This application claims priority to application number 03257017.8-1255, filed Nov. 6, 2003 and application number 04255736.3 filed Sep. 21, 2004 in the European Patent Office, the disclosure of which is incorporated herein by reference.
The present invention is directed to a glazed door having a peripheral doorframe, and first and second door facings secured to opposing sides of the doorframe. Each door facing has an opening. A saddle is secured to the first and second door facings, and surrounds the opening. A first glazing bead is secured to a first receiving portion of the saddle. A second glazing bead is secured to a second receiving portion of the saddle. A glazing panel is secured within the opening between the first and second glazing beads. A method of forming the glazed door is also disclosed.
As known in the art, door facings may be secured to a support structure or frame to form a hollow core door. Such facings may be molded from a planar cellulosic mat, which typically includes cellulosic fibers or particles and a resin binder. The mat may be molded to include one or more depressions or grooves, such as one or more square or rectangular depressions. These depressions may define the perimeter of one or more simulated panels. Alternatively, the facings may be flush.
It is sometimes desirable for such doors to have a glazing unit, frequently provided in the form of a cassette. A cassette is a framed window assembly adapted to be mounted to a door. In addition to a perimeter frame, the door facings are secured to a window frame. A portion of each door facing is routed or cut out in an area corresponding to the area defined by the window frame. The cassette is mounted within the window frame, and secured to the window frame using screws, pins, or the like.
Various cassette designs have been developed. Many designs comprise first and second halves that hold a glass unit. The first halve of the cassette is positioned against one facing. The glass is then placed in position, and the second halve is positioned against the opposing facing, sandwiching the glass therebetween. The cassette is then secured in place on the door using pins or screws.
Cassettes typically are bulky, having a thickness greater than the thickness of the doorframe. As such, cassettes often protrude outwardly from the exteriorly disposed surfaces of the door facings. The cassette on such a glazed door may be easily damaged, particularly during transit, given it protrudes from the exterior plane of the door facings. The fasteners used to secure the cassette to the door are usually visible and can be unsightly.
Glazed doors having conventional glazing units are relatively expensive to manufacture. Such doors must be specially made with an internal window frame. The cassette halves are typically fragile, and must be stored and handled with care to avoid damage. The cassette halves and glass unit must be carefully positioned and secured with pins or screws, thereby increasing labor costs for such doors.
Therefore, there is a need for a glazed door, and a method of making a glazed door, that is cost efficient, aesthetically pleasing to consumers and allows glass to be retrofitted to a standard hollow core door.
The present invention is directed to a glazed door. The glazed door includes a peripheral doorframe, and first and second door facings secured to opposing sides of the doorframe. Each door facing has an opening. A saddle is secured to the first and second door facings, and surrounds the opening. A first glazing bead is secured to a first receiving portion of the saddle. A second glazing bead is secured to a second receiving portion of the saddle. A glazing panel is secured within the opening between the first and second glazing beads.
The present invention also relates to a method of forming a glazed door. A door is provided having first and second door facings secured to opposing sides of a peripheral doorframe. Each of the facings has a panel portion. The panel portion is removed from each of the facings to form an opening in the door. A saddle is secured to the door facings surrounding the opening. A first glazing bead is secured to a first receiving portion of the saddle. A glazing panel is positioned within the opening and against the first glazing bead. A second glazing bead is secured to a second receiving portion of the saddle so that the glazing panel is secured between the first and second glazing beads.
As best shown in
As best shown in
First and second legs 44, 46 are preferably flush with, and grip, exterior surfaces 20, 24 of first and second facings 14, 16, respectively, thereby securing saddle 32 in place around opening 26. An adhesive, such as polyvinyl acetate, may also be used to secure saddle 32 in place. However, first and second legs 44, 46 are preferably configured such that saddle 32 may be securely fitted in place without the use of an adhesive or other fastening means. In this way, saddle 32 may be quickly and easily clipped around opening 26 during manufacture of glazed door 10. To ensure a secure fit, legs 44, 46 should be spaced from each other a distance that is substantially equal to the thickness of door 10. In addition, legs 44, 46 should extend onto exterior surfaces 20, 24 a sufficient amount to securely grip facings 14, 16.
Saddle 32 also includes an integral glazing bead 48 extending outwardly into opening 26. Glazing bead 48 includes an inner surface 50 extending from central portion 42, which abuts one side of glazing panel 36. Glazing bead 48 may include a contoured portion 52, though a planar angular side may also be provided. Contoured portion 52 may provide additional support to inner surface 50. Alternatively, inner surface 50 may have sufficient thickness so that no additional structural support by contoured portion 52 is required. Contoured portion 52 preferably extends from first end 38 to inner surface 50. Contoured portion 52 preferably is configured to enhance the decorative appearance of door 10. It should be understood that the configuration of contoured portion 52 might vary. However, contoured portion preferably does not extend outwardly beyond the plane of exterior surfaces 20, 24 to reduce the possibility of damaging the glazing system. In this way, any damage to doors 10 during transport, or when stacked, is minimized.
Saddle 32 also includes an inner clip 54 and an outer clip 56. Inner clip 54 extends outwardly from central portion 42 into opening 26, and is proximate inner surface 50. Clips 54 and 56 preferably extend parallel to inner planar surface 50. Outer clip 56 extends into opening 26, and is proximate second end 40. Outer clip 56 may be coplanar with second leg 46. Inner and outer clips 54, 56 preferably include hooked ends 58, 60, respectively, which curve inwardly toward each other.
Saddle 32 may also include a central stud 62, which extends outwardly into opening 26, as best shown in
Saddle 32 is preferably formed of plastic, such as polyvinyl chloride, in order to provide sufficient flexibility to allow saddle 32 to be clipped into place about opening 26 and yet have sufficient rigidity to maintain glazing panel 36 secured during use of door 10. In addition, all of the components of saddle 32 are preferably integrally formed. It should be understood that the precise dimensions of saddle 32 may vary depending on the dimensions and thickness of door 10, as well as the dimensions and thickness of glazing panel 36. Further, the dimensions of saddle 32 may vary depending on the material used to form saddle 32. Glazing bead 48 preferably extends into opening 26 a sufficient distance so that inner surface 50 provides sufficient support to glazing panel 36. Legs 44, 46 should be sufficiently spaced, and have a sufficient length, so that saddle 32 grips facings 14, 16.
As best shown in
Glazing bead 34 may also include a second contoured portion 70, which preferably corresponds to the configuration of contoured portion 52, as best shown in
Glazing bead 34 is preferably formed of plastic, such as polyvinyl chloride. As with saddle 32, the precise dimensions of glazing bead 34 may vary depending on the dimensions of door 10 and glazing panel 36, as well as the material used to form glazing bead 34.
The present invention is also directed to a method of forming a glazed door, such as glazed door 10. As best shown in
Glazing panel 36 may then be secured to door D within opening 26 using saddle 32 and glazing bead 34, as best shown in
Next, glazing panel 36 is positioned against inner surface 50 of glazing bead 48 on saddle 32, as best shown in
A glazed door 10A according to a second embodiment is best shown in
Glazed door 10A includes a saddle 100, which extends from first edge 28 of first facing 14 to second edge 30 of second facing 16. Glazing beads 102, 104 are secured to saddle 100. Edge 37 of glazing panel 36 abuts saddle 100. Panel 36 is secured within opening 26 between glazing beads 102, 104. Door 10A may include a core material, such as in the first embodiment, disposed between first and second door facings 14, 16. Alternatively, door 10A may include a void V between first and second door facings 14, 16.
As best shown in
First and second legs 112, 114 are preferably flush with and grip interior surfaces 18, 22, respectively, when secured thereon, thereby securing saddle 100 in place around opening 26. First and second legs 112, 114 are also preferably spaced from first and second ends 106, 108, respectively, a distance substantially equal to the width of first and second edges 28, 30 of facings 14, 16. In this way, first end 106 of saddle 100 is substantially flush with exterior surface 20 of facing 14, and second end 108 is substantially flush with exterior surface 24 of facing 16.
An adhesive, such as polyvinyl acetate, may be used to secure saddle 100 to facings 14, 16. However, first and second legs 112, 114 are preferably configured and spaced from each other such that saddle 100 may be securely fitted in place against facings 14, 16 without the use of an adhesive or other fastening means. In this way, saddle 100 may be quickly and easily clipped around opening 26 during manufacture of glazed door 10A.
Saddle 100 includes first and second receiving portions 116, 118 extending outwardly from second side 111 of central portion 110. First receiving portion 116 includes a first stepped bore 120 extending therein, and second receiving portion 118 includes a second stepped bore 122 extending therein.
Saddle 100 may also include a central stud 117, which extends outwardly into opening 26 from second side 111 of central portion 110. Stud 117 is intermediate first and second receiving portions 116, 118. Stud 117 and first and second receiving portions 116, 118 preferably extend outwardly from second side 111 of central portion 110 substantially the same distance, as best shown in
As best shown in
Glazing bead 102 includes a first inner wall 130 which abuts one side of glazing panel 36, and a stepped second inner wall 132. Second inner wall 132 includes a first portion 132a which abuts second side 111 of saddle 100, and a second portion 132b which abuts first receiving portion 116. First and second portions 132a, 132b are preferably parallel to and spaced from each other. A ledge 132c extends between first and second portions 132a, 132b. Preferably, prong 124 extends outwardly from ledge 132c and is inwardly disposed relative to inner wall 130. Prong 124 is also preferably parallel to first and second portions 132a, 132b.
Glazing bead 102 may also include an outer leg 134 that extends outwardly from an end 136 of first portion 132a. Outer leg 134 extends outwardly and away from opening 26, and is adjacent exterior surface 20 of first facing 14 when glazing bead 102 is secured to saddle 100, as best shown in
Glazing bead 102 also preferably includes a contoured portion 138 extending between end 136 and first inner wall 130. Contoured portion 138 is preferably configured to enhance the decorative appearance of door 10A. However, a planar angular side may also be provided between end 136 and first inner wall 130. Furthermore, the configuration of contoured portion 138 may vary depending on consumer preference. However, contoured portion 138 preferably does not extend outwardly beyond the plane of exterior surface 20 to reduce the possibility of damaging the glazing system.
Glazing bead 104 preferably has an identical configuration to glazing bead 102. Accordingly, like components of glazing beads 102, 104 are identified with identical reference numerals, and a description of same will not be repeated hereafter. Note that prong 126 preferably has an identical configuration to prong 124, but is received in bore 122. In this way, glazing panel 36 is secured between first inner wall 130 of glazing bead 102 and first inner wall 130 of glazing bead 104, as best shown in
As in the first embodiment, saddle 100 is preferably formed of plastic, such as polyvinyl chloride, and is sufficiently flexible to allow barbed prongs 124, 126 to be inserted into bores 120, 122, respectively. In addition, all of the components of saddle 100 preferably are integrally formed. The precise dimensions of saddle 100 may vary depending on the dimensions and thickness of door 10A, as well as the dimensions and thickness of glazing panel 36. Likewise, glazing beads 102, 104 are also preferably formed of plastic, such as polyvinyl chloride. The precise dimensions of glazing beads 102, 104 may also vary depending on the dimensions of door 10A and glazing panel 36, as well as the material used to form glazing beads 102, 104.
A method of forming glazed door 10A is described with reference to
As best shown in
Glazing bead 102 is then secured to saddle 100 by inserted prong 124 into first opening 120, as best shown in
As best shown in
Glazing panel 36 may then be secured within opening 26 to form glazed door 10A by securing glazing bead 104 to saddle 100, as best shown in
Certain aspects of the present invention have been explained according to preferred embodiments. However, it will be understood to one of ordinary skill in the art that various modifications and variations can be made in construction or configuration without departing the scope or spirit of the invention. It is intended that the present invention include all such modifications and variations, provided they come within the scope of the following claims and their equivalents.
Number | Date | Country | Kind |
---|---|---|---|
03257017.8-1255 | Nov 2003 | EP | regional |
04255736.3 | Sep 2004 | EP | regional |