Note: Descriptions are shown in the official language in which they were submitted.
DOOR ASSEMBLY USING A TWO PIECE END CAP
This application is a division of Canadian Serial No. 2,757,718, filed
November 14, 2011.
BACKGROUND OF THE INVENTION
1. TECHNICAL FIELD
The invention relates generally to interlocking door skins and end caps, and a
1.0 method of forming a door using these elements. More particularly, the
invention
relates to door skins having a plurality of interlocking tabs which function
to secure
the door skins as a unit and thereby define an upper opening and a lower
opening
for placing the end caps therein. Specifically, the invention relates to
interlocking
door skins which are secured together and formed to accept a top and bottom
end
cap which are formed by a separate locking clip element secured to a beam
element.
2, BACKGROUND INFORMATION
Doors in general, but industrial doors in particular, have suffered from a
variety of defects which lead to dangerous operating conditions or
unsatisfying build
quality. Since wood is generally light and can be shaped and cut easily,
wooden
doors do not suffer from unsatisfying build quality. Nevertheless, wooden
doors
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cannot withstand the harsh environments required of industrial applications
and are
therefore inappropriate.
Steel or metal doors, on the other hand, provide strength and the ability to
withstand extreme environmental conditions. Due to the heavy material, the
metal
.. doors generally have a hollow cavity in order to substantially reduce the
overall
weight.
Traditionally, the metal door was manufactured with two door skins if the top
and bottom pieces were manufactured integral to the respective door skins or
four
pieces if the top and bottom pieces were not integral to one of the door
skins. One
traditional method of manufacturing the door is to weld the pieces together at
the
seams. The welded door provides great resistance to the harsh environment and
can generally withstand fires, but suffers from being a time consuming and
costly
procedure as well as unattractive.
The welded door is unattractive due to the welded seams which contain a
variety of bumps and ridges from the welding process. Further, the welding
process
is generally unreliable and may cause material flexing and fitment issues due
to the
extreme heat required to weld the door together. Finally, the welded door is
costly to
produce because an acceptable door must be prepped for welding and then
welded.
Not only is welding expensive and time consuming, the unattractive seams that
result must be sanded and polished to provide an acceptable finish. The
sanding
and polishing procedures are objectionable because they are both labor
intensive
and messy.
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A second method of manufacturing a metal door is to use an adhesive. While
the adhesive is easier, cheaper, and faster than welding, the adhesive is
unable to
endure the high heat of a fire and will melt, thereby posing a safety hazard.
The
process of adhering the doors skins with an adhesive still takes more time
than is
desired because the skins cannot be glued and then moved to the next
processing
station, but instead must remain untouched until the adhesive hardens.
Further, if
the doors are moved before the adhesive hardens, then the door skins will not
be
properly aligned and the door may have to be scraped, thereby increasing
production costs. Thus there is a demonstrated need for an interlocking door
io assembly which is capable of being produced quickly and efficiently
without welding
and is able to withstand harsh environments as well as the extreme heat of a
fire.
Furthermore, traditional monolithic end caps are difficult to manufacture due
to the conflicting requirements of the end cap. The end cap should be
manufactured
from a durable material to conform to the overall strength and appearance of
the
metal door. Conversely, the end cap also requires the formation of intricate
connecting elements thereon to connect the end cap to the door skins.
Therefore,
the main portion of the end cap should be formed from a durable material, yet
the
connecting should be formed from a more formable material, such as plastic. In
addition, the end cap should also provide a thermal break in the metal
material
which forms the front and rear door surfaces. Metal material is desired due to
its
durability, yet the thermal conductivity of metal is such that thermal energy
is easily
transferred between the front and back door surfaces. For example, cold
outdoor
temperatures may be transferred to the interior facing door surface through
the end
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caps and thereby act to cool the interior of the building, thus increasing
heating
costs for the building owner. As such, it is desirable that the end cap be
formed
of a material which has the property of low thermal conductivity, thus
transfer of
thermal energy through the door will be minimized. Therefore, there is a
demonstrated need for a non-monolithic end cap which may be formed from two
different materials, while also being formed of different materials from the
front
and rear door panels.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention there is
provided a metal door comprising: a base skin having an integrally formed
first
mechanical connector; a top skin having an integrally formed second mechanical
connector configured to engage the first mechanical connector to mechanically
secure the top skin to the base skin to define an opening; a beam; a locking
clip
configured to be partially received in the beam to form an end cap; and
wherein
the end cap is complementary shaped to be slidably received in the opening.
In accordance with a further embodiment of the present invention there is
provided a metal door comprising: a base skin having an integrally formed
first
mechanical connector and a locking tab; a top skin having an integrally formed
second mechanical connector configured to engage the first mechanical
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connector to mechanically secure the top skin to the base skin to define an
opening; a beam; a locking clip configured to be partially received in the
beam to
= form an end cap, the locking clip having a slot; and wherein the end cap
is
complementary shaped to be slidably received in the opening and the locking
tab
engageable with the slot to secure the end cap in the opening.
A still further embodiment of the present invention provides a metal door
comprising: a base skin having an integrally formed first mechanical connector
and a locking tab; a top skin having an integrally formed second mechanical
connector configured to engage the first mechanical connector to mechanically
secure the top skin to the base skin to define an opening; a beam having a
channel; a locking clip having a base and a flange extending from the base,
the
flange having a shoulder and a slot, wherein the base is received in the
channel
forming an end cap whereby the shoulder abuts the beam to generally prevent
the flange from passing into the channel; and wherein the locking tab engages
with the slot to secure the end cap in the opening.
Yet another embodiment of the present invention provides a metal door
comprising: a base skin having an integrally formed first mechanical connector
and a locking tab; a top skin having an integrally formed second mechanical
connector configured to engage the first mechanical connector to mechanically
secure the top skin to the base skin to define an opening; a beam having a
channel; a locking clip having a base and a flange extending from the base,
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wherein the base is received in the channel forming an end cap and the
shoulder
abuts the beam to generally prevent the flange from passing into the channel;
and wherein the locking tab engages with the flange to secure the end cap in
the
opening.
The door of the present invention comprises a first skin having a first
mechanical connection means extending from a first wall and a second
mechanical connection means, a second skin having a third mechanical
connection means, an end cap having a fourth mechanical connection means,
wherein the end cap is secured to the first skin upon sliding engagement of
the
first mechanical connection means and the fourth mechanical connection means;
and wherein the second skin is secured to the first skin upon engagement of
the
second mechanical connection means and the third mechanical connection
means. The engagement of the first mechanical connection means and the
fourth mechanical connection means prevents removal of the end cap. The first
skin further comprises a stop preventing movement of the end cap beyond the
stop. The first mechanical connection means may be at least one locking tab,
the second mechanical connection means may be at least one mounting slot, the
third mechanical connection means may be at least one protrusion, and the
fourth mechanical connection means may be at least one slot. The first
mechanical connection means may be at least one slot, the second
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..
mechanical connection means may be at least one protrusion, the third
mechanical
connection means may be at least one mounting slot, and the fourth mechanical
connection means may be at least one locking tab. The at least one mounting
slot
includes a positioning portion and a locking portion wherein the second skin
is
releasably secured to the first skin upon sliding engagement of the at least
one
protrusion form the positioning portion to the locking portion. The at least
one
mounting slot may be a plurality of mounting slots disposed about a periphery
of the
first skin. The end cap of the present invention includes a plurality of
bosses and
may be fixedly secured to the first skin with an adhesive and the second skin
is
fixedly secured to the first skin with an adhesive. The first skin includes at
least one
locating tab wherein the end cap is releasably secured within the locating
tab.
The first skin further includes a second wall generally parallel to and
adapted
to be spaced away form the first wall by a side wall, wherein the side wall
includes at
least one axial protrusion, a plurality of sliding locks, and at least one
mounting hole.
The present invention may further include at least one hinge reinforcement
plate
having at least one mounting slot, a plurality of locking slots, and at least
one
securing hole wherein the at least one hinge reinforcement plate is fixedly
secured to
the side wall upon sliding engagement of the at least one axial protrusion and
the at
least one mounting slot. The hinge reinforcement plate may be fixedly secured
to
the side wall upon sliding engagement of the plurality of sliding locks and
the
plurality of locking slots.
The method of manufacturing a door of the present invention comprises
stamping a first skin with at least one locking tab and at least one mounting
slot,
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stamping a second skin with at least one protrusion, stamping an end cap with
at
least one slot, applying a first layer of adhesive within the first skin,
inserting the end
cap within the first skin and in contact with the first adhesive, applying a
second
layer of adhesive on a top side of the end cap and the first skin, and
disposing the
second skin at least one protrusion within the at least one mounting slot and
in
contact with the second layer of adhesive. Alternatively, adhesive may be
applied to
the second skin directly. The method also includes stamping a side wall in the
first
skin, stamping at least one axial protrusion, a plurality of sliding locks,
and at least
one mounting hole in the side wall, and disposing a hinge reinforcement plate
on the
at least one axial protrusion and the plurality of sliding locks. The method
further
includes stamping a positioning portion and a locking portion in the at least
one
mounting slot and urging the second skin at least one protrusion within the at
least
one mounting slot from the positioning portion to the locking portion.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the invention, illustrative of the best modes in
which Applicant has contemplated applying the principles of the invention, are
set
forth in the following description and are shown in the drawings.
Figure 1 is a front view of a first embodiment interlocking door assembly with
.. hinges;
Figure 2 is an exploded view of the first embodiment interlocking door
assembly;
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Figure 3 is a top view of the first embodiment end rail with bosses and
mounting slots;
Figure 4 is a side view of the first embodiment end rail with bosses;
Figure 5 is an endwise side view of the first embodiment end rail with bosses;
Figure 6 is an enlarged front view of the first embodiment base skin with
mounting slots;
Figure 7 is an endwise view of the first embodiment base skin with mounting
slots;
Figure 8 is an enlarged side view of the first embodiment of the securing
assembly of a hinge reinforcement portion of a base skin taken generally along
line
8-8 in Figure 2;
Figure 9 is an enlarged front view of the first embodiment top skin with
mounting protrusions;
Figure 10 is an endwise view of the first embodiment top skin with mounting
protrusions;
Figure 11 is an enlarged perspective view of the first embodiment mounting
protrusion;
Figure 12 is a sectional view of the first embodiment mounting protrusion
taken generally along line 12-12 in Figure 9;
Figure 13 is a perspective view of the first embodiment hinge reinforcement
plate being located on a base skin;
Figure 14 is a front view of the first embodiment hinge reinforcement plate
located on a base skin securing assembly;
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Figure 15 is a front view of the first embodiment hinge reinforcement plate
releasably secured to a base skin;
Figure 16 is a perspective view of a corner of preferred embodiment end rail
being secured to a base skin;
Figure 17 is a top view of the first embodiment end rail secured to a base
skin;
Figure 18 is a sectional view of the secured end rail and base skin taken
generally along line 18-18 in Figure 17;
Figure 19 is a perspective view of a corner of the first embodiment top skin
being located on a combined base skin and end rail;
Figure 20 is a perspective view of a corner of the first embodiment top skin
secured to a combined base skin and end rail;
Figure 21 is a sectional view of the first embodiment interlocking door
assembly taken generally along line 21-21 in Figure 20;
Figure 22 is an enlarged endwise view of one side of the first embodiment
end rail secured to the bottom of an interlocking door assembly;
Figure 23 is a perspective view of a second embodiment of the end cap of the
door assembly;
Figure 24 is a perspective view of one end of the end cap;
Figure 25 is a perspective view of a locking clip and a beam which comprise
the end cap of the second embodiment;
Figure 26 is a top elevational view thereof;
Figure 27 is a side elevational view thereof;
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Figure 28 is an end elevational view thereof;
Figure 29 is a perspective view of the end cap of the second embodiment and
the base skin;
Figure 30 is a top view similar to Figure 29 showing the end cap in phantom;
Figure 31 is a cross-sectional view taken along line 31-31 of Figure 30;
Figure 32 is a cross-sectional view taken along line 32-32 of Figure 30;
Figure 33 is a perspective view of the second embodiment of the door
assembly in the assembled state; and
Figure 34 is a cross-sectional view taken along line 34-34 of Figure 33.
Similar numbers refer to similar parts throughout the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
At the outset, it should be appreciated that like drawing numbers on different
drawing views identify identical, or functionally similar, structural elements
of the
invention. While the present invention is described with respect to what is
presently
considered to be the preferred embodiments, it is to be understood that the
invention
as claimed is not limited to the disclosed aspects.
Unless defined otherwise, all technical and scientific terms used herein have
the same meaning as commonly understood to one of ordinary skill in the art to
which this invention belongs. Although any methods, devices or materials
similar or
equivalent to those described herein can be used in the practice or testing of
the
invention, the preferred methods, devices, and materials are now described.
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The interlocking door of the present invention is indicated generally at door
assembly 30, as is particularly shown in Figures 1 and 2. Door assembly 30 is
mounted to wall 32 with hinges 34. Similar to a traditional door, door
assembly 30
may include housing 35 for mounting door handle 36 and dead bolt 38.
In accordance with one of the main features of the invention, door assembly
30 generally includes base skin 40, top skin 42, lower end cap 44, and upper
end
cap 46. Base skin 40 includes mounting slots 48 and top skin 42 includes
protrusions 50.
Averting now to Figures 3, 4, and 5, lower end cap 44 preferably includes
fastening ends 52 with slots 54. The lower end cap 44 further includes bosses
56
located between fastening ends 52 on both the top and bottom sides of the end
cap
44 to provide a gap for an adhesive. Advantageously, fastening ends 52 are
slightly
smaller than the endwise opening of the base skin 40 (described infra) to
allow the
fastening ends 52 to fit securely within the base skin 40 endwise opening. The
lower
end cap 44 may be composed of steel, stainless steel, aluminum, polycarbonate,
or
any other suitable plastic or metal composition. The foregoing description of
lower
end cap 44 is applicable to upper end cap 46 which is both structurally and
functionally similar.
In accordance with another the main features of the invention, Figures 6, 7,
and 8 illustrate various views of base skin 40. The base skin 40 includes
first wall
58, side walls 60, and second wall 62. In a first embodiment, the first wall
58 and
second walls 62 are generally parallel and spaced apart a distance
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= equal to the length of the side walls 60. In addition, side walls 60 are
generally
perpendicular to both the first wall 58 and second wall 62.
First wall 58 includes locking tab 64, locating tab 66, and mounting slots 48.
Locking tab 64 has a first end 70 and second end 72. Preferably, first end 70
is
generally parallel and located on the same plane as first wall 58. Second end
72 is
preferably located above or below the plane of the first wall 58 and is
generally offset
from first wall 58. Similar to locking tab 64, locating tab 66 includes a
depressed end
a flush end. However, the depressed and flush ends of locating tab 66 are
generally
the opposite of the locking tab ends and function only to limit the distance
an object
may be inserted within the base skin 40 and to facilitate alignment of the
inserted
object. In a first embodiment, mounting slots 48 are generally located about
the
periphery of the base skin 40 and include positioning portion 74 and locking
portion
76 arranged to receive the protrusions of the top skin 42.
Referring to Fig. 8, hinge reinforcement area 78 incorporates axial
protrusions
80, sliding locks 82, and mounting holes 84. Sliding locks 82, similar to
locking tab
64, has a first end which is generally flush with side wall 60 and a second
end
opposite the first end which is depressed or raised from side wall 60.
Preferably,
sliding locks 82 are opposed to one another, meaning that the flush end of one
sliding lock 82 is adjacent to the raised end of another sliding lock 82.
Finally, side
wall 60 includes mounting holes 84 which are arranged to receive screws or
bolts
and secure hinges 34 as well as a hinge reinforcement plate 96 (described
infra).
The hinge reinforcement area 78 has been described as a single area, but may
be
utilized along the side wall at any position where a hinge is located. The
base skin
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may be composed of steel, stainless steel, aluminum, polycarbonate, or any
other
suitable plastic or metal composition.
Averting now to Figures 9, 10, 11, and 12, top skin 42 is shown with
protrusions 50 axially extending from a top side. In a first embodiment, top
skin 42
.. includes upper layer 86 parallel to, adjacent to, and generally situated
atop lower
layer 88. Upper layer 86 may be formed by folding an outer portion of lower
layer 88
backwards and on top of lower layer 88. Advantageously, protrusions 50 extend
axially from upper layer 86 so that lower layer 88 is a solid, flat wall and
is
aesthetically pleasing. While the present invention has been described with
1.o protrusions 50 extending from an upper layer 86, it is within the
spirit and scope of
the present invention as claimed to incorporate protrusions 50 extending
directly
from the lower layer 88, thereby rending the upper layer 86 unnecessary.
Protrusions 50 must be designed and manufactured with certain
specifications and tolerances to fit within the base skin 40 mounting slots 48
and still
be releasably secured. Width 90 of the protrusions 50 must be less than the
width of
positioning portion 74 but more than the width of locking portion 76. Width 92
of the
protrusions 50 must be less than both positioning portion 74 and locking
portion 76.
Advantageously, widths 90 and 92 allow the protrusions 50 to be axially
disposed
within positioning portion 74 and then slid into locking portion 76. Further,
height 94
zo of the protrusions 50 must provide sufficient clearance to allow the
base skin 40 to fit
between the protrusion 50 and the top skin 42. Widths 90 and 92 and height 94
do
not have to be any particular dimensions, but must be collectively scaled with
the
mounting slots 48 to fit securely within the mounting slots 48. The top skin
42 may
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= be composed of steel, stainless steel, aluminum, polycarbonate, or any
other
suitable plastic or metal composition.
Averting now to Figure 13, hinge reinforcement plate 96 is illustrated with
mounting slots 98, locking slots 100, and securing holes 102. Mounting slots
98
include positioning portion 104 and locking portion 106. Mounting slots 98 are
arranged to function similar to the base skin 40 mounting slots 48 and thus
the
operation and interaction need not be repeated. Further, locking slots 100 are
arranged to fit securely around sliding locks 82 to prevent movement of hinge
reinforcement plate 96.
Having now described the structure of the interlocking door assembly 30, a
method of assembling the door will be described in detail. While the following
is
described as a series of steps, no particular order is to be inferred and is
limited only
by the appended claims. Figures 13, 14, and 15 illustrate hinge reinforcement
plate
96 being installed on base skin 40 at side wall 60. Mounting slots 98 of the
hinge
reinforcement plate 96 are axially disposed on the side wall axial protrusions
50 in
the direction indicated by arrow 108. In particular, positioning portion 104
of the
mounting slots 48 are axially disposed on axial protrusions 80 in the
direction
indicated by arrow 108. Next, hinge reinforcement plate 96 is slid in the
direction
indicated by arrow 110 so that protrusions 80 are located within locking
portions 106,
sliding locks 82 are secured within locking slots 100, and mounting holes 84
are
aligned with securing holes 102.
Figure 16 shows lower end cap 44 being inserted within base skin 40 in the
direction indicated by arrow 112. Figures 17 and 18 are views of the assembled
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corner of lower end cap 44 inserted within base skin 40. Prior to installation
of lower
end cap 44, adhesive 114 is applied to the inside of second wall 62. Fastening
end
52 is then inserted within the base skin 40 until the fastening end 52 is
secured
between the bottom side of first wall 58 and locating tab 66. Further, the
lower end
cap 44 and base skin 40 are fixedly secured by engagement of slots 54 and
locking
tab 64, as well as fixedly secured by adhesive 114. As described supra, slot
54 is
fixedly secured by second end 72 since the second end is disposed within slot
54
and prevents any movement of the lower end cap 44 in the direction indicated
by
arrow 116. Thus, the lower end cap 44 may readily be inserted within the base
skin
io 40 but may not be removed and is still fixedly secured within the base
skin 40 if the
adhesive were to be dissolved or melted. The foregoing description of lower
end
cap 44 is applicable to upper end cap 46 which is both structurally and
functionally
similar and is inserted within the base skin 40 in the same manner.
Averting now to Figures 19 and 20, where lower end cap 44 is shown inserted
within base skin 40. Adhesive 118 is applied to the top of first wall 58 and
lower end
cap 44. Top skin 42 is then placed on top of adhesive 118 in the direction
indicated
by arrow 120 so that the protrusions 50 of top skin 42 (not shown) are located
within
the positioning portion of mounting slots 48. The top skin 42 is then slid in
the
direction indicated by arrow 122 to locate the top skin 42 protrusions 50
within the
locking portion of the mounting slots 48. Advantageously, the top skin 42
protrusions 50 are secured within the locking portions by the downward force
of
gravity once the door assembly 30 is mounted in a doorway. Alternatively,
adhesive
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= 118 may be applied to top skin 42 directly and then installed onto the
top of first wall
58 and end caps 44.
Further, Figure 21 is a sectional view of a first embodiment door assembly 30
with protrusions 50 secured within locking portion 76 of mounting slots 48.
Figure 22
is an enlarged endwise view of door assembly 30 with adhesive 114 and adhesive
118 fixedly securing the base skin 40, top skin 42, lower end cap 44, and
upper end
cap 46 of door assembly 30.
Having now described structure and a method of assembling the interlocking
door, a method of manufacturing the door will be described in detail and
should be
viewed in light of Figures 1 though 22. Although the following is described as
a
series of steps, no particular order of steps is implied and as such is
limited only by
the appended claims.
Door assembly 30 is manufactured by stamping base skin 40 with locking
tabs 64, mounting slots 48 having positioning portions 74 and locking portions
76,
and side wall 60. Side wall 60 is then stamped with axial protrusions 80,
sliding
locks 82, and mounting holes 84. Hinge reinforcement plate 96 is then secured
on
axial protrusions 80 and sliding locks 82. Next, top skin 42 is stamped with
protrusions 50 and end caps 44 and 46 are stamped with slots 54 and fastening
ends 52. Adhesive 114 is then applied to an interior portion of base skin 40
and
lower end cap 44 and upper end cap (not shown) are inserted within the base
skin
40, respectively, and in contact with the adhesive. Adhesive 118 is then
applied to a
top side of lower end cap 44, upper end cap (not shown), and base skin 40 or
to top
skin 42. Next, protrusions 50 of the top skin 42 are disposed within mounting
slots
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= 48 and top skin 42 is in contact with adhesive 118. Finally, the top skin
42 and
protrusions 50 are urged from positioning portion 74 to locking portion 76 in
the
direction indicated by arrow 122.
Accordingly, the interlocking door assembly is an effective, safe,
inexpensive,
and efficient device that achieves all the enumerated objectives of the
invention,
provides for eliminating difficulties encountered with prior art devices,
systems, and
methods, and solves problems and obtains new results in the art.
With reference to Figs. 23-34, a second embodiment of the present invention
is shown in door assembly 230. Door assembly 230 includes a lower end cap 232
and an upper end cap (not shown). It will be readily understood that lower end
cap
232 and upper end cap are generally similar in shape and function, therefore
only
lower end cap 232 will be discussed herein. Lower end cap 232 is generally
similar
to lower end cap 44, however, rather than being formed from one solid piece of
material, such as lower end cap 44, lower end cap 232 is formed by securing a
locking clip 234 to a beam 236. Locking clip 234 is formed from a first
material and
beam 236 is formed from a second material, wherein first material and second
material may be different, and wherein the first and second materials may be
different from the overall door material used to form base skin 40 and top
skin 42.
As shown in Fig. 25, locking clip 234 includes a base 238 and a flange 240
extending therefrom. Base 238 is a U-shaped member which includes an outer
sidewall 266, an inner sidewall 268, and a top wall 270 extending
therebetween.
Flange 240 includes a first shoulder 244, a second shoulder 245, a locating
ledge
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248, and a slot 246 defined by locating ledge 248 which is similar in shape
and form
to slots 54 of lower end cap 44.
As shown in Fig. 25, beam 236 includes an upper retaining lip 260 adjacent
an upper sidewall 256, a lower retaining lip 262 adjacent a lower sidewall
258, and a
back wall 264 having an edge 265 and extending between upper sidewall 256 and
lower sidewall 258. Upper retaining lip 260, lower retaining lip 262, upper
sidewall
256, lower sidewall 258, and back wall 264 cooperate to define a channel 242
extending through beam 236. Channel 242 has a generally rectangular cross-
sectional shape which is complementary shaped to the generally rectangular
cross-
sectional shape of base 238 of locking clip 234. Channel 242 is shown in Fig,
25
extending entirely through beam 236, however, channel 242 may terminate within
beam 236 without departing from the spirit of the invention. A plurality of
bosses 252
extend outwardly from upper sidewall 256, and a plurality of bosses 254 extend
outwardly away from lower sidewall 258. While beam 236 is shown with a void
272
defined between upper retaining lip 260 and lower retaining lip 262, it will
be readily
understood that void 272 may be removed and filled with a continuous solid
wall, or
portions thereof, extending between upper retaining lip 260 and lower
retaining lip
262 without departing from the spirit of the invention.
As shown in Fig. 27, beam 236 generally extends along an imaginary
longitudinal line 274 with upper sidewall 256 having a first longitudinal
length 276
and lower sidewall 258 having a second longitudinal length 278. As seen in
Fig. 25,
first length 276 is shorter than second length 278, which creates a void 280
(Fig. 25)
for flange 240 to fill when locking clip 234 is properly engaged with beam 236
(Fig.
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24). As shown in Fig. 27, while locking clip 234 heretofore has been discussed
with
particularly reference to one end of beam 236, beam 236 includes a first end
282
and a second end 284, whereby void 280 may be defined at either first end 282
or
second end 284, or both, depending on the desired configuration of the
manufacturer. Thus, locking clip 234 or a pair of locking clips 234 may be
employed
in the second embodiment without departing from the spirit of the invention.
Therefore, it will be readily understood that the manufacturer may wish to use
a
hybrid system for an end cap having locking clip 234 proximate one end of the
hybrid beam, and fastening end 52 described in the first embodiment proximate
the
other end of the hybrid beam.
As shown in Figs. 24-29, end cap 232 is assembled in the following manner.
Inasmuch as the cross-sectional rectangular shape of base 238 is
complementarily
shaped to fit into the cross-sectional rectangular shape of channel 242,
locking clip
234 is slidably engaged with beam 236 by way of base 238 fitting inside
channel
.. 242. Base 238 is prevented from sliding within channel 242 beyond the
correct
position by way of first shoulder 244 abutting upper sidewall 256 (Fig. 24).
Second
shoulder 245 is sized and positioned to receive edge 265 of back wall 264
therein
and thereby form a firm abutment between flange 240 and back wall 264 when
base
238 is received in channel 242. As shown in Fig. 24, when base 238 is
positioned
.. inside channel 242, outer sidewall 266 abuts lower retaining lip 262 as
well as upper
retaining lip 260. Likewise, inner sidewall 268 abuts back wall 264, and top
wall 270
abuts upper sidewall 256 (Fig. 24).
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End cap 232, when assembled in the above manner, operates in the same
manner as lower end cap 44 as discussed above and is engaged with base skin 40
and top skin 42 in the same manner. End cap 232 is inserted into base skin 40
having fresh adhesive 114 disposed thereon, and is securely held thereto by
way of
slot 246 engaging locking tab 64 and locating ledge 248 engaging locating tab
66.
Locating tab 66 prevents end cap 232 from progressing within base skin 40
beyond
the desired position and ensures end cap 232 is properly aligned within door
assembly 230. Bosses 252 and 254 operate to properly hold end cap 232 a
specific
distance away from base skin 40 and top skin 42, as discussed in the first
embodiment with respect to bosses 56.
While end cap 232 operates generally similarly to end cap 44, end cap 232
has the advantages of being comprised of two separate components, namely
locking
clip 234 and beam 236. This allows the user or manufacturer to form locking
clip
234 and beam 236 out of appropriate materials, which may be different for each
element. Thus, a benefit is realized by separating end cap 232 into two
elements.
Locking clip 234 may be manufactured from a first material such as an
elastomeric
material, to utilize current injection molding techniques, and to more easily
form slot
246. Likewise, beam 236 may be manufactured from a second material to provide
certain desired thermal qualities to door assembly 230. Beam 236 may be formed
of
a low thermal conductivity material to provide a thermal break in the
assembly.
Thereby beam 236 reduces or prevents the flow of thermal energy between base
skin 40 and top skin 42. Inasmuch as the general door frame is separated into
two
separate interior and exterior pieces, when base skin 40 and top skin 42 are
joined
19
CA 3025922 2018-11-30
with a less conductive material, temperature transfer between base skin 40 and
top
skin 42 are reduced. This produces an extremely thermally efficient door while
also
providing the manufacturer with separate door components which may be
specifically tailored to the intended environment. As such, beam 236 may be
formed
of various materials having low thermal conductivity, such as plastic-based
and
fiberglass-based materials.
In the foregoing description, certain terms have been used for brevity,
clearness, and understanding; but no unnecessary limitations are to be implied
therefrom beyond the requirement of the prior art, because such terms are used
for
1.0 descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention is by way of
example, and the scope of the invention is not limited to the exact details
shown or
described.
Having now described the features, discoveries, and principles of the
invention, the manner in which the interlocking door is constructed and used,
the
characteristics of the construction, and the advantageous new and useful
results
obtained; the new and useful structures, devices, elements, arrangement,
parts,
combinations, and methods are set forth in the appended claims.
CA 3025922 2018-11-30
