Patent Application
20110107703
1. Technical Field
The invention relates generally to hinged door assemblies which are mounted in an entry way. More particularly, the invention relates to a door assembly having skins secured to a frame. Specifically, the invention relates to a door assembly with a plurality of skins secured to a frame with protrusions, in a variety of skin arrangements, and a method of manufacturing the door.
2. Background Information
Doors are movable barriers used to cover an opening. A traditional household door can come in a variety of shapes and sizes depending on the desired look. However, the inner and outer skin of a door share the same profile, meaning that the design on the outside is the same as the design on the inside.
A traditional hinged door is secured on one side to a door frame opening with hinges and secured to the other side with a locking mechanism. The frame may be comprised of four pieces, including a top and bottom rail secured between a hinge stile and a lock stile. The connection points of the frame may have dovetail joints machined in them so that the frame is a sturdy assembly. Skins are then secured to each face of the door frame assembly with an internal core separating these skins. The skins may be composed of fiberglass, wood, or any other suitable material, while the core may also be solid wood or a spray foam composite material. Traditionally, the back side of each skin is flush and adapted to receive an adhesive to secure the skin to the frame assembly. In order to assemble the door, the frame is assembled and one of the skins is secured to one side of the frame. Next, a foam core is inserted between the frame assembly and against the installed skin. Finally, the opposing skin is then glued to the open side of the door frame.
The present invention broadly comprises a door including a frame having a plurality of slots, a first skin having a plurality of protrusions extending from a first skin back side, a second skin having a plurality of protrusions extending from a second skin back side, an adhesive disposed intermediate the frame and the first skin back side, and an adhesive disposed intermediate the frame and the second skin back side.
The present invention also broadly comprises a door including a frame having a plurality of protrusions on a first side and a second side, a first skin and a second skin each having a back side with a plurality of slots, an adhesive disposed intermediate the first side and the first skin back side, an adhesive disposed intermediate the second side and the second skin back side, and wherein the first skin plurality of slots receive the first side plurality of protrusions and the second skin plurality of slots receive the second side plurality of protrusions.
The present invention further broadly comprises a method of manufacturing a door including the steps of forming a plurality of slots in a frame, forming a plurality of protrusions on a back side of a first skin, applying a layer of adhesive on at least one of the frame and the skin, and inserting the plurality of protrusions into the plurality of slots.
A preferred embodiment of the invention, illustrated of the best mode in which Applicant contemplates applying the principles, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims.
Similar numbers refer to similar parts throughout the drawings.
At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the invention. While the present invention is described with respect to what is presently considered to be the preferred embodiments, it is to be understood that the invention as claimed is not limited to the disclosed aspects.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of the ordinary skill in the art to which this invention belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices, and materials are now described.
The door assembly of the present invention is indicated generally at 20, and is particularly shown in
Door frame 28 includes four components in a preferred embodiment. A lock stile 30 is parallel and spaced apart from a hinge stile 32. The hinge and lock stiles define the vertical perimeter of the door and are preferably spaced apart approximately the same distance as the length of a top rail 34 and a bottom rail 36. Lock stile 30 includes dovetail joints 38 extending from a top end 39 and a bottom end 41 to ensure a secure engagement with the top and bottom rails. Hinge stile 32 also includes dovetail joints 38 extending from a top end 45 and a bottom end 47.
In accordance with one of the main features of the present invention, a plurality of slots 40 is formed in both a front side 42 and a back side 44 of lock stile body 46. In a preferred embodiment, slots 40 are formed in body 46 and extend vertically the full length of body 46, however, it is within the spirit in the scope of the present invention as claimed that the slots extend for merely 25% of the height of the frame, 50% of the height of the frame, or any other suitable length. As seen in
Moving on to
Referring to
In accordance with yet another main feature of the present invention,
Having described the structure of the first embodiment, only those portions of the second embodiment which are different than the first embodiment are described in detail. Likewise, similar numerals refer to similar parts throughout the various embodiments.
Another advantage of the preferred embodiments is the ability to selectively size the door using protrusions 60 and slots 40. Specifically, protrusions 60 may align with only a portion of slots 40, thereby having a portion of the skins hang over the frame. The skin can then be trimmed to reduce the side of the door. The hinge and lock stiles may then include an additional member bolted thereon to ensure a proper door size.
In a second preferred embodiment, frame 88 is composed of six pieces, top rail 34 and bottom rail 36 remaining the same as the previous embodiment. However, lock stile 90 includes a high quality outer piece 92 and a low quality interior piece 94. Hinge stile 96 also includes a high quality outer piece 98 and a low quality inner piece 100. High quality pieces 92 and 98 both include dovetail joints at the top and bottom portions and define the outer most edges of the frame. High quality pieces 92 and 98 are also thin and incorporated at the ends to provide the appearance of a hard wood or high quality door throughout the frame construction, while reducing costs by incorporating low quality pieces 94 and 100. Further, low quality pieces 94 and 100 include protrusions 40 similar to the first embodiment throughout their length. Advantageously, incorporating low quality pieces 94 and 100 for the entire length of the slots ensures that machining of the slots is more readily accomplished without a waste of material.
Finally, high quality piece 92 is preferably adhesive secured to low quality piece 94, while high quality piece 98 is also adhesively secured to low quality piece 100. Accordingly, when the high quality and low quality pieces are attached, they form the lock stile and hinge stile described in the first preferred embodiment in a more cost effective manner.
Having described the structure of the first two embodiments, only those portions of the third embodiment, which are different than the first two embodiments, are described in detail. Likewise, similar numerals refer to similar parts throughout the various embodiments.
In accordance with one of the main features of the present invention, lock stile 110 and hinge stile 112 (not shown) include a plurality of protrusions 114 extending from both sides of each stile. Further, skins 102 and 104 each include a back side 116 and 118 respectively. A plurality of slots 120 are formed within back sides 116 and 118 so that slots 120 are arranged to receive protrusions 112 of lock stile 110 and hinge stile 112.
As discussed in the first preferred embodiment, installation of the third preferred embodiment skins is similar in that first skin 104 is forced in the direction associated with arrow 122 until protrusions 114 are inserted within slots 120, while the second skin is forced in the direction associated with arrow 124 until protrusions 114 are inserted within slots 120. Once again, this arrangement provides for an increased adhesion contact area as well as an interference fit between the skins and the stiles.
Having described the structure of the preferred embodiments, a preferred method of manufacturing will be described in detail and should be read in light of
Initially, plurality of slots 40 are formed in frame 28, and preferably in lock stile 30 and hinge stile 32. Next, a plurality of protrusions 40 are formed on back side 58 and 72 of the skins. The slots may be formed by machining or any other suitable removable technique. Similarly, protrusions 60 may be formed by removing material with a machining apparatus or by adhesively securing preformed protrusions on the back side of each skin. Alternatively, slots 40 may be formed in the skins, while protrusions 60 may be formed on frame 28 without departing from the spirit of the invention.
Next, adhesive is located on either frame 28 or back side 58 and 72 of skins 22 and 26. The skins are then directed towards the frame such that the protrusions 60 are inserted within the respective slots 40 of the frame. After one side has been inserted, foam core 68 is disposed within the frame or may be placed by blowing foam insulation within the frame.
Frame assembly 28 is formed by machining top rail 34 with receiving portions 56 on each end and bottom rail 36 with the same receiving portions 56. Lock stile 30 and hinge stile 32 each include dovetail joints 38 on each end. The dovetail joints and receiving protrusions are complimentary shaped to ensure a tight and secure fit as well as provide increased contact surface for the adhesive to cure. Frame 28 is finally formed by securing the dovetail joints and receiving portions of the lock stile, hinge stile, top rail and bottom rail with adhesive.
While the above method of manufacturing utilizes protrusions on the back side of each skin, it is within the spirit of the scope of the present invention to form protrusions on both sides of the lock and hinge stiles and machine slots in the back side of each skin. Further, a combination of the two may also be used without departing from the spirit of the scope of the invention as claimed. For example, one side of the lock stile may have protrusions, while the opposite side of the same stile may have slots therein. Still further, the lock stile may have protrusions on both ends, and a combination of protrusions and slots while the hinge stile only has slots. Thus, it is seen that any useful combination of slots and protrusions on the stiles and skins may be used without departing from the spirit and scope of the present invention as claimed.
Thus, door assembly 20 provides an increased contact surface area between a door frame and the skins. The door skins are also arranged so that a first skin may have a unique and distinct outward appearance, while the opposing second skin may have a completely different appearance to enable the purchaser to custom fit his/her desired application. Further, a cheaper and more cost effective version of the invention may be incorporated by providing both high quality and low quality wood strategically placed to provide the increased contact surface as well as different skin options.
It will be evident to one skilled in the art that a variety of changes can be made that are within the spirit and scope of the present invention. For instance, the protrusions may be located on either the skin or the stile, while the slots may also be located on either the skin or stiles. Further, any suitable skin design may be used in combination with any other suitable skin design such that the purchaser has a great deal of flexibility in his/her door skins.
Accordingly, the door assembly is an effective, safe, inexpensive, and efficient device that achieves all of the desired objectives of the invention, provides for eliminating difficulties encountered with prior art devices, systems, methods, and solves problems and obtains new results in the art.
In the foregoing description, certain terms have been used for brevity, clearness, and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention is an example, and the scope of the invention is not limited to the exact details shown or described.
Having now described the features, discoveries, and principles of the invention, the manner in which the door frame is constructed and used, the characteristics of the construction, and the advantageous new and useful results obtained; the new and useful structures, devices, elements, arrangement, parts and combinations are set forth in the appended claims.
