These and other objects and advantages of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings wherein:
FIG. 1 illustrates a front view of a two-door sliding glass door assembly constructed in accordance with the invention;
FIG. 2 illustrates a cross-sectional side view of the assembly of FIG. 1;
FIG. 3 illustrates a cross-sectional top view of the assembly of FIG. 1;
FIG. 4 illustrates a cross-sectional view of a frame extrusion profile in accordance with the invention;
FIG. 5 illustrates a cross-sectional view of the snap-in gasket mounted in the intermediate wall of a frame profile in accordance with the invention;
FIG. 6 illustrates a cross-sectional view of a roller or sill track extrusion in accordance with the invention;
FIG. 7 illustrates a side view of the track cover in accordance with the invention;
FIG. 8 illustrates a cross-sectional view of the frame channel plain cover in accordance with the invention;
FIG. 9 illustrates a bottom view of the molded plastic self-closing device of the spring return assembly;
FIG. 10 illustrates a side view of the molded plastic self-closing device of the spring return assembly;
FIG. 11 illustrates a cross-sectional view of a plurality of access openings for inserting, attaching and modifying the tension in the spring return assembly;
FIG. 12 illustrates a cross-sectional view of the common sash extrusion profile in accordance with the invention;
FIG. 13 and FIG. 14 illustrate views of a plain sash cover for mounting on a vertical profile of the sash;
FIG. 15 illustrates a cross-sectional view of a sash cover with a bulb seal mounted therein;
FIG. 16 illustrates a cross-sectional view of a sash profile with an integral handle;
FIG. 17, FIG. 18, and FIG. 19 illustrate views of a wheel housing assembly for mounting in the bottom of the sash in accordance with the invention;
FIG. 20 illustrates a part cross-sectional view of a sash button mounted in a sash in accordance with the invention;
FIG. 21 illustrates a cross-sectional view of a glazing bead for holding a glass unit in the sash;
FIG. 22 illustrates a view of a three-door embodiment in accordance with the invention; and
FIG. 23 schematically illustrates an exploded view of the three-door embodiment of FIG. 22.
Referring to FIG. 1, the sliding door assembly 30 is particularly constructed for use with insulated glass units but also may be made with monolithic glass or non-glass units or panels, based on OEM or end-user performance or aesthetic requirements.
The sliding glass door assembly 30 is comprised of a frame 31 and a pair of doors or sashes 32 that are slidably disposed in the frame 31 to move laterally between a closed position and an open position relative to the frame 31.
As illustrated, the frame 31 is of rectangular shape and is constructed to fit onto or within a refrigeration cabinet or refrigerated space or unit (not shown). The frame 31 is made of four plastic extrusion profiles 33 that are integrally secured together, as by thermal welding, to define a rectangular opening with each profile 33 having a mitered end 34 integrally secured to the mitered end 34 of an adjacent profile 33. In this respect, the four frame profiles 33 are formed from a single extrusion that is cut to length, mitered at each end and separated into four profiles. The resulting four profiles are then thermally welded together to form a strong joint and frame.
Referring to FIG. 4, each frame profile 33 has the same cross-section formed of the rounded peripheral section 35 and a main section 36.
The peripheral section 35 is formed of two hollow portions 37,37′ that define an L-shape for fitting against a cabinet (not shown). Where necessary, a metal stiffener (not shown) may be inserted into a gap 38 formed between the two portions 37,37′. For example, a standard steel or aluminum stiffener for strengthening the frame extrusion should a customer's cabinet not provide sufficient strength for the system in its base design. This provides the “option” of being able to stiffen the system as needed, as opposed to having to build in stiffening for every component shipped.
The main section 36 has a rectangular hollow body 39 from which a pair of hollow end walls 40 project to define a C-shape and a hollow intermediate wall 41 of shorter height disposed in parallel between the two end walls 40 to define a pair of longitudinal recesses or C-channels 43. In addition, the intermediate wall 41 has a longitudinal groove 44 in the upper end, as viewed.
In addition, an upstanding mounting channel 45 extends from the body 39 within each longitudinal recess or C-channel 43. As illustrated, each mounting channel 45 is of box-like cross-section with an elongated slot 46 at the upper end, as viewed.
Referring to FIGS. 2 and 3, a kerf bulb seal 47 is disposed on the intermediate wall 41 of each frame profile 33, for example in the groove 44 shown in FIG. 5, for sealingly engaging with a side of each of the sashes 32.
As illustrated in FIG. 5, each bulb seal 47 has a narrow dual-durometer plastic barb 48 that is co-extruded with a foam-filled gasket 49 so that the barb 48 can be readily and easily inserted into the groove 44 in the intermediate wall 41 of each frame profile 33. The shaping of the barb 48 is such that the seal will not easily pull out of the groove 44 in the intermediate wall 41 during normal use, yet can be removed for replacement at a later date should the need arise.
As illustrated, the foam filled gasket 49 is of circular cross-section and of a diameter so that when mounted in place is sufficient to sealingly contact the side of a sash 32 in the frame 31 and to fit within a gap between two overlapping sashes 32. Of note, three gaskets of different diameters are used that are very similar to that shown in FIG. 5. An oval gasket is used at the top of the frame and round ones are used on the sides and bottom of the frame, and also between the doors.
When the sashes 32 are in the closed position as illustrated in FIG. 1, the four bulb seals 47 that are mounted in the frame 31 contact three sides of each sash 32 in sealed relation.
Referring to FIG. 2, a pair of plastic sill track extrusions 50 are snap fitted into the mounting channels 45 of the lowermost horizontally disposed frame profile 33, i.e. the sill of the frame, for receiving the sashes 32 thereon.
Referring to FIGS. 6 and 7, each plastic track extrusion 50 has a main body 51 that is provided with a pair of resilient depending tangs 52 that allow for the extrusion 50 to be snap-fitted through the slot 46 of a mounting channel 45 of the frame profile (see FIG. 4). The remainder of the body 50 extends between the end walls 40 of the frame profile 33 in sealed relation to provide a smooth flat appearance.
In addition, each extrusion 50 has an upstanding rail 53 that extends mid-way along the extrusion 50. As indicated in FIG. 7, the forward and rear ends of the rail 53 are shortened during fabrication to facilitate the assembly of all of the snap-in components of the frame 31 and to address NSF cleaning requirements in the event of spills, so as to reduce bacteria growth by promoting ease of cleaning.
Also, each extrusion 50 is provided with bifurcated ends to fit around the mounting channel 45 in an adjacent vertical frame profile 33. Alternatively, the sill tracks may be butt-cut and the C-channels on the vertical jambs of the frame may be notched where they meet the sill of the frame to simplify installing the sill tracks and to clean up the silicone sealing of the sill tracks into the frame.
Referring to FIGS. 6 and 7, a stainless steel cover 54 is mounted over the rail 53 of each track extrusion 50 for wear purposes and to promote smooth operation of the doors.
As shown in FIG. 7, each cover 54 is provided with a “hold open” notch 55 for purposes of holding a sash 32 in an open position as explained below. A similar “hold close” notch 55′ may also be provided in the cover 54 near the right-hand end of the rail, as viewed, to hold a sash 32 in the closed position.
Referring to FIG. 3, each mounting channel 45 on a vertical frame profile is provided with a cover 56 to present a flat aesthetic appearance. As illustrated in FIG. 8, each channel cover 56 is formed of an extrusion having a body 57 from which a pair of tangs 58 depend for snap fitting into the slot 46 defined by the mounting channel 45 of the frame profile 33. The body 57 of the channel cover 56 is of a width substantially equal to the width of the mounting channel 45.
In an alternative embodiment, not shown, the channel cover 56 may be provided with an upstanding slot or groove on an opposite side from the tangs 58 in order to receive an elongated T-slot bulb seal. In this embodiment, the bulb seal would include a T-shaped plastic base that slides within the slot of the channel cover and a foam-filled gasket of circular cross-section on the outside of the cover 56 that serves as a cushion against which a sash 32 may impact when moved into the closed position and as a redundant weather-seal to aid in insulation as needed.
Referring to FIG. 2, a pair of spring return assemblies 59 are mounted on the uppermost horizontally disposed frame profile 33 for biasing the two sashes 32 from their open positions to their closed positions. As illustrated, each spring return assembly 59 includes an elongated coil spring 60 and a slider 61. The spring 60 is mounted within a mounting channel 45 of the horizontal frame profile 33 with one end anchored as by a screw (not shown) to the frame profile 33 while the opposite end of the spring 60 is secured to the slider 61.
Referring to FIGS. 9 and 10, the molded plastic self-closing device (slider) 61 is formed with a main body 62 that is positioned in the mounting channel 45 and that has an opening 63 at a forward end to receive the coil spring 60 (not shown) for sliding within the channel 45. In addition, the slider 61 has a narrow depending stem 64 that projects downwardly through the slot 46 of the mounting channel 45 and a widened face 65 on the forward end of the stem 64 to abut against a sash 32.
The spring return assembly 59 is mounted in the horizontal frame profile 33 in a manner so that when a sash 32 is moved from the closed position, as shown in FIG. 3, to an open position, the spring 60 is elongated and placed under tension in order to bias the slider 61 and thus the sash 32 toward the closed position.
Referring to FIG. 11, the mounting channels 45 in which the springs 60 are mounted are each provided with a plurality of access openings 66, (for example three) so as to permit access to the installation screws (not shown) that anchor the springs 60 in place so that adjustments may be made in the tension of the springs 60.
Referring to FIG. 1, each sash 32 is comprised of a plurality of plastic extrusion profiles 67, for example four, that are integrally secured together, as by thermal welding to define a rectangular opening. In addition, each sash profile 67 has mitered ends 68 that are integrally secured to a similar mitered end 68 of an adjacent sash profile 67.
Referring to FIG. 12, each sash profile 67 is extruded with a hollow main body 69 of rectangular or box-shaped cross-section, a pair of hollow parallel flanges 70 that extend outwardly of the body 69 to define an outwardly directed channel to one side of the body 69 and a single hollow flange 71 that extends from the main body 69 to define an inwardly directed ledge on an opposite side of the body 69. In addition, a recess 71′ is formed in the main body 69 on the side of the single flange 71 for receiving a glazing bead (not shown).
Referring to FIG. 3, each sash 32 is provided with a plain cover 72 to cover over the flanges 70 on the exposed vertical side of the sash 32. As illustrated in FIGS. 13 and 14, the sash cover 72 has a main body 73 from which a pair of tangs 74 project. The cover 72 is constructed to be slidably mounted in the side of the sash 32. In this respect, the flanges 70 that define the channel in the sash profiles 67 are each provided with an inwardly directed lip 75 (see FIG. 12) while the tangs 74 of the cover 72 are each provided with a small foot 76 (see FIG. 13) so that the tangs 74 can be slid between or snapped onto the lips 75 with the feet 76 of the tangs 74 engaging under the lips 75. In this way, the cover 72 cannot be pulled away from the side of the sash 32 but may be readily removed from one end of the sash 32 for replacement purposes.
As indicated in FIG. 13, the cover 72 is provided with a notch 77 at opposite ends to conform to the channel defined by the flanges 70 of the sash profiles 67 and not interfere with the movement of the sash 32 in the frame 31.
Referring to FIGS. 3 and 15, the sash cover 72′ on one of the sashes 32 is also provided with an extension 78 that carries a longitudinal T-shaped groove or slot 79 that receives a T-slot bulb seal 80. As indicated in FIG. 15, the seal 80 includes a T-shaped plastic body 81 that is slidably mounted in the groove 79 of the extension 78 and a foam-filled gasket 82 of circular cross-section carried by the plastic body 81.
As shown in FIG. 3, the bulb seal 80 sealingly engages against the flange 71 forming the ledge on the vertical sash profile 67 of the adjacent sash 32.
Referring to FIGS. 2 and 3, each sash 32 is provided with a handle 83 for opening and closing of a sash 32. Whereas three of the sash profiles 67 are formed from the same extrusion, the sash profile 67′ carrying the handle 83 is separately extruded from a different extrusion. As illustrated in FIG. 16, the handle 83 is integrally extruded with the sash profile 67′ and is in the form of a projecting double walled hollow handle. If desired, plastic end caps 84 (see FIG. 2) may be fitted into the hollow ends of the handle 83. Each handle 83 extends over a substantial height of the vertical sash profile 67.
Referring to FIG. 2, each sash 32 carries a pair of roller assemblies 85, each of which is removably mounted in the lowermost one of the horizontally disposed sash profiles 67 for rolling on the stainless steel cover 54 on a track extrusion 50.
Referring to FIGS. 17, 18 and 19, each roller assembly 85 includes a plastic housing 86 that can be snap fitted into a recess (not shown) formed in the bottom of the horizontal sash profile 67. For example, the housing 86 has a skeletal box-like section 87 that projects through the recess (not shown) into the sash profile 67 and a peripheral flange 88 that seats against the outside of the sash profile 67. Both the box-like section 87 and the flange 88 are cut out to receive the ends of an axle 89 in snap fit relation upon which a ball bearing roller 90 is mounted for rotation.
Two of the opposite side walls of the box-like section 87 are provided with outwardly directed projections 91 that snap fit into the recess provided in the sash profile 67 to releasably hold the roller assembly 85 in place.
The mounting of each roller assembly 85 is such that the ball bearing roller 90 and axle 89 may be readily removed without removing the plastic housing 86 should the roller 90 need replacing.
The roller assemblies 85 provide for smooth rolling and low resistance and allow for installation without mechanical fasteners and allow for the wheel housings 86 to be field-replaceable without special hardware in the event of wear or damage. Likewise, the open wheel housing 86 allows the ball bearing roller 90 to be replaced without having to remove the entire housing 86 in the event of roller damage.
Referring to FIG. 20, the uppermost horizontal sash profile 67 may be provided with a glide button 92 at each end for guiding the sash 32 within the frame 31 and to assist in aligning the top of the sash 32 to ensure proper compression of the center bulb seal 47. As indicated, the glide button 92 is snap-fitted into one of the walls of a hollow flange 70 of the sash profile 67.
Referring to FIGS. 2 and 3, each sash 32 is provided with an insulating glass unit 93 that is dropped into place against the flange 71 forming the ledge of the sash 32 and is held in place by a glazing bead 94. As illustrated in FIG. 21, each glazing bead 94 has a channel-like cross-section with one leg 95 that fits into the recess 71′ of the sash profile 67 and a second leg with a bifurcated end 95′ that abuts the glass unit 93 in order to hold the glass unit 93 in place. As shown in FIG. 21, the leg 95 carries a shoulder. As shown in FIGS. 2 and 3, the leg 95 is snap-fit via the shoulder into the recess 71′ to hold the glazing bead 94 in place The snap-in glazing bead construction combined with the drop-in construction of the insulated glass unit enables the insulating glass units to be field-replaceable if damaged, worn-out, or if end user simply desires to replace them for to improve performance, extend the life of the unit, update marketing presentation, and the like.
After each of the frame 31 and two sashes 32 have been fabricated, each sash 32 is fitted into the frame 31. In this respect, with the sash held at an angle, the flanges 70 at the top end of one sash 32 are fitted into the recesses defined to either side of the mounting channel 45 in the uppermost frame profile 33 between one of the end walls 40 and the intermediate wall 41 of the horizontal frame profile 33. During this time, the slider 61 of the adjacent spring biased assembly 59 is moved out of the way manually. The sash 32 is then lifted and rotated so that the bottom end of the sash 32 can be placed onto the sill track, that is between end wall 40 and intermediate wall 41 of the lowermost horizontal frame profile 33 to rest the roller assemblies 85 on the stainless steel sill track covers 54 of the sill track extrusions 50 therein. The slider 61 is then allowed to abut against the sash 32.
Thereafter, the second sash 32 is fitted into place in the frame 31 in the same manner.
Once the sashes 32 are in place, each sash 32 fits within the recesses provided by the frame profiles 33 so that the edges of the sashes 32 are hidden from view along three sides. As indicated in FIGS. 1 and 3, the exposed ends of the two sashes 32 are disposed in overlapping relation with the bulb seal 80 therebetween. As shown in FIG. 3, when each sash 32 is in a closed position, the flanges of the vertical sash profiles 67 fit between the end wall 40 and mounting channel 45 and between the channel 45 and the intermediate wall 41 of a vertical frame profile.
As shown in FIG. 3, the vertical sash profile 67 that faces the mounting channel 45 is provided with one or more bumpers 96 in the form of a neoprene stop that is glued on to the sash profile 67. This bumper 96 serves to cushion the impact of the sash 32 against the frame profile 33 when the sash 32 moves into a closed position.
In order to obtain access to a refrigerated cabinet upon which the door assembly is mounted, the user simply moves the handle 83 of a sash 32 from the closed position until the ball bearing roller 90 of the sash 32 nearest the handle 83 fits into the notch 55 in the stainless steel cover 54 (see FIG. 7). The notch 55 in the rail cover 54 is sufficient to hold the sash 32 against the biasing force of the return spring assembly 59. In order to close the sash 32, a slight force is imposed on the handle 83 to release the bearing roller 90 from the notch 55 in the rail cover 54. The tension in the spring 60 of the return spring assembly 59 then causes the sash 32 to move into the closed position within the contours of the vertical frame profile 33.
The sash 32 closing operates smoothly by balancing the closing forces of the linear tension spring 60 against the friction generated by the gasketing system 47, 80 to ensure minimal air infiltration while enabling smooth overall sash (door) operation.
As indicated in FIGS. 2 and 3, the two sashes 32 are sealed relative to the frame 31 and relative to each other by the respective seals 47, 80 to provide an efficient air-tight sealing system. The performance of the seals 47, 80 is sufficient to pass current industry standard thermal performance specifications for condensation prevention combined with required refrigeration requirements for cooling and achieving and maintaining desired product temperature.
Referring to FIGS. 22 and 23, wherein like reference characters indicate like parts as above, the door assembly 30′ may be constructed with a frame 31 to accommodate a trio of moveable sashes 32 or as high as five or more doors based on opening size and equipment limitations.
As schematically illustrated in FIG. 23, each sash 32 is provided with a pair of roller assemblies 85 and cooperates with a spring return assembly 59 in the uppermost horizontal frame sash 33. In this respect, the middle sash 32 cooperates with a spring return assembly 59 that moves the sash 32 from a closed position, as shown, to an open position to the left, as viewed. In this respect, the middle sash 32 is provided with a handle 83 on the right-hand side.
In addition, the middle sash 32 is provided with covers 72 on both vertical sash profiles 67. Also, the covers 72 on the vertical sash profiles 67 of the left hand and right hand sashes 32 are provided with a seal 80 to seal against the glazing beads 94 on the middle sash 32. In this respect, should the left hand or right hand sash be open, only one of the seals 80 is moved relative to the middle sash 32.
The invention thus provides a fully assembled sliding door assembly that can be readily installed by an end user, for example, on a refrigerated cabinet or storage unit that utilizes components that can be readily replaced in the field should the components become damaged or worn.
The invention further provides a door assembly employing a frame and a sash made substantially completely of plastic, that does not require supplemental insulation against heat transfer between the sash and frame, and that does not require electrical insulation against electrical shock in the frame.
The invention provides a frame extrusion that utilizes an opposing open-leg or C-channel construction that creates an interior “accessory slot” that is utilized throughout the overall construction to create a “carrier” that can accept a wide variety of snap-in accessory extrusions or components. This feature allows the structural frame extrusion to be “customized” for many different sliding glass refrigerator door requirements by simply changing accessory extrusions that easily “snap-in” to the frame C-channel. This feature also allows for the rapid re-tooling or replacement of most of the key wear components in the overall door assembly without the need for any tools or complicated fabrication. This feature also provides a “platform” to facilitate future design improvements, enhancements, and the like, without the need for re-tooling the expensive structural extrusion components (i.e., frame, common sash and handle sash extrusions.)
Patent Application
20080092452
