same result. These variations in the
relative position
of stop wall 512 of the cap base 500, 501, 502 allow for fine tuning the range
of motion
of the rigid articulating top portion 402 of the upper cap 400.
101231 In one common situation, a door panel 200 may sag such that the gap
between the
door bottom and the entryway system 10 is smaller adjacent to the latch side
of the door
than the hinge side of the door. In this situation, the door can "stick" or
become difficult
to open and close due to contact with the entryway system 10. In order to
reduce this
resistance, the upper cap 400 would preferably have a decreased maximum height
adjacent to latch side of the door. To provide the upper cap 400 with a
decreased
maximum height at the end adjacent the door latch while maintaining the full
maximum
height of the upper cap 400 at the opposite, hinged end, and thereby
accommodating the
difference in gap, the cap base 500 supporting the end of the upper cap 400
adjacent the
door latch may be different from the cap base 501 supporting the opposite end
of the
upper cap 400. For example, with reference to FIG. 26, the cap base 500 on the
left
distal end may have a stop wall 512 that is relatively high or relatively thin
to fill a
standard margin at the hinge side of the door, while the cap base 501 on the
right distal
end may have a stop wall 512 that is relatively lower or thicker to fill a
lower margin on
the latch side of the door.
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10124j Each dap base 500, 501, 502 may further define a base channel 520
extending
along the length thereof. The base channel 520 is configured to accept the
second leg
438 of the upper cap 400. With the help of the flexible barbs 440 disposed on
the second
leg 438, the second leg 438 forms a friction fit within the base channel 520.
Therefore,
the at least one cap base 500 holds the front wall 406 of the upper cap 400
within the sill
channel 13. To fit the upper cap 400 to the cap base 500, insert second leg
438 into base
channel 520. Slide the cap base 500 relative to the upper cap 400 to position
the cap
base 500 in the proper location along the upper cap 400, then snap the locking
wall 408
down past the stop wall 512.
101251 An optional biasing spring 451, as shown in FIG. 26, can be disposed
under the
top wall 407 of the upper cap 400, and may be held in place by the cap bases
500, 501,
502.
101261 Referring again to the side gaskets 700, best seen in FIG. 26, the side
gaskets 700
can also be used in combination with any of the threshold caps 100 shown in
FIGs. 1-6.
The side gaskets 700 can be adhered to non-adjustable portions of the caps 100
or
adhered to a door jamb or mullion disposed at the end of the entryway system
10. The
side gaskets 700 may be those described in a co-pending application number
13/761,709
filed February 7, 2013 and having the same inventors as the instant
disclosure. The co-
pending application is incorporated herein by reference.
101271 As shown in FIG. 27, the articulating upper cap 400 may interact with
another
exemplary embodiment of a door sweep 600. The door sweep 600 may be integral
with
or otherwise attached, secured or fixed to a bottom portion of the door panel
200. In
some instances, the door panel 200 includes an underside or bottom edge 201
with the
door sweep 600 flush thereagainst. According to some aspects, the door sweep
600 may
include a support wall 603 secured to the bottom edge 201 of the door panel
200 and
extending along the width thereof. In a preferred embodiment, the support wall
603 may
be partially adhered to the door bottom using a strip of caulk applied along
the exterior
portion and longitudinal ends of the support wall 603.
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101281 A front flange 604, a resilient bulb 602, a first projection 605, and a
second
projection 610 depend from the support wall 603. The front flange 604 and
resilient bulb
602 are preferably flexible, while projections 605, 610 are preferably rigid.
In some
instances, all four may be integrally formed with the support wall 603, by,
for example,
co-extrusion. While it is preferred that resilient bulb 602 be generally
ovoid, other
suitable shapes are possible. It should be understood that resilient bulb 602
extends the
length of the door sweep 600, but since the cross-sectional shape is bulb-
like, it is
described as a bulb.
[0129] The front flange 604 may include a flexible seal fin 607 that fits
between the door
panel 200 and support wall 603 for sealing the joint between the door panel
200 and door
sweep 600, thus preventing water penetration along the joint.
[0130] The first projection 605 can be configured to interact with the
threshold cap 100
(FIG. I) or upper cap 400 so as to force the articulating top portion 102, 402
thereof in a
substantially downward direction (toward the floor 18 of the sill channel 13)
as the door
panel 200 is moved to the closed position. The first projection 605 may be
constructed
of any suitable material, such as, for example, a plastic material, and may be
integrally
formed with the support wall 603. The first projection 605 extends
substantially the
entire length of the door sweep 600 and is positioned adjacent to the front
flange 604.
The first projection 605 includes at least an inclined portion 608 extending
downward
and rearward relative to the support wall 603. In this regard, the inclined
portion 608
may be a sloped configuration with respect to the support wall 603 such that
the inclined
portion 608 provides the initial contact between the door sweep 600 and the
threshold
cap 100 or upper cap 400 of the second embodiment of the self-articulating
threshold cap
100. Upon contact, the top portion 102, 402 of the threshold cap 100, or upper
cap 400
rides along the inclined portion 608. In other words, the inclined portion 608
acts as a
ramp to force the top portion 102, 402 of the articulating threshold cap 100,
or upper cap
400 downward. As the top portion 102, 402 moves past the end of the inclined
portion
608, the top portion 102, 402 will re-adjust in an upward direction.
10131j The second, preferably rigid, projection 610 is an arm extending
downward and
rearward relative to the support wall 603. The second projection 610 can
extend
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substdntially the entire length of the door sweep 600 and is disposed adjacent
to an
outward side of the resilient bulb 602. The second projection 610 is
configured to
interact with the top portion 102, 402 of the articulating threshold cap 100,
or upper cap
400 thereof to properly position the top portion 102, 402 to be at the correct
height for
forming a seal with the resilient bulb 602.
(01321 The above descriptions of preferred embodiments of the disclosure are
intended
to illustrate various aspects and features of the invention without
limitation. Persons of
ordinary skill in the art will recognize that certain changes and
modifications can be
made to the described embodiments without departing from the scope of the
invention.
All such changes and modifications are intended to be within the scope of the
appended
claims. Features from one embodiment or aspect may be combined with features
from
any other embodiment or aspect in any appropriate combination. For example,
any
individual or collective features of method aspects or embodiments may be
applied to
apparatus, product or component aspects or embodiments and vice versa.
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