U.S. patent application number 09/755210 was filed with the patent office on 2002-07-11 for rigid plastic door with slatted vane construction.
Invention is credited to Amin-Javaheri, Hossein.
Application Number | 20020088560 09/755210 |
Document ID | / |
Family ID | 25038175 |
Filed Date | 2002-07-11 |
United States Patent
Application |
20020088560 |
Kind Code |
A1 |
Amin-Javaheri, Hossein |
July 11, 2002 |
Rigid plastic door with slatted vane construction
Abstract
Extruded plastic doors having two side stiles and a top and
bottom rail forming a generally rectangular configuration and
having horizontal vanes covering the interior of the door. The
stiles have mating indentations along their interior edge for
receiving the vanes and holding the vanes in a permanently fixed
position relative to the stiles and rails when the stiles and rails
are assembled into a rectangular configuration. The stiles, rails
and vanes are formed by an extrusion process so as to have a
substantially hollow interior with reinforcing cross-members.
Inventors: |
Amin-Javaheri, Hossein;
(Houston, TX) |
Correspondence
Address: |
Attn: James H. Riley II
SHOOK, HARDY & BACON L.L.P.
600 Travis Street, Suite 1600
Houston
TX
77002-2911
US
|
Family ID: |
25038175 |
Appl. No.: |
09/755210 |
Filed: |
January 5, 2001 |
Current U.S.
Class: |
160/135 |
Current CPC
Class: |
E06B 7/082 20130101 |
Class at
Publication: |
160/135 |
International
Class: |
A47G 005/00 |
Claims
I claim:
1. A synthetic resinous plastic door having a generally rectangular
configuration comprising two vertical side stiles, and a top and
bottom horizontal rail defining the perimeter of the door, and
vanes covering the interior of the rectangular configuration, the
stiles having indentations along their interior edge for receiving
the vanes so as to hold the vanes in a permanently fixed position
relative to the stiles and rails when the stiles and rails are
assembled into a rectangular configuration, and the stiles, rails
and vanes being formed by an extrusion process and having a
substantially hollow interior with reinforcing cross-members,
wherein the two panels of the door are attached to each other by a
first hinge to permit folding of the door and one of the panels is
attached to a door frame by a second hinge.
2. The door of claim 1 further comprising a middle horizontal
rail.
3. The door of claim 1 wherein the foamed plastic comprises about
65% to 75% PVC, about 12% to 18% calcium carbonate, about 8% to 12%
stabilizer, and about 3% to 7% titanium dioxide.
4. The door of claim 3 wherein the foamed plastic comprises about
70% PVC, about 15% calcium carbonate, about 10% stabilizer, and
about 5% titanium dioxide.
5. A synthetic resinous plastic door comprising two panels, each
having a generally rectangular configuration comprising two
vertical side stiles, and atop and bottom horizontal rail defining
the perimeter of the door, and vanes covering the interior of the
rectangular configuration, the stiles having mating indentations
along their interior edge for receiving the vanes so as to hold the
vanes in a permanently fixed position relative to the stiles and
rails when the stiles and rails are assembled into a rectangular
configuration, and the stiles, rails and vanes being formed by an
extrusion process and having a substantially hollow interior with
reinforcing cross-members, wherein the two panels of the door are
each attached a door frame by a hinge to permit the panels to open
from the middle.
6. The door of claim 5 further comprising a middle horizontal
rail.
7. The door of claim 5 wherein the foamed plastic comprises about
65% to 75% PVC, about 12% to 18% calcium carbonate, about 8% to 12%
stabilizer, and about 3% to 7% titanium dioxide.
8. The door of claim 7 wherein the foamed plastic comprises about
70% PVC, about 15% calcium carbonate, about 10% stabilizer, and
about 5% titanium dioxide.
9. A synthetic resinous plastic door having a generally rectangular
configuration comprising two vertical side stiles, and a top and
bottom horizontal rail defining the perimeter of the door, a
vertical center stile and vanes covering the interior of the
rectangular configuration, the stiles having mating indentations
along their interior edge for receiving the vanes so as to hold the
vanes in a permanently fixed position relative to the stiles and
rails when the stiles and rails are assembled into a rectangular
configuration, and the stiles, rails and vanes being formed by an
extrusion process and having a substantially hollow interior with
reinforcing cross-members.
10. The door of claim 9 further comprising a middle horizontal
rail.
11. The door of claim 9 wherein the foamed plastic comprises about
65% to 75% PVC, about 12% to 18% calcium carbonate, about 8% to 12%
stabilizer, and about 3% to 7% titanium dioxide.
12. The door of claim 9 wherein the foamed plastic comprises about
70% PVC, about 15% calcium carbonate, about 10% stabilizer, and
about 5% titanium dioxide.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates to doors made from extruded plastic.
More specifically, it relates to bi-fold or half doors made from
rigid plastic, such as polyvinyl chloride (PVC). The side stiles,
horizontal rails, and slatted vanes that make up the door are
individual pieces that are generally hollow, except for reinforcing
interior cross-members. The individual pieces are formed by
extruding plastic through a die. The invention contemplates that
the door be assembled in a manner similar to that used for a
conventional wooden bi-fold door.
[0005] 2. Description of the Related Art
[0006] Traditionally, bi-fold or half doors have been made of wood,
but the expense of wood has caused the industry to search for other
suitable materials. Recently, manufacturers have turned to
fabricating such doors from synthetic resins by injection molding,
as described in U.S. Pat. No. 3,985,175. However, the injection
molding process is limited in its application. Typically, the
injection molding process involves making two rectangular hollow
pans and joining the pans together by the edges to form a hollow
door. U.S. Pat. No. 3,985,175 describes a particular type of
construction wherein a front face is made of injection molded
plastic and has reinforcing members on the back side but no back
face. Such a construction, while serving to maintain rigidity,
provides a door having only one good side. Such a door is unsuited
for general applications in the home or office.
[0007] One of the main problems with full length doors made from
injection molded plastic is their lack of rigidity. Therefore,
there is a need in the industry for a plastic door that has
sufficient rigidity and is aesthetically pleasing from both
sides.
SUMMARY OF THE INVENTION
[0008] Full length bi-fold and half doors may be constructed from
rigid plastic, such as PVC, that is extruded to form the various
pieces used to construct the door. Rigid plastic has the advantage
of being lighter in weight than wood because the interior of the
rails, stiles, and vanes are basically hollow except for the
reinforcing cross-members that are formed during the extruding
process. This type of construction offers several advantages over
wood. A rigid plastic door is much more fire resistant than wood,
and it does not warp from humidity. Additionally, the finished
product manufactured from plastic does not require painting and is
a solid color throughout so scratches from ordinary use are not
readily visible. Finally, rigid plastic is easier to clean, can be
produced with a glossy finish, and is generally more durable than
wood.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic representation of a bi-fold door in
accordance with the present invention.
[0010] FIG.2 is a schematic representation of a half door in
accordance with the present invention.
[0011] FIG.3 is a cross-section view of a rail used for the top,
middle and bottom horizontal support members.
[0012] FIG. 4 is a cross-section of the side support members or
stiles.
[0013] FIG. 5 is a cross-section of a slatted vane that fits
between the side stiles.
DETAILED DESCRIPTION OF INVENTION
[0014] The invention is directed to a full length bi-fold and half
door constructed from synthetic resinous, rigid plastic that is
extruded to form the various pieces used to make the door. Rigid
plastic has the advantage of being lighter in weight than wood
because the interior of the rails, stiles, and vanes are basically
hollow except for the reinforcing cross-members that are formed
during the extruding process. This type of construction offers
several advantages over wood. A rigid plastic door is much more
fire resistant than wood, and it does not warp from humidity.
Additionally, the finished product manufactured from plastic does
not require painting and is a solid color throughout so scratches
from ordinary use are not readily visible. Finally, plastic is
easier to clean, can be produced with a glossy finish, and is
generally more durable than wood.
[0015] FIG. 1 and FIG. 2 show the preferred embodiment of the
invention wherein extruded rigid plastic bi-fold and half doors
have two side stiles and a top and bottom rail forming a generally
rectangular configuration and have horizontal vanes covering the
interior of the door. The stiles have mating cutouts formed along
their interior edge for receiving the vanes and holding the vanes
in a permanently fixed position relative to the stiles and rails
when the stiles and rails are assembled into a rectangular
configuration.
[0016] The preferred plastic material is PVC because of its
strength, durability, and ease of extruding. However, other
suitable materials, such as polyethylene and polypropylene could be
used. The preferred formulation of PVC is about 65% to 75% PVC,
about 12% to 18% calcium carbonate, about 8% to 12% stabilizer, and
about 3% to 7% titanium dioxide. The especially preferred
formulation is about 70% PVC, about 15% calcium carbonate, about
10% stabilizer, and about 5% titanium dioxide. The preferred
ingredients include a tin stabilizer. Other ingredients include a
paraffin wax lubricant, such as XL165, a process aid, such as
methyl methacrylate which is commercially available as K-120N from
Rohm & Haas, and an impact modifier, such as modified acrylic
available as D-200 from Elf-Autochem. Titanium dioxide should be
added in an amount sufficient to impart the desired shade of white,
and pigment may be added to achieve other color variations.
[0017] The basis extrusion process is old and well known to a
person skilled in the art. Various dies may be used to extrude the
individual pieces with a variety of profiles, but FIG. 3 shows the
preferred cross-section view of a rail used for the top and bottom
of the horizontal rail section. Preferably, the door also has a
middle rail of the same or similar configuration as the top and
bottom rails. This middle rail provides extra stability for the
door and also provides a means for attaching an opening mechanism,
such a knob.
[0018] FIG. 4 shows the preferred construction of the side stiles.
This construction also allows for hardware, such as hinges, to be
securely attached. Of, course, other designs are acceptable so long
as they provide the needed strength and rigidity.
[0019] FIG. 5 shows the preferred construction of the slatted vanes
that cover the interior of the door. These vanes are basically
hollow, but preferably have one or more cross-members for support.
The vanes are designed to fit into the side stiles in a permanently
fixed position when the door is fully assembled. The slatted vanes
allow light and air to pass through the door yet provide a high
degree of privacy. Because the vanes are somewhat flexible, an
individual vane may be removed from the door and replaced with a
new vane, if the need arises, without disassembling the door.
[0020] The stiles and rails may be fastened together by any
suitable means, such as glue or screws. The preferred method of
construction is a screw fastener. For aesthetic purposes, the
screws should be countersunk so that the heads can be covered with
a plug to make the assembly virtually invisible.
[0021] The hinges associated with mounting the bi-fold or two piece
door could be standard metal hinges that attach to the stiles with
screws. In order to securely fasten hardware to the doors, it is
preferred that small plastic anchors be inserted into the stiles
where the screws for the hinges and knob attach. These anchors will
provide more support for the screws than the relatively thin wall
of the stiles and will help prevent the screws from stripping
during the final assembly.
[0022] This invention is directed mainly toward bi-fold and half
doors, rather than full doors, because the vanes in a bi-fold and
half door are relatively short and will maintain their structural
integrity if pressure is applied on the vanes when the door is in
use. However, this invention could be made to work well on a full
size door by using a center stile that would permit the use of
short vanes on both sides of the center stile. Without a center
stile on a full size door, the rigid plastic vanes covering an
expanse of about two feet would tend to be too flexible and would
probably not be suitable. Alternatively, if additional supporting
cross-members were added to the interior of the vanes or if the
vanes were made thicker, they could be made to work on a larger
expanse. The obvious disadvantage of this configuration would be
the expense of the extra material needed to make the vanes and the
additional weight of the door.
[0023] As is apparent from the foregoing description, there are
various modes of carrying out the invention. It is to be fully
understood that all of the foregoing is intended to be merely
illustrative and is not to be construed or interpreted as being
restrictive or otherwise limiting of the present invention.
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