U.S. patent application number 10/598831 was filed with the patent office on 2007-08-23 for improved method of assembling metal doors and metal doors assembled thereby.
This patent application is currently assigned to Malaysia Woodworking (Pte) Ltd.. Invention is credited to Tong Hwa Yong, Toong Chuan Yong.
Application Number | 20070193206 10/598831 |
Document ID | / |
Family ID | 35150050 |
Filed Date | 2007-08-23 |
United States Patent
Application |
20070193206 |
Kind Code |
A1 |
Yong; Toong Chuan ; et
al. |
August 23, 2007 |
Improved Method of Assembling Metal Doors and Metal Doors Assembled
Thereby
Abstract
A method to fabricate and assemble metal doors and panels, or
similar structures, is taught. Under the present invention,
profiled edges of two or more skins forming the sides of the door
or panel are moved together. The skins are only locked together
when a locking bar or wedge is applied to the channels formed by
the profiled edges. Under the present invention, less effort is
required to assemble such metal doors and panels as the contact
between the profiled edges of the skins is not tight. This allows
the skins to be easily moved together or repositioned. The present
invention also provides for the skins to be either reversibly or
irreversibly locked, and for non-rectangular metal doors and panels
to be fabricated
Inventors: |
Yong; Toong Chuan;
(Singapore, SG) ; Yong; Tong Hwa; (Singapore,
SG) |
Correspondence
Address: |
LAWRENCE Y.D. HO & ASSOCIATES PTE LTD
30 BIDEFORD ROAD, #02-02, THONGSIA BUILDING
SINGAPORE
229922
SG
|
Assignee: |
Malaysia Woodworking (Pte)
Ltd.
18, Kranji Loop
Singapore 739552
SG
|
Family ID: |
35150050 |
Appl. No.: |
10/598831 |
Filed: |
February 24, 2005 |
PCT Filed: |
February 24, 2005 |
PCT NO: |
PCT/SG05/00054 |
371 Date: |
September 13, 2006 |
Current U.S.
Class: |
52/745.19 ;
52/741.1 |
Current CPC
Class: |
E06B 3/827 20130101 |
Class at
Publication: |
052/745.19 ;
052/741.1 |
International
Class: |
E04B 1/00 20060101
E04B001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 13, 2004 |
SG |
200402021.0 |
Claims
1. A method for assembling two or more skins of a metal structure,
the method comprising: temporarily fastening a first skin with at
least one profiled edge to a work surface; overlaying a second skin
with at least one profiled edge by moving the second skin with at
least one profiled edge to engage the at least one profile edge
with the at least one profiled edge of the first skin, thereby the
engaged profiled edges forming at least one channel; and applying
at least one locking means into the at least one channel; and
finishing the metal structure.
2. The method of claim 1, wherein the metal structure is a
door.
3. The method of claim 1, wherein the metal structure is a
panel.
4. The method of claim 1, wherein the step of moving comprises
sliding the second skin over the first skin from one end of the
first skin.
5. The method of claim 1, wherein the step of moving comprises
placing the second skin over the first skin.
6. The method according to claim 1, wherein the channel distorted
by the applying of the locking means.
7. The method according to claim 1, wherein the channel not
distorted by the applying of the locking means.
8. The method according to claim 1, wherein the at least one
profiled edge of the first skin and the at least one profiled edge
of the second skin comprise engagement members; the engagement
members of the first skin further complementary to the engagement
members of the second skin.
9. The method of claim 8, wherein the complementary engagement
members are only brought into engagement by the applying of the
locking means.
10. The method of claim 1, wherein the application of the locking
means is reversible.
11. The method of claim 1, wherein the application of the locking
means is not reversible.
12. The method of claim 1, wherein in the application of the
locking means causes the skins to be locked together.
13. The method of claim 1, wherein the step of the finishing of the
metal structure further comprises: welding the skins; applying
fasteners; installing ironmongery; capping any exposed ends; and
painting the structure.
14. A metal structure comprising: a first skin with at least one
profiled edge substantially forming one side of the structure; at
least one more skin with at least one profiled edge substantially
forming the other side of the structure; and a locking means for
engaging the skins together; wherein the at least one profiled edge
of the first skin and the at least one profiled edge of the second
skin form at least one channel, and a tight fit between the skins
is obtained only after the locking means is applied to the at least
one channel.
15. A metal structure according to claim 14, wherein the structure
is a door.
16. A metal structure according to claim 14, wherein the structure
is a panel.
17. A metal structure according to claim 14, wherein the at least
one profiled edge of the first skin and the at least one profiled
edge of the at least one more skin comprise engagement members; the
engagement members of the first skin further complementary to the
engagement members of the at least one more skin.
18. (canceled)
19. A metal structure according to claim 14, wherein the locking
means is a locking bar.
20. A metal structure according to claim 14, wherein the locking
means is a wedge.
21. A metal structure according to claim 14, wherein the metal
structure further comprises: welding; additional fasteners;
ironmongery; end caps; and paint.
22. A metal structure according to claim 15, wherein the at least
one profiled edge forming the one side of the first door is the
shorter side (rail) of the door.
23. A metal structure according to claim 15, wherein the at least
one profiled edge forming the one side of the first door is the
longer side (stile) of the door.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to metal doors and panels.
[0002] In particular, this invention relates to improved methods to
fabricate metal doors and panels, and metal doors and panels
fabricated by these improved methods.
BACKGROUND OF THE INVENTION
[0003] Metal building doors are typically fabricated by joining two
metal sides or skins of the door together (FIG. 1). The edges of
the longer sides (stiles) of each skin (13, 23) are profiled such
they mate in a complementary fashion. Examples of such profiles are
shown in FIGS. 2 and 3.
[0004] Under one current technique of the art, one skin 10 of the
door is temporarily fastened onto a horizontal work surface 11
(FIG. 1). Any supporting structures such as beams, or materials or
fittings in the interior of the door such as sound or fire proofing
materials, or even armor plates, may now be fastened onto the first
skin.
[0005] The other skin 20 is then positioned at one end of the first
skin. The shorter side (rail) 24 of the second skin nearest the
first skin is then aligned with the rail 14 of the first skin
either manually or with the aid of a hoist.
[0006] When ends of the stiles of the second skin have engaged the
nearest ends of the complementary stiles of the first skin fastened
to the work surface, the second skin is then moved by being pushed,
pulled, or both push-and-pulled over the first skin. This may be
done manually or with the help of winches and pulleys.
[0007] This is possible as the opposite sides of the skins having
the profiled edges are substantially parallel to each other and to
the complementary profiled edges of the other skin of the door. The
two skins are mated by moving their skins together until their
complementary profiled edges are fully engaged along their entire
lengths.
[0008] The lower skin is then released from the work surfaced and
the door further processed. This further processing may include
fastening the two skins in place by welding or the addition of
conventional fasteners, capping of any exposed ends, installation
of ironmongery such as locksets, handles, and hinges, and finishing
the door by painting.
[0009] There are a number of problems associated with this method
of assembling the two skins of these metal doors. Firstly, a great
deal of effort has to be exerted to bring the two skins together as
friction along the stiles increases as the length of the
complementary stiles engaged increases.
[0010] Secondly, the fit of the complementary edges is usually very
tight and once the two skins are engaged, even partially, it is
extremely difficult to separate them for any reason, such as to
realign the two skins, or to reposition the materials or fittings
in the interior of the door.
[0011] Another difficulty is that the tolerance of manufacture for
the complementary edges must be high for a good fit in the
assembled door. This raises the cost of manufacture.
[0012] Therefore, a need clearly exists for an improved method of
fabricating or assembling metal-skinned doors that overcomes the
problems of the prior art.
SUMMARY OF THE INVENTION
[0013] The present invention seeks to provide, in one aspect, a
method for assembling two or more skins of a metal structure, the
method comprising: [0014] temporarily fastening a first skin with
at least one profiled edge to a work surface; [0015] moving a
second skin with at least one profiled edge to engage the at least
one profile edge with the at least one profiled edge of the first
skin thereby forming at least one channel; [0016] applying at least
one locking means; and [0017] finishing the metal structure.
[0018] In another aspect, the present invention provides a metal
structure comprising: [0019] a first skin with at least one
profiled edge substantially forming one side of the structure; and
[0020] at least one more skin with at least one profiled edge
substantially forming the other side of the structure; wherein
[0021] the at least one profiled edge of the first skin and the at
least one profiled edge of the second skin form at least one
channel; and a tight fit is obtained only after a locking means is
applied.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] A preferred embodiment of the present invention will now be
more fully described, by way of example, with reference to the
drawings of which:
[0023] FIG. 1 illustrates a how a metal skinned door may be
fabricated under a method of the prior art;
[0024] FIG. 2 is an elevational view of the complementary edges of
the two skins of a metal door;
[0025] FIG. 3 is a cross-section of a metal skinned door showing
how the two complementary edges mate;
[0026] FIG. 4 is shows how the two skins of one embodiment of the
present invention is locked by means of locking bars;
[0027] FIG. 5A-C show cross-sectional views of the complementary
edges of another embodiment the door of the present invention
before and after a locking bar is inserted;
[0028] FIG. 6 shows interruptions of one complementary edge in yet
another embodiment of the invention; and
[0029] FIG. 7 shows the invention applied in a non-rectangular
panel.
DETAILED DESCRIPTION OF THE DRAWINGS
[0030] A detailed description of the present invention will now be
given in accordance with a preferred embodiment of the invention.
In the following description, details are provided to describe the
preferred embodiment. It shall be apparent to one skilled in the
art, however, that the invention may be practiced without such
details. Some of these details may not be described at length so as
not to obscure the invention.
[0031] There are many advantages of the preferred embodiment of the
invention. One advantage of the preferred embodiment is that less
effort is needed to move the two skins of the door together under
the method of the present invention. The method and product of the
present also allows the two skins of the assembled door in one
embodiment to be subsequently separated for any reason with less
effort than using the techniques of the current art.
[0032] Another advantage of the present invention is to provide
metal door skins with lower manufacturing tolerances, hence
lowering manufacturing costs but without detracting from the fit,
finish or overall quality of the door.
[0033] The door fabricated under the present invention can lower
manufacturing cost with its ease of manufacture and assembly. Waste
is also reduced as the doors thus fabricated may be disassembled
easily to correct any deficiencies before delivery instead of being
scrapped.
[0034] While the description that follows uses the assembly and
fabrication of a metal door for a building as an example, it is
contemplated that the method and product of the present invention
is applicable to the assembly and fabrication of other similar
structures. These structures include metal panels and metal doors
for equipment, vehicles and enclosures other than buildings.
Examples of these other structures include cladding panels,
building partitions, access doors for heavy equipment, and the
like.
[0035] Under the present invention, the two skins for a metal door
are initially positioned as in the method of the prior art as shown
in FIG. 1. The door skins of the present invention also mate in a
complementary fashion.
[0036] However, the profiles of the door edges of the present
invention differ from prior art in two aspects. The first
difference is that the mating of substantially parallel and
complementary edge profiles by moving the skins together do not
result in a tight fit. As the two profiled edges (FIG. 4B) do not
form a tight fit, much less effort is needed to move the two skins
together. At this stage, the two skins may also be easily moved
apart again for any reason.
[0037] The second difference is that a channel 30 is formed by the
complementary profiled edges after the two skins are moved together
(FIG. 4B). A locking means such as a locking bar 40 with a tapered
end and a length substantially the same as the height of the
finished door, is then applied (FIG. 4A). The locking bar may be
applied by driving it from one end of each of these channels into
the channels to lock the two skins together, resulting in the tight
fit in the edge profiles of the skins (FIG. 4C). The dimensions and
cross-sectional shape of the locking means and that of the profiled
edges are predetermined to provide ease of assembly, and subsequent
disassembly if desired.
[0038] As such, the choice of the profiled edges and the locking
means determine whether the application of the locking means is
reversible or not reversible, rendering the locking of the two
skins either permanent or temporary as desired.
[0039] For example, in one embodiment, the profile of the channels
formed by the two skins and a locking bar of known dimensions and
cross-sectional shape may be selected. When the locking bar is
applied, say by tapping it into a channel with a mallet, the
locking bar distorts the cross-sectional shape and dimensions of
the channel sufficiently to permanently lock the two skins together
(FIGS. 4B and 4C). In an embodiment of the present invention, such
a channel may be oval in cross-section. When a locking bar with a
round cross-section of sufficient diameter is driven in, the
channel will then be distorted and approximate a circle in
cross-section, locking the two skins together.
[0040] Alternatively, in another embodiment, the channel initially
formed by the two skins may be rectangular in cross-section and
locking means may be a bar with a round cross-section of a
predetermined diameter (FIGS. 4B and 4C). The diameter of the
locking bar may be selected such that when driven in, the locking
bar forms an interference or press fit with the channel. Such a
locking bar may be readily applied or removed subsequently to
disassemble the door should such a need arise.
[0041] In yet another embodiment, the channel formed by the two
profiled edges of the may be interrupted instead of being
continuous along its length (FIG. 6). After a locking means has
been driven in, the total area of contact between the channel and
the locking means is less than that for a continuous channel. As
such, it will be easier to remove the locking means by driving it
out should the need to disassemble the door arise.
[0042] In another embodiment, the locking means may be two locking
bars, substantially shorter than the length of the door, driven in
at either end of the channels formed by the two skins of the door.
Other locking means such as wedges may also be used. Again, such
doors may be subsequently disassembled by removal of the locking
means used.
[0043] In yet another embodiment, the profiled edges of the two
skins of a metal door comprise complementary engagement members of
a tab 50 and a slot 60 that do not engage each other before the
locking means is driven in (FIG. 5).
[0044] A locking means such as a locking bar 40 is then driven into
the channels formed by the profiled edges of the skins. As the bar
is driven in, the complementary engagement members comprising tabs
50 and slots 60, found at intervals along the complementary edges
of the respective skins, will be progressively pushed by the
locking bar into engagement. Although a locking bar with a flat cut
end may be used, a domed or pointed end as shown in FIG. 5 will
facilitate the driving in of the locking bar into the channel. This
embodiment of the present invention provides for a permanent
locking of the door skins when disassembly of the skins is not
required.
[0045] A person skilled in the art will appreciate by looking at
the cross-section of the edge profiles in FIG. 5C that the skins of
doors or panels of this embodiment need not be slid together to
mate as with doors of the prior art and the other embodiments of
the present invention. They may simply be laid one over the
other.
[0046] This embodiment allows non-rectangular doors and panels to
be assembled and fabricated. In FIG. 7, a panel with a trapezoid
cross-section may be fabricated by simply laying one skin over
another, ensuring that the two skins are aligned and then locking
them together with two locking bars. As may be seen from FIG. 7,
the complementary edge profiles need not be parallel as the skins
need not be slid together.
[0047] Such skins may simply be aligned and positioned by lowering
a second skin over a first skin temporarily fastened over a work
surface. Proper alignment of the two skins may be ensured by
verifying the positions of suitable indexing holes or marks.
[0048] A person skilled in the art will appreciate that once the
complementary engagement members of the skins are engaged, the
skins remain locked even if the locking bar 40 is removed as the
locking tabs 50 would have engaged the slots 60 (FIG. 5). This
embodiment teaches a method that permanently locks the door skins
together.
[0049] A person skilled in the art will also appreciate that this
embodiment of the present invention allows non-rectangular doors or
panels to be assembled and fabricated as the two skins of the door
or panel need not be moved by sliding one skin over the other. The
complementary engagement members of the profiled edges in this
embodiment allow the two skins, essentially mirror images of each
other, to be placed together without the need to slide them
together. As such, doors or panels having a non-rectangular (eg
trapezoid cross-section as shown in FIG. 7) may be fabricated under
the present invention.
[0050] Once a metal door has been assembled by the method of the
present invention, it may be finished by any additional steps, like
that of the prior art. These additional steps, some of which are
optional, comprise welding the door, application of fasteners,
installation of ironmongery items, capping of exposed ends and
painting the door. However with the self-locking features of the
present invention, the amount of welding or additional fasteners is
substantially reduced or even obviated.
[0051] A person skilled in the art will appreciate that
conventional manufacturing methods may be readily adapted to
manufacture the door skins of the present invention. Sheet metal of
the desired thickness and shape are first fabricated. If the
embodiment employing locking tabs and slots are desired, then these
tabs and slots may be punched out along the edges of the metal
sheets using a press and die after being aligned by a jig.
[0052] Thereafter the skins of the present invention with the
desired profiled edges may be obtained by folding the edges of the
metal sheets by the use of presses, jigs and guides. These skins
may then be assembled according to the methods of the present
invention as described above.
[0053] A person skilled in the art will appreciate that the present
invention provides a novel and inventive method that uses locking
means driven into the channels formed by the two skins of a metal
door to lock the two skins together. The channels are formed by
novel and inventive edge profiles of the skins of the metal
doors.
[0054] By selecting the profiled edges of the skins, and the
locking means to be used, the locking of the channels may be
temporary or permanent. The profiled edges of the skins may also be
continuous or interrupted (FIG. 6) under the scope of the present
invention.
[0055] A person skilled in the art will also appreciate that while
the stiles or longer sides of the skins are profiled to form the
channels (FIG. 4A), the rails or shorter sides of the metal door
may also be fabricated into profiled edges. In such an embodiment,
the skins of the door are simply placed "side by side" instead of
"top to bottom", and then slid into position.
[0056] The present invention also provides an embodiment that is
formed by placing or lowering, instead of sliding, one skin over
another (FIG. 7). This may be achieved by the profiled edges 70 and
80 shown in FIG. 5.
[0057] While the fabrication or assembly of a metal door with two
skins has been described, it is contemplated that any number of
skins may also be used to form the door under the present
invention. For example, one side of the door may be comprised of
one skin but the other side of the door may be comprised of two or
more skins.
[0058] In addition, while the present invention has described the
assembly of whole metal door skins, the present invention also
covers door skins that have cut outs made in them. These cut outs
may be subsequently be covered by panels made of other materials
for various purposes such as for viewing or decorative panels.
While building doors have been described, the present invention is
also applicable to the fabrication or assembly of panels and
partitions, and in doors of machinery and structures other than
buildings, under the scope of the present invention.
[0059] While metal doors have been described, it will be
appreciated that other suitable materials, such as composites, may
also be fabricated or assembled under the present invention.
[0060] A person skilled in the art will appreciate that the method
of the present invention, and the various embodiments of the
present invention, solve, or at least alleviate, the problems of
the prior art.
[0061] It will be appreciated that although a few embodiments have
been described in detail, various modifications and improvements
can be made by a person skilled in the art without departing from
the scope of the present invention.
* * * * *