U.S. patent application number 10/383761 was filed with the patent office on 2004-09-16 for industrial door assembly and method of assembling same.
Invention is credited to Vermette, Robert M..
Application Number | 20040177585 10/383761 |
Document ID | / |
Family ID | 32961326 |
Filed Date | 2004-09-16 |
United States Patent
Application |
20040177585 |
Kind Code |
A1 |
Vermette, Robert M. |
September 16, 2004 |
Industrial door assembly and method of assembling same
Abstract
An industrial door assembly is disclosed comprising a rigid
internal frame having first and second sides; a door capping
attached to edges of the rigid internal frame, the door capping
providing generally parallel faces generally parallel to the first
and second sides; side panels attached to the generally parallel
faces of the door capping generally parallel to the first and
second sides of the rigid internal frame; and synthetic insulating
material injected within the rigid internal frame and bonding the
side panels together. A method of assembling this industrial door
assembly is also disclosed.
Inventors: |
Vermette, Robert M.;
(Winnipeg, CA) |
Correspondence
Address: |
AIKINS PATENT COMPANY
30TH FLOOR
360 MAIN STREET
WINNIPEG
MB
R3C 4G1
CA
|
Family ID: |
32961326 |
Appl. No.: |
10/383761 |
Filed: |
March 10, 2003 |
Current U.S.
Class: |
52/656.4 ;
52/309.4 |
Current CPC
Class: |
E06B 3/88 20130101; E06B
3/485 20130101; E06B 3/822 20130101; E06B 7/2307 20130101 |
Class at
Publication: |
052/656.4 ;
052/309.4 |
International
Class: |
E04C 002/38; E04C
001/00 |
Claims
Embodiments of the Invention in Which an Exclusive Property or
Privilege is claimed are Defined as Follows:
1. An industrial door assembly comprising: a rigid internal frame
having first and second sides; a door capping attached to edges of
the rigid internal frame, the door capping providing generally
parallel faces,generally parallel to the first and second sides;
side panels attached to the generally parallel faces of the door
capping generally parallel to the first and second sides of the
rigid internal frame; and synthetic insulating material injected
within the rigid internal frame and bonding the side panels
together.
2. The industrial door assembly of claim 1 wherein the rigid
internal frame is composed of steel tubing.
3. The industrial door assembly of claim 1 wherein the door capping
is a synthetic material extrusion.
4. The industrial door assembly of claim 3 wherein the door capping
is a PVC extrusion.
5. The industrial door assembly of claim 1 wherein the side panels
are ABS sheeting.
6. The industrial door assembly of claim 1 wherein the side panels
are stainless steel sheeting.
7. The industrial door assembly of claim 1 wherein the synthetic
insulating material is a urethane foam insulation.
8. The industrial door assembly of claim 1 wherein the synthetic
insulating material is an expanding foam material.
9. The industrial door assembly of claim 1 wherein the rigid
internal frame and door capping comprise vent holes to allow air
within the rigid internal frame to escape in response to injection
of the synthetic insulating material.
10. The industrial door assembly of claim 1 wherein the door
capping comprises receiving means for receiving door hardware and
synthetic gaskets.
11. The industrial door assembly of claim 2 wherein the rigid
internal frame comprises steel gussets.
12. A door capping for use with an industrial door, the industrial
door having a rigid internal frame and side panels, the door
capping comprising: an elongate core body; and two generally
parallel flanges attached to the elongate core body extending along
a length of the core body, the elongate core body and two generally
parallel flanges forming a receiving channel for slideably
receiving an edge of the rigid internal frame, the two generally
parallel flanges providing generally parallel faces to which the
side panels can be attached.
13. The door capping of claim 12 wherein the core body comprises
receiving means for receiving door hardware and synthetic
gaskets.
14. The door capping of claim 12 wherein the door capping is a
synthetic material extrusion.
15. The door capping of claim 12 wherein the door capping is a PVC
extrusion.
16. The industrial door assembly of claim 1 wherein the door
capping comprises: an elongate core body; and two generally
parallel flanges attached to the elongate core body extending along
a length of the core body, the elongate core body and two generally
parallel flanges forming a receiving channel for slidably receiving
an edge of the rigid internal frame, the two generally parallel
flanges providing generally parallel faces to which the side panels
can be attached.
17. A method of assembling the industrial door assembly of claim 1
comprising the steps of: (a) assembling the rigid internal frame;
(b) attaching the door capping to the rigid internal frame; (c)
bonding the side panels to the generally parallel faces of the door
capping; (d) providing an access means through the door capping and
rigid internal frame to an inner space defined by the rigid
internal frame and side panels; and (e) injecting the synthetic
insulating material through the access means into the inner space,
the synthetic insulating material bonding to the side panels.
18. The method of claim 17 wherein the rigid internal frame is
composed of steel tubing and is assembled by welding.
19. The method of claim 17 wherein the door capping is mechanically
fastened to the rigid internal frame.
20. The method of claim 17 wherein the access means are at least
one hole drilled through the door capping and rigid internal
frame.
21. The method of claim 17 wherein the bonding of the side panels
to the generally parallel faces of the door capping is a chemical
bonding.
22. The method of claim 17 wherein the door capping comprises
receiving means for receiving door hardware and synthetic gaskets,
the method further comprising the final step of inserting hardware
and synthetic gaskets into the receiving means.
23. The method of claim 17 wherein the synthetic insulating
material is an expanding foam material, the method further
comprising the final step of allowing the synthetic insulating
material to expand.
24. The method of claim 17 wherein the rigid internal frame and
door capping comprise vent holes to allow air within the rigid
internal frame to escape in response to injection of the synthetic
insulating material, the method further comprising the final step
of allowing air to escape from the rigid internal frame through the
vent holes in response to injection of the synthetic insulating
material.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to industrial doors, and more
particularly to insulated doors for use in industrial and retail
settings.
BACKGROUND OF THE INVENTION
[0002] In certain industrial and retail settings, such as
supermarket stockrooms or the storerooms of the pharmaceutical and
food processing industries, it is desirable to provide access doors
that are designed for increased strength and enhanced insulating
ability.
[0003] A standard industrial door used in such settings comprises a
section of solid synthetic foam material with insulating
properties, to which material two side panels are glued. However,
this industrial door assembly is inherently weak, there being no
bonded strength or internal strengthening frame.
[0004] Prior attempts to address this problem include U.S. Pat. No.
5,655,351 to Pohl, et al., which discloses a reinforced
refrigerator door assembly. The reinforcement is in the form of
cross brace members running diagonally within the door, thereby
providing added strength. However, the door uses a door shell of
set dimensions, limiting the usefulness of this invention in the
context of industrial doors, which doors must be and are designed
to various dimensions as required for different applications and
settings.
[0005] Another standard insulated door currently on the market
employs two pieces of free-floating internal steel to prevent
warping of the door, but the shell is again of a one-piece moulded
construction. It is easily damaged, and again does not lend itself
to the varied door dimensions required by the industry.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the present invention there is
provided an industrial door assembly comprising:
[0007] a rigid internal frame having first and second sides;
[0008] a door capping attached to edges of the rigid internal
frame, the door capping providing generally parallel faces
generally parallel to the first and second sides;
[0009] side panels attached to the generally parallel faces of the
door capping generally parallel to the first and second sides of
the rigid internal frame; and
[0010] synthetic insulating material injected within the rigid
internal frame and bonding the side panels together.
[0011] In exemplary embodiments of this first aspect of the present
invention, the rigid internal frame may be composed of steel tubing
for enhanced strength, and steel gussets may be added to inside
corners to further enhance the structural strength. The door
capping is preferably a synthetic material extrusion, most
preferably a PVC extrusion, and the side panels are preferably but
not necessarily ABS sheeting or stainless steel sheeting. The
synthetic insulating material is preferably urethane foam
insulation, but it may be any synthetic insulating material that
has insulating properties and can strongly bond to the side panels,
and it is preferably an expanding foam material that can expand to
fill the available space. The rigid internal frame and door capping
preferably comprise vent holes to allow air within the rigid
internal frame to escape in response to injection of the synthetic
insulating material. The door capping preferably comprises
receiving means for receiving door hardware and synthetic
gaskets.
[0012] According to a second aspect of the present invention there
is provided a door capping for use with an industrial door, the
industrial door having a rigid internal frame and side panels, the
door capping comprising:
[0013] an elongate core body; and
[0014] two generally parallel flanges attached to the elongate core
body extending along a length of the core body, the elongate core
body and two generally parallel flanges forming a receiving channel
for slidably receiving an edge of the rigid internal frame, the two
generally parallel flanges providing generally parallel faces to
which the side panels can be attached.
[0015] In exemplary embodiments of this second aspect of the
present invention, the core body comprises receiving means for
receiving door hardware and synthetic gaskets, and the door capping
is preferably a synthetic material extrusion, most preferably a PVC
extrusion. This door capping can be used in the industrial door
assembly of the first aspect of the present invention.
[0016] According to a third aspect of the present invention there
is provided a method of assembling the industrial door assembly of
the first aspect of the present invention comprising the steps
of:
[0017] (a) assembling the rigid internal frame;
[0018] (b) attaching the door capping to the rigid internal
frame;
[0019] (c) bonding the side panels to the generally parallel faces
of the door capping;
[0020] (d) providing an access means through the door capping and
rigid internal frame to an inner space defined by the rigid
internal frame and side panels; and
[0021] (e) injecting the synthetic insulating material through the
access means into the inner space, the synthetic insulating
material bonding to the side panels.
[0022] In exemplary embodiments of this third aspect of the present
invention, the rigid internal frame can be composed of steel tubing
and the assembling step (a) involves welding. The attaching step
(b) preferably but not necessarily involves mechanical fastening of
the door capping to the rigid internal frame, and the access means
of step (d) can be at least one hole drilled through the door
capping and rigid internal frame. The bonding of step (c) is
preferably a chemical bonding. A final step is preferably included
wherein the door capping comprises receiving means for receiving
door hardware and synthetic gaskets, the method further comprising
the final step of inserting hardware and synthetic gaskets into the
receiving means. Where, in preferred embodiments, the synthetic
insulating material is an expanding foam material, step (e) would
be followed by a final step allowing the synthetic insulating
material to expand. Where, in preferred embodiments, the rigid
internal frame and door capping comprise vent holes to allow air
within the rigid internal frame to escape in response to injection
of the synthetic insulating material, the method further comprises
the final step of allowing air to escape from the rigid internal
frame through the vent holes in response to injection of the
synthetic insulating material.
[0023] The present invention accordingly provides an industrial
door assembly that has enhanced strength and insulating ability,
while providing greater flexibility in terms of possible door
dimensions, in that the rigid internal frame can be designed to any
desired dimensions while the door capping enables foam injection to
bind the assembly together.
[0024] A detailed description of an exemplary embodiment of the
present invention is given in the following. It is to be
understood, however, that the invention is not to be construed as
limited to this embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] In the accompanying drawings, which illustrate an exemplary
embodiment of the present invention:
[0026] FIG. 1 is a cross-sectional view along line 1-1 of FIG.
2B;
[0027] FIG. 2A is a front elevational view of the industrial door
assembly without the side panels or synthetic insulating
material;
[0028] FIG. 2B is a front elevational view of the fully-assembled
industrial door assembly;
[0029] FIG. 3A is a detailed end view of a synthetic gasket used in
single-door applications;
[0030] FIG. 3B is a detailed end view of a synthetic gasket used in
double-door applications; and
[0031] FIG. 4 is a perspective view of a length of the door
capping.
DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT
[0032] Referring now in detail to the accompanying drawings, there
is illustrated an industrial door assembly according to the present
invention, generally referred to by the numeral 10. As can best be
seen in FIGS. 1, 2A, and 2B, the exemplary embodiment of the
industrial door assembly 10 comprises a rigid internal frame 12
having first and second sides 14, the rigid internal frame 12 being
of steel tubing in this embodiment and welded together, and a door
capping 16 attached to edges 18 of the rigid internal frame 12, the
door capping 16 providing generally parallel faces 20 which are
generally parallel to the first and second sides 14. The rigid
internal frame 12 comprises steel gussets 30 in every inside corner
to strengthen the industrial door assembly 10 and help prevent
premature delamination. The industrial door assembly 10 further
comprises side panels 22 which are attached to the generally
parallel faces 20 of the door capping 16 in an orientation
generally parallel to the first and second sides 14 of the rigid
internal frame 12. The hollow structure thus formed is filled, in
the manner set out in the following description, with a synthetic
insulating material 24, specifically a urethane foam insulation in
the exemplary embodiment, which acts to bond the side panels 22
together and thus strengthens the industrial door assembly 10. The
synthetic insulating material 24 is preferably an expanding foam
that can expand after injection to fill the hollow structure.
[0033] The door capping 16 in the exemplary embodiment is a
synthetic material extrusion, specifically a PVC extrusion.
Referring to FIGS. 1 and 4, the door capping 16 comprises an
elongate core body 32 from which extend two generally parallel
flanges 34, the generally parallel flanges 34 being either attached
to or formed as a unity with the elongate core body 32, the
generally parallel flanges 34 being oriented along the long axis of
the elongate core body 32. The elongate core body 32 and the two
generally parallel flanges 34 form a receiving channel 36 for
slideably receiving the edge 18 of the rigid internal frame 12, and
the two generally parallel flanges 34 provide the two generally
parallel faces 20 to which the side panels 22 are attached. The
door capping 16 further comprises receiving means 26 for receiving
any desired door hardware (not shown) or synthetic gaskets 28a,b.
Two common designs of synthetic gaskets 28a,b are illustrated in
FIGS. 3A and 3B; the synthetic gasket 28a of FIG. 3A is used with
single-door applications, while the synthetic gasket 28b of FIG. 3B
is used with double-door applications.
[0034] The side panels 22 can be composed of diverse materials, but
are preferably composed of ABS sheeting, which adhere to the
generally parallel faces 20 of the door capping 16 and bond with
the synthetic insulating material 24 when injected. The side panels
22 can also be composed of stainless steel sheeting, which is
desirable in many industrial and retail contexts. The side panels
22 are preferably of the same width as a recess 42 in the door
capping 16, as can be seen in FIG. 1, allowing for a smooth surface
continuity between the side panels 22 and the door capping 16.
[0035] In the preferred method of assembling the industrial door
assembly 10, the first step is to weld steel tubing together to
form the rigid internal frame 12 to desired specifications, along
with steel gussets 30 welded in all inside corners. Then, the door
capping 16 is attached to the rigid internal frame 12, preferably
by mechanical fastening means. The side panels 22 can then be
bonded to the generally parallel faces 20 of the door capping 16,
preferably by a chemical bonding. As can be seen in FIG. 2A, an
access means 38 is provided, in this exemplary case a simple
drilled hole, through the door capping 16 and the rigid internal
frame 12, into an inner space (not numbered) defined by the rigid
internal frame 12 and side panels 22. More than one hole may be
required for the access means 38 to be adequate in a given context.
The synthetic insulating material 24 is then injected through the
access means 38 into and filling this inner space, such that it
bonds to the side panels 22 and provides a firm, strong structure.
To enable air within the inner space to escape in response to
injection of the synthetic insulating material 24, a vent hole 40
is provided through the door capping 16 and the rigid internal
frame 12, although more than one vent hole 40 may be required.
Finally, any door hardware (not shown) or synthetic gaskets 28a,b
can be fitted within the receiving means 26 as desired. Window
openings (not shown) can also be cut out of the industrial door
assembly 10 once the synthetic insulating material 24 hardens after
injection, and windows (not shown) inserted therein.
[0036] The utility of the present invention resides in its
usefulness in industrial and retail settings which require strong,
insulated doors of various desired dimensions and designs. The
present invention addresses this need.
[0037] While a particular embodiment of the present invention has
been described in the foregoing, it is to be understood that other
embodiments are possible within the scope of the invention and are
intended to be included herein. It will be clear to any person
skilled in the art that modifications of and adjustments to this
invention, not shown, are possible without departing from the
spirit of the invention as demonstrated through the exemplary
embodiment. For example, the generally parallel flanges 34 may not
be necessary if the core body 32 itself can be designed to directly
accept the side panels 22 and be firmly attached to the rigid
internal frame 12. The invention is therefore to be considered
limited solely by the scope of the appended claims.
* * * * *