Patent Application
20200131842
The present disclosure concerns two-piece door kits, where the door may be a primary door, a storm door, a screen door, or a security door, which comprises frame members comprising two or more components that can be connected with one or more connectors, top and bottom panels that can be movably attached to the frame members.
Door systems for entrances into residential and commercial buildings are well known in the art. Primary doors provide the main security and protection from exterior elements, while secondary doors such as screen doors, storm doors, and security doors offer additional functionality such as enhanced ventilation, energy efficiency, and security when paired with an existing primary door.
Despite their widespread use, existing door systems have limitations. For instance, even single-panel doors for a typical 32″ or 36″ wide by 80″ tall residential opening can be cumbersome to handle and transport. They are often larger than can be easily carried in a car, resulting in the need to borrow or rent a larger vehicle (inconvenient), arrange for delivery (costly), or not purchasing and installing the door at all (undesirable for both the purchaser and seller). As shopping and purchasing trends shift to a higher percentage of products being selected and purchased over the internet instead of through brick-and-mortar retail locations, shipping of large door systems that are outside of mainstream shipping carriers' size limits can be cost-prohibitive. Existing door systems often require specialized knowledge or skills to install properly, which may also result in the installation of a door to be done poorly or not at all. And furthermore, today's doors may lack the functionality or selection that appeals to a wide variety of consumers and decision-makers.
The present disclosure seeks to address these issues, and may be utilized for primary and secondary residential and commercial door systems.
This disclosure describes a two-piece door kit comprising a latch frame member comprising two or more components that can be connected with one or more connectors, a hinge frame member comprising two or more components that can be connected with one or more connectors, a top frame member that can be connected to the top of the latch frame member and the hinge frame member, a bottom frame member that can be connected to the bottom of the is latch frame member and the hinge frame member, a bottom panel that can be movably attached to the bottom frame member and the hinged frame member or elements thereof, a top panel that can be movably attached to the hinge frame member and the top frame member or elements thereof, and an optional awning that can be attached to the top frame member.
In some embodiments, the two-piece door kit further comprises a latch to secure the bottom panel, or the top panel or both panels to the latch frame member.
In other embodiments, the bottom and top panels move together or independently.
In some embodiments, the two-piece door kit further comprises an adjustable connector to secure the bottom and top panels together.
In other embodiments, the bottom and top panels are opaque materials, transparent materials, translucent materials, or screen materials.
In some embodiments, the bottom and top materials are the same or different materials.
In other embodiments, the bottom and top panels move about two or more pins.
In some embodiments, at least one pin is spring-biased to an extended position.
In other embodiments, the awning is further comprises one or more accessories including a door light, security camera, alarm system, intercom, automatic door opening and closing mechanism, or a solar cell and battery to collect, store, and provide power to the accessories.
In some embodiments, the two or more latch frame members and hinge frame members snap together with the connectors.
In other embodiments, the two-piece door is a primary door, a storm door, a screen door, or a security door.
In some embodiments, an assembled two-piece door may be attached to the exterior face of a door frame, or alternatively may be attached within the exterior opening of a door frame.
In other embodiments, a packaged two-piece door kit may be contained in a carton in which the total of the carton length plus twice the carton width plus twice the carton thickness is less than or equal to 165 inches. For example, a packaged two-piece door kit may be contained in a carton approximately 36 inches×36 inches×8 inches.
All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified.
As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise.
As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
As used herein, “have”, “having”, “include”, “including”, “comprise”, “comprising” or the like are used in their open ended sense, and generally mean “including, but not limited to.” It will be understood that the terms “consisting of” and “consisting essentially of” are subsumed in the term “comprising,” and the like.
The following index describes the reference numbers used throughout the figures:
A door system according to the present disclosure may be comprised of a latch frame member, a hinge frame member generally parallel to the latch frame member, a top frame member, a bottom frame member generally parallel to the top frame member, a lower panel pivotable with respect to the frame members, an upper panel pivotable with respect to the frame members, a panel connecting mechanism that permits the upper and lower panels to pivot together or independently of each other, latching hardware that enables the panels to selectively latch to or disengage from the latch frame member, and a top valence.
The latch frame member may be comprised of an upper section and a lower section, joined together by an intermediate latch frame connector. The upper and lower sections may be formed of aluminum, steel, extruded or molded plastic, fiberglass, or other suitable material. The intermediate latch frame connector may be formed of metal or plastic, and may be molded, die cast, machined, or formed using some other process. In addition to containing features to receive the upper and lower latch frame members, the intermediate latch frame connector may also contain a latch strike, deadbolt strike, or both. The latch frame member may also carry upper and lower corner connectors. The connectors may also be assemblies of multiple parts.
The hinge frame member may be comprised with an upper section and a lower section, joined together by an intermediate hinge frame connector. The upper and lower sections may be formed of aluminum, steel, extruded or molded plastic, fiberglass, or other suitable material. The intermediate hinge frame connector may be formed of metal or plastic, and may be molded, die cast, machined, or formed using some other process. In addition to containing features to receive the upper and lower hinge frame members, the intermediate hinge frame connector may also contain a protrusion carrying a hole capable of receiving a hinge post. The hinge frame member may also carry upper and lower corner connectors. Corners of the upper and lower panels may have hinge pins or receivers. Alternately hinge-side corner connectors may carry holes to receive a hinge pin or a hinge pin capable of sliding into a hinge pin receiver. Intermediate hinge frame connector may also carry a hinge pin capable of sliding into a hinge pin receiver, or both.
The top frame member may be a unitary member, and may be formed of aluminum, steel, extruded or molded plastic, fiberglass, or other suitable material. The ends of the top frame member are adapted to slide onto the upper corner connectors carried by the latch frame and hinge frame members, forming a 90-degree corner at each upper corner. The underside of each end of the top frame member may include a hole sized and shaped to receive a bushing, in turn sized and shaped to receive a hinge pin.
The bottom frame member may be a unitary member, and may be formed of aluminum, steel, extruded or molded plastic, fiberglass, or other suitable material. The ends of the bottom frame member are adapted to slide onto the lower corner connectors carried by the latch frame and hinge frame members, forming a rigid 90-degree corner at each lower corner. Each end of the bottom frame member may include a hole sized and shaped to receive a bushing, in turn sized and shaped to receive a hinge pin. Top and bottom frame members may carry the corner connectors instead of the latch and hinge frame members. In some embodiments the top and bottom frame members may not have the holes to receive a hinge pin.
The assembled frame may be positioned over an existing door frame and door panel when it is to be used as a secondary door to enhance an existing primary door. The frame is attached to the existing door frame or building structure surrounding the existing doorway, utilizing screws, nails, adhesive, or other suitable attachment devices. In one embodiment, screws are prepositioned in the frame members and ready to be driven into the existing door frame or building structure, in a direction perpendicular to the plane of the wall. Alternately, when the door assembly is to be used as a primary door, the assembled frame may be positioned within the rough opening. In this embodiment, screws prepositioned in the frame members would be driven into the studs forming the rough opening, in a direction parallel to the plane of the wall. In some embodiments screws may be prepositioned in the connectors instead of the frame members.
A lower panel may be comprised of a top horizontal rail, bottom horizontal rail, and left and right vertical stiles surrounding a glass insert. A lower corner of the lower panel carries a hinge pin (not visible), sized and shaped to engage with the bushing in one of the ends of the bottom frame member. An upper corner of the lower panel is notched to mate with the protrusion extending from the intermediate hinge frame connector, and may include a hole sized and shaped to receive a bushing, in turn sized and shaped to receive a hinge post.
The hinge pin of in the lower corner of the lower panel is inserted into the bushing in one of the ends of the bottom frame member, the sash is positioned such that the bushing in the upper corner of the lower sash is aligned axially with the hole in the protrusion extending from the intermediate hinge frame connector, and a hinge post is inserted through the hole in the protrusion and into the bushing in the upper corner of the lower sash.
An upper panel may be comprised of a top horizontal rail, bottom horizontal rail, and left and right vertical stiles surrounding a glass insert. A lower corner of the upper panel is notched to mate with the protrusion extending from the intermediate hinge frame connector, and may include a hole sized and shaped to receive a bushing, in turn sized and shaped to receive the hinge post. An upper corner of the upper panel carries a hinge pin, which may be a spring-loaded or spring-biased retractable hinge pin, sized and shaped to engage with the bushing in one of the ends of the top frame member. Upper and lower panels may not be comprised of 2 rails and 2 stiles, but may be a unitary (such as injection-molded around the panel material).
The bushing in the lower corner of the upper panel may be positioned over the hinge post, the sash is positioned such that the hinge pin in the upper corner of the upper sash is aligned axially with the bushing in one of the ends of the top frame member, and the hinge pin in the upper corner of the upper sash is engaged with the bushing in one of the ends of the top frame member.
An exterior handle and an interior handle are each attached to the latching hardware.
A valence mounts to the upper corner connectors of the latch and hinge frame members. Mounting methods may include receptacles designed to receive the upper corner connectors, screws, adhesive, or any other suitable fastening device. Such a valence may be adapted to receive one or more accessories, including but not limited to a door light, security camera, alarm system, intercom, automatic door opening and closing mechanism, and solar cell and battery to collect, store, and provide power to other accessories.
A panel connecting mechanism permits the upper and lower panels to pivot together or independently of each other. In one embodiment, this may be a bolt affixed to one panel that may be thrown to engage a strike on the other panel, thereby causing the panels to pivot together with respect to the frame members or pivot independently of each other. In another embodiment, connection of the panels may be accomplished through the latching hardware. Rotation of one of the handles in an upward direction, for example, may enable the upper panel to pivot independently of the lower panel while the lower panel remains latched to the latch frame member, while rotation of one of the handles in a downward direction, for example, may connect the panels together, enabling the upper and lower panels to pivot at the same time.
The modular design of the product along with the package design produces a product that can be easily transported in nearly any typical vehicle or shipped easily and inexpensively following a purchase over the internet. In one embodiment, the packaged product is approximately 36″×36″×6″ and includes a carrying handle. Within the package, presentation of the individual components is in the sequence in which the parts are used during installation, and designed in such a manner that all parts are well protected from damage and abuse.
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It is recognized that other embodiments of the present may be possible. Other such embodiments include but are not limited to the following:
Various modifications and alterations of this disclosure will become apparent to those skilled in the art without departing from the scope and principles of this disclosure, and it should be understood that this disclosure is not to be unduly limited to the illustrative embodiments set forth hereinabove.
This application claims priority to U.S. Provisional Patent Application No. 62/750,293, filed Oct. 25, 2018, entitled “TWO PIECE DOOR AND INSTALLATION SYSTEM,” of which is incorporated by reference herein, in the entirety and for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 62750293 | Oct 2018 | US |
