Patent Application
20120272601
The present invention generally relates to a door having a frame and panel construction, a door unit, and a method of constructing the door.
Aluminum has a high strength to weight ratio and is commonly used in constructing door frames, particularly for domestic homes, as it provides a good level of security. A typical aluminum framed door further includes a panel comprising plastics (often PVC) material sandwiching a thermally insulating foam material. Despite the security afforded by the strength of the aluminum frame the plastics panel can be relatively easily punctured, which reduces the security of the door construction. The plastics panel is also relatively flexible, which detracts from the quality feel afforded by a solid wood door, for example.
Solid wood doors have their own disadvantages in that they can be susceptible to distortion with seasonal changes, are generally more expensive, and are more difficult to maintain and weatherproof.
There is a need for an improved door that is solid, secure, durable, thermally and acoustically insulated, has high aesthetic appeal, is easy to maintain, and which can be highly customized.
A first aspect of the invention provides a door having a frame and panel construction, wherein the panel comprises a plurality of planks received in a rebate formed in the surrounding frame, and the planks include extruded aluminum profiles.
A further aspect of the invention provides a method of assembling a door having a frame and panel construction, the method comprising assembling an incomplete frame having a rebate, assembling a panel by arranging a plurality of planks received in the rebate in the surrounding frame, and completing the frame after the panel assembly is complete, wherein the planks include extruded aluminum profiles.
The invention is advantageous in that the extruded aluminum planks received in the rebated frame provide a particularly solid, secure, durable, thermally insulated, highly customizable, low maintenance door that can be provided in a variety of aesthetic finishes and colors, including wood grain effect.
The planks preferably interlock to form the panel. The planks may interlock using a tongue and groove system. Preferably the planks interlock with an interference fit and without fasteners. Alternatively, the planks may be clipped together to form the panel.
The panel is preferably received in the rebated frame with an interference fit, and without fasteners and without exposed beading. The panel therefore contributes significantly to the structural rigidity of the door, and is highly secure as there are no exposed beads or trims that can be removed.
The planks may be oriented horizontally, vertically, or at any intermediate angle. The panel may be divided into a plurality of plank portions each containing one or more of the planks, and at least one plank portion includes planks oriented differently to at least one other plank portion. The panel may include a generally H-shaped profiled section interlocked between adjacent plank portions. The H-shaped profile provides an overlapping weatherproof connection between the edges of each section.
This provides a highly customizable modular design to create a wide variety of panel designs from only a few different plank profiles. Typically less than ten, and preferably less than five, different plank profiles of various widths are required for a complete range of doors. The extruded aluminum planks may be provided as long lengths, which can be cut to size depending on the panel design and the door dimensions.
The panel may further comprise a glass pane surrounded by the planks. The panel may include a generally H-shaped profiled section interlocked between the glass pane and the surrounding planks.
Each plank preferably includes a pair of back-to-back extruded aluminum profiles with one or more thermally insulating bridges extending between the profiles. Similarly, the H-shaped profiled section may include a pair of back-to-back extruded aluminum profiles with a thermally insulating bridge extending between the profile. The insulating bridge preferably includes polyamide material. The bridge may be dovetailed to the aluminum profiles to provide a secure connection.
The frame preferably includes extruded aluminum profiles. The frame may have a similar construction to planks and preferably includes a pair of back-to-back extruded aluminum profiles with one or more thermally insulating bridges extending between the profiles.
The frame may comprises rails and stiles. The frame may include top and bottom rails and a pair of vertical stiles to provide a rectangular frame. Each of the rails and stiles may have the same extruded aluminum profiles. The stiles and rails may be mitred at each corner. A truncated frame, for fitting under eaves for example, may include a pentagonal frame.
The planks and/or the frame may be painted or anodised. In one embodiment, the paint provides a textured wood grain effect finish. The resultant door may therefore have the appearance of a traditional solid timber door.
The door may be provided as a door unit comprising one or more doors according to the invention mounted for movement with respect to a doorway frame.
For the purpose of illustrating the invention, the drawings show aspects of one or more embodiments of the invention. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:
a-d illustrate various planks having common tongue and groove dimensions but different widths;
a illustrates the H-shaped profile used to join between two planks, and
a-zd illustrate various doors having different panel arrangements; and
The plank 6 includes substantially planar opposing outer surfaces 17, 18 which form the panel surfaces on either side of the door 1. Chamfered edges 19 form V-shaped grooves in the panel surfaces in the assembled door. The completed door 1 therefore has the exterior appearance of a traditional solid wood door.
a illustrates the H-shaped profiled section 21 used to join between cut ends of the planks 6.
The door 1 is assembled by cutting the extruded aluminum frame sections 2a, 2b, 2c and the planks 6 to desired lengths. Three of the frame sides are connected to form an open frame. The planks 6 are then loaded into the rebate 4 in the open frame before the frame is closed with the fourth side. The completed frame 2 fully retains the panel 5 securely without any fixings.
The planks 6 and the frame 2 may be painted or anodised prior to cutting and assembly. By applying the surface finish prior to assembly, the finish covers all areas which may otherwise be hard to reach after assembly, including intricate hidden areas at the door edge. The paint may applied in any color or may alternatively be applied to provide a textured wood grain effect finish. Combining the textured wood grain effect finish with the structural appearance of a traditional solid wood door provides a true likeness of a solid wood door without any of the disadvantages typically associated with solid wood doors. The texture wood grain effect is a result of the fusion of two materials, which are applied separately and subjected to high temperatures within a kiln. This process ensures a consistent thickness, texture and exceptionally hard and luxurious finish.
Each of the doors illustrated in
b shows a door 102 in which the panel includes five portions each comprising a plurality of horizontal planks 6, with an H-profile 21 between the adjacent portions.
d shows a door 104 similar to
g shows a door 107 similar to the door 104 but with a glass pane 25. An H-profile 21 is provided between the glass pane 25 and the planks 6 surrounding the edge of the glass pane.
k shows a door 111 having a glass pane 25 arranged similarly to the door 110 and with detailing provided by H-profiles 21 surrounding a plurality of horizontal planks 6.
o shows a door 115 having a plurality of horizontal planks 6.
u shows a door 121 with inclined and horizontal planks 6 and an upper glass pane 25.
zb, 9zc and 9zd each show double doors 128, 129, 130 respectively comprising two discrete frames arranged with vertical symmetry.
Although the invention has been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope of the invention as defined in the appended claims.
