Patent Grant
10731400
This application claims priority of patent application CA 2,947,994 filed on Nov. 8, 2016, the specification of which is hereby incorporated by reference.
The technical field generally relates to door panel for a patio door, and more particularly to a tightening connector assembly and a door panel connection assembly for a patio door engageable with elongated door frame members to define at least partially a rectangular door panel frame.
Patio doors are used to provide access from indoors to outdoors. Known patio doors usually include two door panels, wherein one is fixed and the other mobile so as to slide with respect to the fixed panel. Each door panel includes elongated frame members defining together a rectangular frame in which is mounted a glass panel.
Different connectors and/or assemblies exist for assembling together the elongated frame members of a door panel frame or a patio door frame. Such connectors and/or assemblies are typically mounted near or at a corner of two adjacent and connecting elongated frame members.
However, it remains a challenge to provide door panel or patio doors that are free of thermal bridges in the elongated frame members made of metal such as aluminum or which provides a continuous weatherstrip member along a periphery thereof.
Therefore, there is a need for improved door panel frame or door panel connection assembly for a patio door that solve at least some of the issues mentioned above.
In accordance with one aspect, there is provided a door panel for a patio door. The door includes a door panel frame, a connector body and at least one tightening connector assembly. The door panel frame includes at least four elongated door frame members and has a longitudinal axis and a transversal axis. The at least one tightening connector assembly includes a connector body, a tightening insert and at least one mechanical faster. The connector body has a first frame segment and a second frame segment extending along a tightening axis and has an insert receiving cavity defined therein with an insert contact surface defining an oblique angle with respect to the tightening axis. The connector body is engageable with two of the elongated door frame members abutting each other and configured in an orthogonal configuration with the first frame segment being engaged with a first one of the two elongated door frame members and the second frame segment being engaged with a second one of the two elongated door frame members. The tightening insert is engageable in the insert receiving cavity of the connector body and has a connector contact surface contacting the insert contact surface when engaged in the insert receiving cavity. The at least one mechanical fastener is insertable into the second one of the two elongated door frame members, the connector body, and the tightening insert. The connector body and the tightening insert pull the second one of the two elongated door frame members towards and against the first one of the two elongated door frame members and along the tightening axis when being secured together.
In some embodiments, each one of the first and second elongated frame members includes two opposite ends, an internal edge, and an external edge, and end edges connecting the internal and external edges. The adjacent ones of the end edges of the first and second elongated frame members are straight end edges and the straight end edge of one of the first and second elongated frame members abuts against the internal edge of the other one of the first and second elongated frame members.
In some embodiments, each one of the first and second elongated frame members includes a connector receiving cavity defined into adjacent ones of the two opposite ends with a respective one of the first frame segment and the second frame segment being insertable therein.
In some embodiments, the connector receiving cavity of one of the first and second elongated frame members is accessible at least through the internal edge and the connector receiving cavity of the other one of the first and second elongated frame members is accessible through the end edge adjacent to the one of the first and second elongated frame members.
In some embodiments, the other one of the first and second elongated frame members includes a profile with two sidewalls defining a central channel including the connector receiving cavity at one of the opposite ends thereof and the central channel is open along the external edge of the other one of the first and second elongated frame members.
In some embodiments, the connector receiving cavity of the one of the first and second elongated frame members is accessible through the end edge.
In some embodiments, the first frame segment of the connector body includes at least one elongated rail and the first one of the two elongated door frame members engageable with the first frame segment includes at least one elongated guide, complementary to the at least one elongated rail and slidably engageable therewith.
In some embodiments, the insert receiving cavity is defined in the second frame segment of the connector body with the insert contact surface extending inwardly of the connector body.
In some embodiments, the insert contact surface has a profile defined by a plurality of oblique segments, each one of the oblique segments forming the oblique angle with respect to the tightening axis, the profile having an average slope defining the oblique angle.
In some embodiments, the connector contact surface is complementary to the insert contact surface.
In some embodiments, the connector body includes a first section of a mechanical fastener channel extending therethrough and being opened in the insert receiving cavity, and the tightening insert includes a second section of the mechanical fastener channel extending therethrough, the second section of the mechanical fastener channel being aligned with the first section when the tightening insert is inserted into the insert receiving cavity of the connector body.
In some embodiments, the second frame segment includes two sidewalls and the insert receiving cavity includes two insert receiving cavities, each one of the two insert receiving cavities being defined in a respective one of the sidewalls and the tightening insert includes two tightening inserts, each one being engageable with a respective one of the insert receiving cavities defined in the two sidewalls.
In some embodiments, the tightening axis extends substantially parallel to the transversal axis of the door panel frame.
In some embodiments, the door panel includes four tightening connector assemblies, each one being provided in a respective corner of the door panel frame.
In some embodiments, each one of the first and second elongated door frame members includes a weatherstrip receiving channel extending longitudinally therein, and the connector body of the at least one tightening connector assembly further includes at least one weatherstrip receiving channel defined therein, the at least one weatherstrip receiving channel of the connector body being aligned with the weatherstrip receiving channel of a respective one of the elongated door frame members when engaged together.
In accordance with another aspect, there is provided a tightening connector assembly for a patio door frame including at least two elongated door frame members and having a longitudinal axis and a transversal axis. The tightening connector assembly includes a connector body and a tightening insert. The connector body has a first frame segment and a second frame segment extending along a tightening axis, has an insert contact surface defining at least partially an insert receiving cavity and a first section of a mechanical fastener channel extending therethrough and being opened in the insert receiving cavity. The insert contact surface defines an oblique angle with respect to the tightening axis, and the connector body is engageable with two of the at least two elongated door frame members abutting each other and configured in an orthogonal configuration with the first frame segment being engageable with a first one of the at least two elongated door frame members and the second frame segment being engageable with a second one of the at least two elongated door frame members. The tightening insert is insertable in the insert receiving cavity of the connector body and has a connector contact surface contacting the insert contact surface when engaged in the insert receiving cavity and a second section of the mechanical fastener channel extending therethrough. The second section of the mechanical fastener channel is aligned with the first section when the tightening insert is inserted into the insert receiving cavity of the connector body.
In some embodiments, each one of the first and second elongated frame members includes two opposite ends, an internal edge, and an external edge, and end edges connecting the internal and external edges, and adjacent ones of the end edges are straight edges and the straight end edge of one of the first and second elongated frame members abuts against the internal edge of the other one of the first and second elongated frame members.
In some embodiments, each one of the first and second elongated frame members includes a connector receiving cavity positioned near adjacent ones of the two opposite ends and configured for receiving a respective one of the first frame segment and the second frame segment therein.
In some embodiments, the connector receiving cavity of one of the first and second elongated frame members is accessible at least through the internal edge and the connector receiving cavity of the other one of the first and second elongated frame members is accessible through the end edge adjacent to the one of the first and second elongated frame members.
In some embodiments, the other one of the first and second elongated frame members includes a profile with two sidewalls defining a central channel including the connector receiving cavity at one of the opposite ends thereof and the central channel is open along the external edge of the other one of the first and second elongated frame members.
In some embodiments, the connector receiving cavity of the one of the first and second elongated frame members is accessible through the end edge.
In some embodiments, the first frame segment of the connector body includes at least one elongated rail and the first one of the two elongated door frame members engageable with the first frame segment includes at least one elongated guide, complementary to the at least one elongated rail and engageable therewith.
In some embodiments, the insert receiving cavity is defined in the second frame segment of the connector body with the insert contact surface extending inwardly of the connector body.
In some embodiments, the insert contact surface has a profile defined by a plurality of oblique segments, each one of the oblique segments forming the oblique angle with respect to the tightening axis, the profile having an average slope defining the oblique angle.
In some embodiments, the connector contact surface is complementary to the insert contact surface.
In some embodiments, the second frame segment includes two sidewalls and the insert receiving cavity includes two insert receiving cavities, each one of the two insert receiving cavities being defined in a respective one of the sidewalls and the tightening insert includes two tightening inserts, each one being engageable with a respective one of the sidewalls.
In some embodiments, the tightening axis extends substantially parallel to the transversal axis of the door panel frame.
In some embodiments, each one of the first and second elongated door frame members includes a weatherstrip receiving channel extending longitudinally therein; and the connector body of the at least one tightening connector assembly includes at least one weatherstrip receiving channel defined therein, the at least one weatherstrip receiving channel of the connector body being aligned with the weatherstrip receiving channel of a respective one of the elongated door frame members when engaged together.
In accordance with another aspect, there is provided a door panel frame for a patio door and having a longitudinal axis and a transversal axis. The door panel frame includes elongated door frame members and at least one connector body. At least one of the elongated door frame members has a weatherstrip receiving channel extending longitudinally therein. The at least one connector body has a first frame segment and a second frame segment, the connector body being engageable with two of the elongated door frame members abutting each other and configured in an orthogonal configuration with the first frame segment being engaged with a first one of the two elongated door frame members and the second frame segment being engaged with a second one of the two elongated door frame members. The connector body has at least one weatherstrip receiving channel defined therein aligned with the weatherstrip receiving channel of a respective one of the elongated door frame members when engaged together.
In some embodiments, the at least one connector body includes a profile having an inside sidewall and an outside sidewall and the at least one weatherstrip receiving channel of the at least one connector body includes two elongated slots extending along a respective one of the inside and outside sidewalls.
In some embodiments, the at least one of the elongated frame members includes a profile with an inside sidewall and an outside sidewall and each one of the inside and outside sidewalls includes one of the weatherstrip receiving channel extending therealong and the two elongated slots of the connector body are aligned with the respective one of the weatherstrip receiving channels provided in the inside and the outside sidewalls of the at least one of the elongated frame members.
In some embodiments, the two elongated slots are defined on inner wall surfaces of the inside and outside sidewalls and faces each other if the connector body is mounted to a lower edge of the door panel frame and the two elongated slots are defined on outer wall surfaces of the inside and outside sidewalls if the connector body is mounted to an upper edge of the door panel frame.
In some embodiments, each one of the elongated door frame members includes a corresponding one of the weatherstrip receiving channel extending therealong and the door panel frame further includes four of the connector body, each one including at least one of the weatherstrip receiving channel, each one of the connector bodies being mounted in a respective corner of the door panel frame to connect two abutting ones of the elongated door frame members, the weatherstrip receiving channels of the elongated door frame members and the connector bodies defining a weatherstrip path extending substantially continuously along a perimeter of the door panel frame.
In some embodiments, each one of the first and second elongated frame members includes two opposite ends, an internal edge, and an external edge, and end edges connecting the internal and external edges, and adjacent ones of the end edges are straight edges and the straight end edge of one of the first and second elongated frame members abuts against the internal edge of the other one of the first and second elongated frame members.
In accordance with another aspect, there is provided a patio door. The patio door includes a patio door frame, a fixed door panel, and at least one door panel connection assembly. The patio door frame defines a door panel receiving cavity. Thea fixed door panel is insertable into the door panel receiving cavity and having a door panel frame including at least four elongated door frame members and at least one connector body connecting together two of the elongated door frame members abutting each other and configured in an orthogonal configuration. The at least one connector body includes at least two elongated body connectors, at least one on each side thereof, the at least two elongated body connectors being accessible when the at least one connector body engages together the two elongated door frame members. The at least one door panel connection assembly includes a patio door frame connector securable to the patio door frame, protruding in the door panel receiving cavity and having at least two elongated frame connectors, at least one on each side thereof and being slidably engageable with the at least two elongated body connectors of the connector body to be engageable therewith when the fixed door panel is inserted into the door panel receiving cavity.
In some embodiments, the door panel frame has a longitudinal axis and a transversal axis and the at least two elongated body connectors include rails protruding along the transversal axis and the at least two elongated frame connectors include complementary elongated grooves. The rails are slidably engageable into a respective one of the elongated grooves.
In some embodiments, the at least one connector body includes a profile having an inside sidewall and an outside sidewall and the at least two elongated body connectors extending along a respective one of the inside and outside sidewalls on inner wall surfaces thereof.
In accordance with another aspect, there is provided a door panel connection assembly for a patio door to engage a fixed door with a patio door frame inside a door panel receiving cavity defined by a plurality of elongated door frame members of the patio door frame. The door panel connection assembly includes at least one connector body, a patio door frame connector and a patio door frame connector. The at least one connector body is engageable with and securable to two of the plurality of elongated door frame members abutting each other and configured in an orthogonal configuration, the connector body including at least two elongated body connectors, at least one on each side thereof, the elongated body connectors being accessible when the at least one connector body engages together the two elongated door frame members. The patio door frame connector securable to the patio door frame, protruding in the door panel receiving cavity when secured thereto and having at least two elongated frame connectors, at least one on each side thereof and being engageable with a respective one of the at least two elongated body connectors of the connector body to be slidably engageable therewith when the fixed door panel is inserted into the door panel receiving cavity.
In some embodiments, the at least two elongated body connectors include rails protruding therealong and the at least two elongated frame connectors include complementary elongated grooves. The rails are slidably engageable into a respective one of the elongated grooves.
In some embodiments, the connector body includes a profile having an inside sidewall and an outside sidewall and the at least two elongated body connectors extending along a respective one of the inside and outside sidewalls on inner wall surfaces thereof.
Other features and advantages of the invention will be better understood upon reading of embodiments thereof with reference to the appended drawings.
In the following description, similar features in the drawings have been given similar reference numerals. In order to not unduly encumber the figures, some elements may not be indicated on some figures if they were already mentioned in preceding figures. It should also be understood herein that the elements of the drawings are not necessarily drawn to scale and that the emphasis is instead being placed upon clearly illustrating the elements and structures of the present embodiments.
Although the embodiments of the patio door, door panel, tightening connector assembly, door panel connection assembly and corresponding sections and/or parts thereof consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential and thus should not be taken in their restrictive sense. It is to be understood, as also apparent to a person skilled in the art, that other suitable components and cooperation thereinbetween, as well as other suitable geometrical configurations, may be used for the patio door and/or door panel, as it will be briefly explained herein and as can be easily inferred herefrom by a person skilled in the art.
Moreover, it will be appreciated that positional descriptions such as “longitudinal”, “transversal”, “left”, “right”, “upper”, “lower”, “external”, “internal”, “outer”, “inner”, “oblique”, “parallel”, “perpendicular” and the like should be taken in the context of the figures only and should not be considered limiting. Moreover, the figures are meant to be illustrative of certain characteristics of the custom helmet and are not necessarily to scale.
Door Panel and Tightening Connector Assembly for a Patio Door
Generally described, a patio door or at least a door panel for a patio door is provided. The patio door or the door panel may be of different kinds, as it will be described in detail below, but is generally understood as being or being part of a sliding glass door that opens or provides access to a balcony, a deck, a patio or the like from a room of a building. A patio door usually includes two door panels wherein one is fixed (i.e. is in a fixed position) and the other mobile so as to slide with respect to the fixed panel. It is understood that a patio door could include more than two door panels or could alternatively include one or more door panels that are movable or slidable along an axis extending along a door frame or a wall. In some embodiments that will be described in more detail, the patio door has two panels, wherein one is an “active panel” (i.e. a sliding panel) and another one is a “stationary panel” (i.e. a fixed panel). As any patio door or door panel for a patio door, the patio door or the door panel which will be described are typically provided in buildings to provide air circulation and light to a room of a building, as well as allowing the access to the room of the building. The patio door and the door panel described herein may include shape, features and configuration similar to the patio door known in the art. Moreover, the patio door, door panel, tightening connector assembly and connector assembly described in the current description can include a thermal break, and so can improve or at least maintain, in some circumstances, the energy efficiency of the patio door.
As will be described in more detail below, there is also provided a tightening connector assembly, a tightening connector with a weatherstrip receiving channel and a door panel connection assembly.
Referring to
In the following, the features and characteristics of the door panels 42, 43, will be described with reference to the door panel 42. It will however be understood that what will be herein described in reference to the door panel 42 also applies to the door panel 43 and vice-versa.
Each one of the door panel 42, 43 has four edges (two transversal edges and two longitudinal edges), each one being defined by a respective elongated frame members 44a,44b,44c,44d. In the closed configuration of the patio door 40, the sliding and fixed door panel 42, 43 meet and engage each other along the inner longitudinal edges 102 which define an interlock. Each one of the sliding and fixed door panels 42, 43 also include outer longitudinal edges 104, extending substantially parallel to the inner longitudinal edges 102, but spaced-apart therefrom. In the closed configuration of the patio door 40, the outer longitudinal edges 104 abut against a patio door frame 122 while the inner longitudinal edges 102 are located inwardly, substantially superposed and optionnally engaged together.
The door panel 42 (also referred to as the “panel”) includes four elongated door frame members 44a,44b,44c,44d. The four elongated door frame members 44a-d are configurable to define a rectangular door panel frame 46. More particularly, each one of the four elongated door frame members 44a-d can be connected to two other ones of the four elongated door frame members 44a-d. For example, as illustrated, the elongated frame member 44a is connected to the frame members 44b and 44d. As it will be later described, a pair of frame members (example the elongated frame members 44a and 44b) can be connected to one another in each corner with a tightening connector assembly to define the door panel frame 46.
Each one of the four frame elongated members 44a-d can be formed of one piece, or could alternatively be divided into a plurality of sections assembled together to form each one of the four frame elongated members 44a-d.
The elongated frame members 44a-d can be made of different materials, such as, and without being limitative, wood, polymers (such as and without being limitative vinyl, fiberglass, rigid polyvinyl chloride (PVC)), metals including metal alloys (such as and without being limitative aluminum and aluminium alloys), combinations thereof, or any other material that can be configured to form a rectangular door frame panel 46. In some embodiments, the elongated frame members 44a-d are made in extruded rigid plastic material such as polyvinyl chloride (PVC). In other embodiments, the elongated frame members are mostly made of metal and metal alloy. As will be described in more detail below, the tightening connector assemblies and the door panel connection assembly can be suitable with elongated frame members mostly made of metal and metal alloy, and can be provided with a thermal break at least along the corner portions of the door panel frame 46 through the tightening connector assemblies, as will be described in more detail below.
When the four door frame members 44a-d are configured to define the rectangular door panel frame 46, the rectangular door panel frame 46 has a longitudinal axis 48 and a transversal axis 50. As illustrated, the panel 42 can slide along the transversal axis 50 inside a door panel receiving cavity defined in the patio door frame 122.
As illustrated in
When assembled, the rectangular door panel frame 46 can be received into a door panel receiving cavity, i.e. a hole provided in a wall for allowing to insert a patio door or door panels). In an embodiment, the i.e. a hole provided in a wall for allowing to insert a patio door or door panels) is defined by a patio door frame 122 (illustrated in
As it has been previously introduced, each one of the four elongated frame members 44a-d can be connected to two other ones of the four elongated frame members 44a-d (e.g. the elongated frame member 44a can be connected to the frame members 44b and 44d). More particularly, when the rectangular door panel frame 46 is assembled, the rectangular door panel frame 46 includes four corners, i.e. two upper corners and two lower corners. The term “corner” is herein understood as a region in which two of the four elongated frame members 44a-d meet and can be engaged with and secured to each other. In the illustrated embodiment, each one of the four corners define a right angle (i.e. an angle approximately equal to 90 degrees). An example of a corner defined by the meeting of a first elongated frame member 44a with a second elongated frame member 44b is illustrated in
In the embodiment shown, each one of the elongated frame members 44a-d has a substantially rectangular cross-section and with two opposite ends ending with a straight angle (straight end edge). Therefore, when juxtaposed, the end edge of one of the elongated frame members 44a-d is juxtaposed to an internal edge of the adjacent one of the elongated frame members 44a-d. In the embodiment shown, the end edges of the transversally-extending frame members 44a, 44c abut against a respective one of the internal edge of the longitudinally extending frame members 44b, 44d.
As exemplified in
With reference to
Now turning to
The connector body 54 includes a first frame segment 56 and a second frame segment 58. The second frame segment 58 extends along a tightening axis 60, which is substantially parallel to the transversal axis 50 of the door panel frame 46 when the four elongated frame members 44a-d are assembled. As their name entails, the first frame segment 56 is configured to be inserted into a first one of the four elongated door frame members 44a-d and the second frame segment 58 is configured to be inserted into a second one of the four elongated door frame members 44a-d, when the door panel frame 46 is assembled. In the embodiment shown, the first frame segment 56 is configured to be inserted into a longitudinally-extending one of the elongated door frame members (e.g. the elongated member 44a), while the second frame segment 58 is configured to inserted into a transversally-extending one of the elongated door frame members (e.g. the elongated frame member 44b).
The connector body 54 defines an insert receiving cavity 62. The insert receiving cavity 62 is at least partially defined by an insert contact surface 64 of the connector body 54. More particularly, the insert receiving cavity 62 is defined in the second frame segment 58 of the connector body 54. The insert receiving cavity 62 is configured to receive a tightening insert 66, which will abut the insert contact surface 64, as it will be described in more detail.
The insert contact surface 64 extends inwardly of the connector body 54. While its general form or shape can differ, the insert contact surface 64 illustrated in
Now turning to
The connector body 54 is engageable with two of the elongated door frame members 44a-d that are abutted against one another to define at least a portion of the door frame 46. For example, sections of the connector body 54 can be engaged with the elongated frame members 44a and 44b. In such circumstances, the elongated frame members 44a and 44b abut each other close to adjacent end edges 51. More particularly, the elongated frame members 44a and 44b are engaged in an orthogonal configuration (i.e. substantially normal or perpendicular). In this configuration, the first frame segment 56 is engaged with a first one of the two elongated frame members 44a,b (e.g. the elongated frame member 44a) and the second frame segment 58 is engaged with a second one of the two elongated frame members 44a,b (e.g. the elongated frame member 44a). In this orthogonal configuration, the first one 44a of the two elongated frame members 44a,b extends substantially perpendicular (i.e. normal to) the second one 44b of the two elongated frame members 44a,b.
In some embodiments, the first frame segment 56 can be slidably engageable with (or insertable in) the first elongated frame member 44a. For example, the first frame segment 56 can be inserted in the connector receiving cavity 45 of the first elongated frame member 44a (through the opening defined in the end edge of the longitudinally-extending frame member), so as the first frame segment 56 is at least partially embedded in the sidewalls forming the first elongated frame member 44a and the second frame segment 58 protrudes outwardly thereof from the opening defined in the internal edge of the frame member 44a. In such embodiments, the first frame segment 56 can comprise rails or elongated guides so as to be engaged with corresponding and complementary rails or elongated guides 65 of the first elongated frame members 44a (extending along the longitudinal axis) in a predetermined position. In some embodiments, the first frame segment 56 can be engaged or fixed to the first elongated frame members 44 with mechanicals fasteners 70 as shown in
As illustrated, the first frame segment 56 of the connector body 54 includes elongated rails. The elongated rails extend longitudinally along outer wall surfaces of the sidewalls of the first frame segment 56 of the connector body 54. The first one 44a of the two elongated door frame members 44a,b is engageable with the first frame segment 76 and comprises at elongated guide(s) 65. The elongated guide(s) 65 are complementary to the elongated rail(s) and slidably engageable therewith. The elongated guides 65 are defined in inner wall surfaces of the sidewalls of the elongated door frame member 44a and extends longitudinally therein. They are accessible through a central channel 111 extending longitudinally inside the profile of the elongated door frame members 44a, in the section corresponding to the connector receiving cavity 45.
The connector body 54 can be made of different materials, such as, and without being limitative, polymers (such as and without being limitative vinyl, fiberglass, rigid polyvinyl chloride (PVC)), metals including metal alloys (such as and without being limitative aluminum and aluminium alloys), combinations thereof, or similar materials. In some embodiments, the connector body 54 is made in extruded rigid plastic material, such as and without being limitative polyvinyl chloride (PVC).
When made of a relative low thermal conductivity material, such as polymers, the connector bodies are thermal insulators provided inside the door panel frame 46, defining a thermal barrier or a thermal break inside the elongated frame members.
Referring to
As illustrated, the tightening insert 66 has a connector contact surface 68, which is configured to contact the insert contact surface 64, when engaged in the insert receiving cavity 62.
The tightening insert 66, and more particularly the connector contact surface 68, has a shape that is substantially complementary to the shape of the insert receiving cavity 62, i.e. when the tightening insert 66 is inserted into the insert receiving cavity 62, the tightening insert 66 substantially or completely fill the space defined by the insert receiving cavity 62.
More particularly, and as better illustrated in
As the insert contact surface 64, one or more segment(s) of the connector contact surface can be parallel or normal to the tightening axis 60. For example, and as better seen in
Now referring to
The tightening insert 66 also includes a second section 89 of the mechanical fastener channel 67. The second section 89 of the mechanical fastener channel 87 is aligned with the first section 85 extending through the connector body 54 when the tightening insert 66 is inserted into the insert receiving cavity 62 of the connector body 54. In this context, the first and second sections 85, 89 of the mechanical fastener channel 87 are aligned so as mechanical fasteners 70 can be inserted into the first section 85 of the mechanical fastener channel 87 and extend through the first and second sections 85, 89 (see for example
The shape, geometrical configuration and dimensions of the first and second sections 85, 89 of the mechanical fastener channel 87 are selected according to the mechanical fasteners 70 to be used to secure a first one elongated frame member to a second one elongated frame member (e.g. the longitudinally-extending elongated frame member 44a with the transversally-extending elongated frame member 44b).
In some embodiments, the tightening insert 66 is a monolithic piece that can be made of for example, and without being limitative, polymers (such as and without being limitative vinyl, fiberglass, rigid polyvinyl chloride (PVC)), metals including metal alloys (such as and without being limitative aluminum and aluminium alloys), combinations thereof, or similar materials. In one embodiment, the tightening insert 66 is made in extruded rigid plastic material, such as and without being limitative rigid polyvinyl chloride (PVC). In other embodiments, the tightening insert 66 is made from a metal allow such as, and without being limitative zinc alloy (e.g. a base metal of zinc with alloying elmenets of aluminium and magnesium, such as “Zamak”). In alternative embodiments, the tightening insert 66 could also be divided into sections, which could be assembled to form the tightening insert 66.
When the tightening insert 66 is engaged into the insert receiving cavity 62, the second frame segment 58 can be engaged with the second one of the two elongated door frame members 44b,d (e.g. the frame member 44b). For example, the second frame segment 58 can be slidably engaged with frame member 44b. The second frame segment 58 can be inserted in the connector receiving cavity 45 of the second elongated frame member 44b (through the opening defined in the end edge 51 of the transversally-extending frame member), so as the second frame segment 58 is at least partially embedded in the sidewalls forming the second elongated frame member 44b. In some implementations, the second frame segment 58 can be engaged or fixed to the second one of the two elongated frame members 44b,d (e.g. the frame member 44b) with mechanicals fasteners 70, as shown in
In an embodiment, the tightening connector assembly 52 also includes at least one mechanical fastener 70. The mechanical fastener(s) 70 is(are) insertable into the second one of the two elongated door frame members 44a-d (e.g. the elongated door frame member 44b), the connector body 54 and the tightening insert 66 to pull the second one of the two elongated door frame members 44a-d (e.g. the elongated door frame member 44b) against the first one of the two elongated door frame members 44a-b (e.g. the elongated door frame member 44a) and along the tightening axis 60 when being secured together, as will be described in more detail below.
Now turning to
In a first step, illustrated in
In a subsequent step, illustrated in
In another step, illustrated in
When the first frame segment 56 is inserted into the first elongated frame member 44a, the second frame segment 58 protrudes outwardly from the opening defined in the internal edge 106 of the first elongated frame member 44a. It is to be noted that, in the illustrated embodiment, the second frame segment 58 is provided with two insert receiving cavities 62, one defined in each sidewall.
In another step, illustrated in
Now referring to
As the mechanical fasteners 70 engage into the first and second frame members 44a,b, the connector body 54 and the tightening insert 66, through the mechanical fastener channel 87 having first and second sections 85, 89 extending through the connector body 54 and the tightening insert 66, the mechanical fasteners 70 exert a force that pulls the second elongated door frame member 44b against the first elongated door frame member 44b. After these steps, the first and second elongated frame members 44a, 44b are rigidly connected (i.e. tighten) to each other so as to achieve and maintain the orthogonal configuration.
The position of the first and second sections 85, 89, and more particularly the orientation/alignment of the first and second sections 85, 59 with respect to the mechanical fasteners inserted into the mechanical fastener channels 87 accessible via the external edges 108 of the second elongated frame member 44b is predetermined and selected such that when the mechanical fasteners 70 (e.g. a screw) are inserted into the mechanical faster channel 87 (i.e. into the first and second sections 85, 89) accessible via the external edges 108 of the second elongated frame member 44b, the first elongated frame member 44a is positioned perpendicularly and tightly juxtaposed against the second elongated frame member 44b.
Tightening Connector with a Weatherstrip Receiving Channel
Referring back to
While the tightening connector body 54 is configured to be mounted to a lower portion of the sliding panel 42 and engage together the elongated door frame members 44a,b meeting in “zone 2”, the tightening connector body 154 is configured to be mounted to an upper portion of the sliding panel 42 and engage together the elongated door frame members 44a,d meeting in “zone 1”. “Zone 1” identified in
The connector body 154 is engageable with two of the elongated door frame members 44a,d, similarly to what has been previously described, i.e. that two of the elongated frame members 44a,d perpendicularly abut each other when assembled, and so are configured in an orthogonal configuration (i.e. that the two elongated door frame members 44a,d define a substantially straight angle). As such, the first frame segment 156 is engaged with a first one of the two elongated door frame members and the second frame segment 158 is engaged with a second one of the two elongated door frame members in the “zone 1” illustrated in
Furthermore, both tightening connector bodies 54, 154 also include a weatherstrip receiving channel 92, the purpose of which will be described in further detail below.
In an embodiment, at least one of the elongated door frame members has a weatherstrip receiving channel. For example, as illustrated in
In an embodiment, the four elongated door frame members 44a-d include a weatherstrip receiving channel 110 extending therealong, following the external edge thereof and being opened to insert a weatherstrip (not shown) therein in a manner such that the weatherstrip is in contact with the door frame 122.
In the embodiment shown, each one of the four elongated door frame members 44a-d includes two weatherstrip receiving channels 110, one being positioned on an inner side of the door panel and the other one being positioned on an outer side of the door panel. The two weatherstrip receiving channels 110 are spaced-apart from one another with a central channel 111 extending longitudinally inside the profile of the elongated door frame members 44a-d. It is appreciated that, in an alternative embodiment, at least one of the elongated door frame members 44a-d can include one weatherstrip receiving channel 110 or more than two weatherstrip receiving channels 110.
In the embodiment shown in
As such, each one of the weatherstrip receiving channels 110 is configured to receive a weatherstrip (not shown) therein. Thus, when inserted and engaged inside a respective one of the weatherstrip receiving channel, the weatherstrip extends along the respective one of the elongated door frame member 44b.
As mentioned above, in one embodiment, each one of the four elongated door frame members can include one or more weatherstrip receiving channel in which a corresponding weatherstrip can be inserted, and the door panel frame 46 can hence be provided with a substantially continuous weatherstrip along its entire perimeter, with discontinuities being provided solely in corners thereof. Alternatively, the weatherstrip could be provided at some specific portions of the perimeter of the door panel frame 46, depending on the required sealing properties.
In an embodiment described in further detail below, the tightening connector bodies 54, 154 are provided with at least one weatherstrip receiving channel 92 to provide a continuous weatherstrip along an entire perimeter of the door panel frame 46.
Now referring back to
Turning to
The weatherstrip receiving channels 92 are embodied by slots provided along the connector body 54, 154, either along the first segment or the first and second segments. Alternatively, the weatherstrip receiving channels can be provided elsewhere onto or into the connector body 54, 154. In such an alternative embodiment, the weatherstrip receiving channels 110 of the corresponding elongated door frame members can be positioned accordingly, so as the weatherstrip receiving channel 92 of the connector body 94 and the weatherstrip receiving channel 110 of the corresponding elongated door frame members 44a-d are aligned when the connector body 54, 154 (and its corresponding first and second segments) is engaged with the elongated door frame members 44a-d.
In some embodiments, shown for example in
In some embodiments, the four elongated door frame members 44a-d comprise a corresponding one of the weatherstrip receiving channel 110 extending therealong. In this embodiment, the rectangular door panel 46 further comprises four tightening connector assemblies, each one including at least one of the weatherstrip receiving channel 92, 192, and each one of the tightening connector assemblies being mounted in a respective corner of the rectangular door panel 46 to connect two abutting ones of the elongated door frame members 44a-d (e.g. 44a and 44b). The weatherstrip receiving channels 110, 92, 192 of the elongated door frame members and the tightening connectors define a weatherstrip path extending substantially continuously along a perimeter of the rectangular door panel 46.
When the elongated frame members 44a-d are engaged together to define the door frame 46, the weatherstrip receiving channels 92, 110, 192 define a channel or slot extending substantially continuously along the periphery of the door frame 46. It is appreciated that small discontinuities can be provided when a longitudinally-extending segment of the weatherstrip receiving channels 92, 110, 192 meets a transversally-extending segment of the weatherstrip receiving channels 92, 110, 192.
Now turning to
For simplicity, the features of the embodiments described below are numbered with reference numerals in the 200, 300, and 400 series respectively which correspond to the reference numerals of the previous embodiments.
In
The tightening connector body 254 includes essentially the same features as the tightening connector bodies 54, 154 with respect to the insert receiving cavity 262 defined therein and having the insert contact surface 264 defining an oblique angle with respect to the tightening axis 60.
Furthermore, as the tightening connector bodies 54, 154, the connector body 254 has two spaced-apart weatherstrip receiving channels 292, each one extending on one side of connector body 254. When the tightening connector body 254 connects together the two elongated door frame members 44c,d meeting in “zone 8”, the weatherstrip receiving channels 292 are aligned and extend continuously with a respective one of the weatherstrip receiving channels 110 of the elongated door frame member 44c,d extending along the transversal axis 50 of the door panel frame 46.
As the tightening connector body 154, which is also mounted in the upper portion of the rectangular door panel 46, the two spaced-apart weatherstrip receiving channels 292 of the tightening connector body 254 are open and accessible outwardly. They are open on opposed outer sides of the connector body 254. More particularly, the tightening connector body 254 has weatherstrip receiving channels 292 provided on the inside and the outside sidewalls, on the outer wall surfaces thereof.
Now referring to
For example, the embodiment depicted in
As the tightening connector body 54, which is also mounted in the lower portion of the rectangular door panel 46, the two spaced-apart weatherstrip receiving channels 392, 492 of the tightening connector bodies 354, 454 are open and accessible outwardly. They are open on opposed outer sides of the connector bodies 354, 454. More particularly, each one of the tightening connector bodies 354, 454 has weatherstrip receiving channels 392, 492 provided on the inside and the outside sidewalls, on the inner wall surfaces thereof.
With reference to
As the tightening connector body 254 which is also mounted in the upper portion of the rectangular door panel 46, the two spaced-apart weatherstrip receiving channels 592 of the tightening connector body 554 are open and accessible outwardly. They are open on opposed outer sides of the connector body 554. More particularly, each one of the tightening connector bodies 554 has weatherstrip receiving channels 592 provided on the inside and the outside sidewalls, on the outer wall surfaces thereof.
Referring now to
Now referring to
It is appreciated that none or at least some of the connector bodies can include one or more insert receiving cavity configured to receive a tightening insert therein. In an embodiment (not shown), all the connector bodies can be free of insert receiving cavity.
Furthermore, in another embodiment wherein at least some of the connector bodies includes one or more insert receiving cavity, it is appreciated that the shape and the configuration of the insert receiving cavity(ies) and the complementary tightening insert(s) can vary from the embodiments shown in the accompanying figures.
It will be understood that in the context of the current description, the term “weatherstrip” refers to a band of material which can be introduced into and extend continuously in respective ones of the weatherstrip receiving channels 92, 192, 292, 393, 492, 592 and the weatherstrip receiving channels 110 so as to provide the rectangular door panel frame 46 (or one of its component/section) with a thermal barrier or a thermal break, and so to prevent the water from flowing towards the interior of the building. More particularly, the weatherstrip can at least partially seal, fill or isolate the gap between some components of the patio door 40 and/or the frame of the patio door 40.
Now referring to
In the embodiments shown, when the connector body is mounted in the upper portion of the rectangular door panel 46, the two spaced-apart weatherstrip receiving channels are provided on the outer wall surfaces of the inside and the outside sidewalls. On the opposite, when the connector body is mounted in the lower portion of the rectangular door panel 46, the two spaced-apart weatherstrip receiving channels are provided on the inner wall surfaces of the inside and the outside sidewalls.
In some embodiments, the weatherstrip is made, from example and without being limitative of polyvinyl chloride (PVC), foam, rubber, vinyl, combinations thereof or the like, and the material can be selected so as to meet particular requirement(s) and/or standard(s). The weatherstrip can also be sticky or be provided with an adhesive, so as to maintain its positioning when installed into the weatherstrip receiving channel 92. The weatherstrip could also be deformable, resilient, or rigid, according to the targeted application.
Dimensions (e.g. its width and/or length) can vary according to one's need, and are usually predetermined so as to be compatible (i.e. complementary) with the dimensions of the weatherstrip receiving channels 92, 192, 292, 392, 492, 592. In some implementations, the patio door 40 is provided with only one continuous section of weatherstrip extending along an entire external perimeter of the four elongated door frame members defining a door panel. In other implementations, the weatherstrip can be provided in more than one section.
While the different characteristics and features of the weatherstrip can vary from one embodiment to another, it will be readily understood that the weatherstrip is embodied by a component which can prevent or reduce, under certain circumstances, drafts and energy loss with a patio door or a patio door panel.
Door Panel Connection Assembly
With reference to
Referring now to
The door panel connection assembly 620 includes the tightening connector body 654, illustrated in
It is appreciated that the shape and the configuration of the connector body 654 can vary from the embodiment shown in
In some embodiments, the connector body 654 includes two elongated body connectors 625a,b (also referred to as “two elongated male or female members”). The two elongated body connectors members 625a,b are positioned on a respective side of the connector body 654, i.e. one on the inside sidewall and one of the outside sidewall. As illustrated, the two elongated body connectors 625a,b are elongated male connectors (or, alternatively “members”) protruding from two opposite sidewalls of the connector body 654, inwardly inside the central channel 111, i.e. protruding from the inner wall surfaces. The two elongated male connectors 625a,b extend along continuously in the first and second frame segments 656, 658 of the connector body 654 and are positioned on a respective inner wall surface 626a,b of the connector body 654, above the weatherstrip receiving channels 692. Alternatively, the elongated connectors 625a,b could both be elongated female members, such as elongated channels defined in the connector body 654, either on the inner wall surfaces or the outer wall surfaces. In another variant, one of the two elongated members could be an elongated male member, while another one of the two elongated members could be an elongated female member.
In the illustrated embodiment, the two elongated body connectors 625a,b (illustrated as elongated male connectors) are similar to a pair of rails, i.e. a pair of bars that can serve as a guide. It will be readily understood that the two elongated body connectors 625a,b could be replaced by any structural member allowing to achieve a similar configuration.
When the connector body 654 engages together two elongated door frame members, the two elongated body connectors 625a,b are physically accessible through the central channel 111. As such, a complementary part or component could be attached or engage with the two elongated body connectors 625a, b.
In addition to the tightening connector body 654, the door panel connection assembly 620 includes patio door frame connector 630 securable to the patio door frame 122 and engageable with the connector body 654.
As its name entails, the patio door frame connector 630 is securable to the patio door frame 122. The patio door frame connector 630 is protruding into the door panel receiving cavity, from an upper edge thereof, when secured to the patio door frame 122. In this context, securing the patio door frame connector 630 to the patio door frame 122 can be achieved with mechanical fasteners, such as screws, nails, snaps or the like.
As illustrated, the patio door frame connector 630 includes two elongated frame connectors 631a,b (also referred to as “two elongated male or female members”), wherein the elongated connectors 631a,b are open or engageable on opposed sides, i.e. one being open on the inner side and the other being open on the outer side with respect to the door panel 43. The two elongated frame connectors 631a,b are configured so as to be engageable with the two elongated body connectors 625a,b of the connector body 654. For example, in one embodiment, the two elongated members 625a,b are elongated rails, i.e. male members, while the two elongated members 631a,b are complementary elongated channels, i.e. elongated female members. In such an embodiment, the two elongated male connectors 625a,b of the connector body 654 can be engaged with the corresponding two elongated female connectors 631a,b of the patio door frame connector 630 when the fixed door panel 43 is slidingly inserted into the door panel receiving cavity. As such, the two elongated male or female members 625a,b of the connector body 654 are complementary to the two elongated male or female members 631a,b of the patio door frame connector 630, i.e. they can engage (or, alternatively, be inserted) with each other by a sliding movement.
In the embodiment shown, the patio door frame connector 630 further includes injection holes 632, 634. The injection holes 632, 634 are positioned and configured so as to allow the injection of an insulating barrier, such as and without being limitative, silicone into a hollow portion of the patio door frame connector 630, as well as evacuating air from the hollow portion of the patio door frame connector 630. In the illustrated embodiment, the injection holes 632, 634 have a circular cross-section and are positioned on a top portion of the patio door frame connector 630, respectively. In such embodiment, the injection hole 632 is configured so as to receive silicone therethrough and the injection hole 634 is configure so as to allow evacuating the air from within the hollow portion of the patio door frame 630. When the silicone is injected into the hollow portion of the patio door 630, the silicone can be in contact with the door frame 122, and so provide a sealed interface. It will be readily understood that the geometrical features and the positioning of the injecting holes could vary, depending on where the insulating barrier should be dispensed and/or injected.
In some embodiments, the patio door frame connector 630 further includes a protuberance 636 extending towards the door panel receiving cavity. The protuberance 636 can promote or enhance the sealing of the fixed door panel 43 once assembled by acting as a physical barrier.
Now turning to
As shown in
As better seen in
A portion of the assembled fixed door panel 43, engaged with the patio door frame 122 inside the door panel receiving cavity, is illustrated in
With reference to
The connection assembly 720 includes a patio door frame connector 730, similar to the patio door frame connector 630. The patio door frame connector 730 can be mounted near the “zone 7” identified in
In the illustrated embodiment, the patio door frame connector 730 has a T-shaped cross-section.
The connection assembly 720 also includes a connector body 754. The connector body 754 is similar to the ones which have been previously described, and so is engageable with two of elongated door frame members (not shown). In the illustrated embodiment of
Similarly to what has been previously presented, one would readily understood that the configuration of the male/female members of the patio door frame connector 730 and/or the connector body 754 could be interchanged. Furthermore, each one of these components (i.e. the patio door frame connector 730 and the connector body 754) could be provided with injecting hole(s) configured to receive an insulating barrier, such as, and without being limitative, silicone.
It is appreciated that, in an alternative embodiment (not shown), the tightening connector body 754 can include an insert receiving cavity configured to receive a tightening insert therein and/or can be free of weatherstrip receiving channel(s).
Once the fixed door panel 43 is assembled in the “zone 5” and the “zone 7”, the result is a fixed door panel 43 insertable into the door panel receiving cavity. Such a fixed door panel 43 usually includes four elongated door frame members and four connector bodies connecting altogether pairs of elongated door frame members. Once assembled, each of the elongated door frame member are abutting two other elongated door frame members. The two elongated body connectors members 725a,b of the connector body 754 are engaged (i.e. inserted) to the corresponding two elongated frame connectors 731a,b of the patio door frame connector 730. Once engaged in a predetermined position wherein the outer longitudinal edge 104 of the fixed door panel 43 abuts against the patio door frame 122, the fixed door panel 43 can be secured to the patio door frame 122 using suitable mechanical fasteners, such as screws or nails, as it is known in the art.
It will be readily understood patio door or door panel for patio door may be conceived and installed according to at least one of the embodiments described above. More particularly, it is appreciated that features of one of the above described embodiments can be combined with the other embodiments, variants, or alternatives thereof.
Several alternative embodiments and examples have been described and illustrated herein. The embodiments of the door panel and door panel connection assembly for a patio door described above are intended to be exemplary only. A person of ordinary skill in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. It is understood that the door panel and door panel connection assembly for a patio door may be embodied in other specific forms without departing from the central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. Accordingly, while the specific embodiments have been illustrated and described, numerous modifications come to mind. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.
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