Patent Application
20070256363
The present invention is directed to a door or wall, and more particularly, is directed to a structural member for use with a door or wall of an air handling unit.
Air handling units typically require doors to access components housed in an air handling unit compartment. One method of manufacturing these doors includes providing a structural member that is cut into segments that are abutted at their ends to form the framework of the door, typically a rectangle. To help secure the structural members in position to form the framework, mechanical fasteners, such as screws, are driven through the corner edge of one structural member and into the corner edge of another structural edge of an adjacent structural member. Door panels are then secured to each side of the framework to form a door. The ends of the structural member typically include a pair of slots that are each parallel to or perpendicular to a web of the structural member with which to receive the periphery of the door panels, depending upon the configuration of the door panels. For example, if each of the panels is planar, the slots for receiving the door panel peripheries are perpendicular to the web of the structural member. However, if the peripheries of the door panels include bent-up flanges so that the door panels resemble a “cake pan,” the slots for receiving the door panel peripheries are parallel to the web of the structural member. Alternately, instead of slots, each of the ends of the structural member may include a pair of flat or curved edges that are overlain by the peripheries of the door panels.
In either construction, the structural members do not readily accommodate dimensional differences or tolerances that result during fabrication of the individual door panels. Further, the door panels are secured to the structural members by additional mechanical fasteners, such as screws or other blind side fasteners. Installing these fasteners is a manual process, further increasing the cost of the door.
What is needed is a structural member that does not require mechanical fasteners and readily accommodates dimensional tolerances between door panels.
The present invention relates to a structural member for constructing a door. The structural member includes a first end portion, a second end portion disposed opposite the first end portion and a web disposed between the first end portion and the second end portion. A channel is disposed between the web and the second end portion, the first end portion being configured to received a portion of a first door panel to permit the first door panel to be connected to the structural member. The second end portion is configured to receive a portion of a second door panel to permit the second door panel to be connected to the structural member. The channel is configured to receive a peripheral portion of the second door panel, the first and second door panels to be connected to the first and second end portions without mechanical fasteners.
The present invention further relates to a door assembly for an air handling unit. The door assembly includes a frame connectable to the air handling unit and a door hingedly connected to the frame, the door comprises a first door panel, a second door panel and a framework including at least one structural member. The at least one structural member includes a first portion and a second portion opposite the first portion and a web disposed between the first portion and the second portion. The at least one structural member further includes a channel disposed between the web and the second portion. A portion of a periphery of the first door panel is secured to the first portion without mechanical fasteners. A portion of the second door panel is secured to the second portion without mechanical fasteners. A peripheral portion of the second door panel is disposed in the channel.
The present invention still further relates to a method for assembling an air handler unit door. The method includes providing a frame connectable to the air handling unit and providing a door hingedly connected to the frame, the door comprises a first door panel, a second door panel and a framework including at least one structural member. The method further includes providing the at least one structural member including a web having a first portion and a second portion opposite the first portion. A channel is disposed between the web and the second portion, the channel being non-parallel to the first portion. The method further includes securing a first door panel to the first portion without mechanical fasteners, wherein a portion of the first door panel overlies the first portion; and securing a second door panel to the second portion without mechanical fasteners, wherein a portion of the second door panel is disposed in the channel.
An advantage of the present invention is that it is inexpensive to manufacture.
A further advantage of the present invention is that it requires fewer parts.
A still further advantage of the present invention is that it does not require mechanical fasteners.
An additional advantage of the present invention is that a structural member disposed between two door panels is configured to accommodate dimensional variations of the door panels.
Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are typically not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention.
One embodiment of a door 12 is shown in
Referring to
At the end of the web 36 opposite the outer flange 38 extends an inner flange 48 that is substantially parallel to the outer flange 38. Disposed between the inner flange 48 and web 36 is a channel 50 for receiving a flange or lip 52 of the inner panel 24. The lip 52 of inner panel 24 extends at an angle from the remaining portions of the inner panel 24, defining a “cake pan” shape, similar to the outer panel 26. Preferably, lip 52 is substantially perpendicular to the remaining portions of the inner panel 24. The opening of channel 50 is larger than the thickness of the lip 52. The large opening of the channel 50 as compared to the thickness of the lip 52 simplifies insertion of the lip 52 inside the channel 50. Additionally, the channel 50 opening is sized to accommodate for dimensional and/or angular deviations of the panel 24 from the nominal design dimensions and angles, also referred to as tolerance build-up. In other words, although the distance between lips 52 of the respective panel 24 can fluctuate, as can the angle between each lip 52 and the respective panel 24, by virtue of the large opening of the channel 50, the lips 52 can still be inserted inside channel 50. This adjustment feature of the channel 50 provides ease of manufacturability as well as a pleasing appearance.
To secure the inner and outer panels 24, 26 to their respective inner and outer flanges 48, 38, preferably a layer of tape 46 having an adhesive applied to the opposed surfaces of the tape 46 is disposed between the inner panel 24 and the inner flange 48 and between the outer panel 26 and the outer flange 38. More preferably, tape 46 is disposed between portions of the inner panel 24 and the inner flange 48 and between the outer panel 26 and the outer flange 38 such that once the assembled door 12 is inserted into the press, the inwardly directed clamping force that is applied by the press to the opposed outward facing surface 27 of the outer panel 26 and the outward facing surface 25 of the inner panel 24 compresses the tape 46. Stated another way, the tape 46 is preferably disposed between portions of the outer and inner flanges 38, 48 that are parallel to each other, so that the compressive forces applied by the press to the door panels 24, 26 compress the tape 46 to secure the door panels 24, 26 to the respective flanges 48, 38. By virtue of the compressive forces applied by the press, the bond between the door panels 24, 26 and the respective flanges 48, 38 of the structural member 22 is enhanced, permitting a door construction that does not require mechanical fasteners, such as rivets, screws, clamps, nuts and bolts or other fastening methods known in the art. Additionally, the tape 46 can be applied as part of an automated process, while typically, mechanical fasteners must be manually installed. It is to be understood that other automated means, such as adhesive or pressure activated bonding process can also be applied directly to either or both of the corresponding portions of the door panels 24, 26 and flanges 48, 38 of the structural member 22.
Referring to
Preferably, the protrusion 54 is recessed with respect to the outwardly facing surface 25 of the inner panel 24, such as defined by plane 56 (
As shown in
Although the embodiments of the present invention have been directed to doors, those skilled in the art can appreciate that the present invention can also be used to construct walls. Further, although the embodiments have been directed to four structural members forming rectangular doors or walls, a door or wall can be constructed of a single curved structural member, or more than four structural members.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
