U.S. patent application number 12/179833 was filed with the patent office on 2009-01-29 for sectional doors made from polymer composites and a method for manufacturing same.
Invention is credited to Anthony George Aquilina, Joseph Aquilina.
Application Number | 20090025334 12/179833 |
Document ID | / |
Family ID | 40294022 |
Filed Date | 2009-01-29 |
United States Patent
Application |
20090025334 |
Kind Code |
A1 |
Aquilina; Anthony George ;
et al. |
January 29, 2009 |
SECTIONAL DOORS MADE FROM POLYMER COMPOSITES AND A METHOD FOR
MANUFACTURING SAME
Abstract
A sectional door includes a plurality of panels. Each panel can
include two or more plies which can be made of thermally compatible
material. A panel of such sectional door includes an outer ply
including a thermoplastic material and a sash frame including a
thermoplastic material. The outer ply forms an outer face of the
door. The sash frame is secured to the outer ply. The outer ply and
the sash frame include thermoplastic materials which have
substantially the same rate of thermal expansion. A desired design
can be formed in the outer face of the door.
Inventors: |
Aquilina; Anthony George;
(Milton, CA) ; Aquilina; Joseph; (Ontario,
CA) |
Correspondence
Address: |
FAY SHARPE LLP
1100 SUPERIOR AVENUE, SEVENTH FLOOR
CLEVELAND
OH
44114
US
|
Family ID: |
40294022 |
Appl. No.: |
12/179833 |
Filed: |
July 25, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60962226 |
Jul 27, 2007 |
|
|
|
Current U.S.
Class: |
52/784.13 ;
52/745.15 |
Current CPC
Class: |
E06B 3/485 20130101 |
Class at
Publication: |
52/784.13 ;
52/745.15 |
International
Class: |
E04C 2/54 20060101
E04C002/54 |
Claims
1. A panel for a sectional door, comprising: an outer ply,
comprising an extruded thermoplastic material, forming an outer
face of the door; a sash frame comprising a thermoplastic material;
a means for securing said sash frame to said outer ply; and,
wherein said outer ply and said sash frame comprise thermoplastic
materials which have substantially the same rate of thermal
expansion.
2. The panel of claim 1 wherein the thermoplastic material for both
said outer ply and said sash frame comprises an extruded cellular
PVC material.
3. The panel of claim 1 wherein said means for securing comprises
an adhesive.
4. The panel of claim 1 wherein said means for securing comprises a
fastener.
5. The panel of claim 1 further comprising a reinforcing member
connected to said sash frame.
6. The panel of claim 5 wherein said reinforcing member comprises a
metal.
7. The panel of claim 6 further comprising a means for securing
said reinforcing member to said sash frame which accommodates
differential rates of thermal expansion between said reinforcing
member and said sash frame.
8. The panel of claim 7 wherein said means for securing comprises
an elongated aperture located in said reinforcing member and a
fastener extending through said elongated aperture and into said
sash frame.
9. The panel of claim 6 wherein the metallic reinforcing member
includes a flange which cooperates with said outer ply.
10. The panel of claim 9 wherein said flange is accommodated in a
groove of said outer ply.
11. The panel of claim 9 wherein said flange contacts an edge of
said outer ply.
12. The panel of claim 6 wherein said reinforcing member includes a
channel for accommodating an edge of said outer ply.
13. The panel of claim 1 further comprising a layer of insulating
material positioned between said outer ply and said sash frame.
14. The panel of claim 1 further comprising an inside skin layer
positioned between said outer ply and said sash frame.
15. The panel of claim 1 wherein the thermoplastic material of said
outer ply is so chosen that it can be worked by routing or milling
to impart a desired design thereinto.
16. The panel of claim 1 wherein said sash frame is thicker than
said outer ply.
17. The panel of claim 1 further comprising a hinge mounted to said
sash frame, to enable the panel to be secured to another panel of
the sectional door.
18. A method of manufacturing a panel for a sectional door,
comprising: a) providing an outer ply of an extruded thermoplastic
material; b) providing a sash frame of the same thermoplastic
material; c) securing the sash frame to the outer ply; and, d)
forming a desired design in an outer surface of the outer ply.
19. The method of claim 18 further comprising securing a
reinforcing member to the sash frame.
20. The method of claim 18 further comprising forming a desired
edge shape on the panel.
21. The method of claim 18 wherein steps a)-d) are performed in a
continuous manufacturing process.
22. The method of claim 18 wherein step d) is performed via routing
of the outer ply.
Description
[0001] This application claims priority from provisional
application Ser. No. 60/962,226 dated Jul. 27, 2007, the subject
matter of which is incorporated by reference hereinto in its
entirety.
BACKGROUND OF THE INVENTION
[0002] The present disclosure relates to doors and other closures.
It finds particular application with regard to composite sectional
doors, such as are used for garages, and methods for manufacturing
such doors. However, it is to be appreciated that the present
disclosure will have wide application for a variety of
closures.
[0003] Garage doors are known to be made from various materials,
including wood, steel, aluminum, vinyl, fiberglass composites, MFD
Board (Medium Fiber Density), recycled wood fiber, and
lignocellulose material such as is described in U.S. Patent
Publication 2006/0272253 dated Dec. 7, 2006, among others. The
foregoing materials have been the materials of choice for the
production of garage doors based on material availability and the
ability to use these materials to make various types of garage and
other doors in various designs.
[0004] Garage doors formed from wood suffer many drawbacks. Wood
can be heavy and is costly, and over time wood is susceptible to
degradation and damage from weathering and from insects. An
advantage of wood doors, however, is that they are easily made with
aesthetically pleasing designs. In this regard, they can be stained
or painted in either single colors or multiple colors, they can
have designs worked into the wood or added over top of the wood.
Moreover, wood doors are plentiful and easily available. As was
stated above, however, wood doors do suffer the drawbacks of being
very heavy, of being constructed from costly materials, and of
being susceptible to damage from weather, boring insects, and mold
and mildew. In addition, wood doors require maintenance on a
regular basis in order to maintain an aesthetically pleasing
exterior.
[0005] Given these drawbacks, wood doors in a garage setting, for
example, have been replaced by steel and aluminum doors in some
instances. These doors can be constructed to be much lighter and
easier to manipulate, and are not susceptible in general to
rotting, insect infestation, and mold and mildew damage. However,
steel and aluminum doors are not generally thought to be
aesthetically pleasing in and of themselves. Therefore, if a
decorative surface is desired, such doors require an overlay of a
material which may include some type of aesthetic design. Further,
painting and staining steel or aluminum can be difficult, and such
painted doors may require special maintenance. If a design on a
metal door is desired, manufacturing such a door requires large,
heavy and very costly equipment to form a design on the exterior
face of the door. Such designs can be stamped on the door by means
of a hydraulic press and a die to emboss or deboss a design or
pattern. Every time a different design is needed, however, the
stamping die has to be changed, which can be expensive and labor
intensive.
[0006] A serious problem with metal doors is that they provide no
insulation for the space they enclose. Thus, a thermal break design
has been developed for such doors. In some doors, the two metal
panels forming the exterior and interior surfaces of the door are
separated by a foam core to provide better insulation. It is also
known to construct garage doors from multi-layered materials
wherein the layers are laminated or otherwise affixed to a frame.
Another problem with steel and aluminum is the ease with which they
can be dented or damaged. For these reasons, steel and aluminum
doors often have overlays created from vinyl, plastic, fiberglass,
or a very thin layer of pressboard or solid wood. The underlying
door, in these instances, is generally formed by a manufacturing
technique called "roll manufacturing" or is referred to as being
"roll formed".
[0007] A roll former is needed in order to shape the sides of a
metal panel of the garage door in order to adapt the panels to each
other. Linear grooves normally are added to the exterior surface of
the metal panel to stiffen the thin sheet metal, and at the same
time give an aesthetic look to the door, instead of having a plain
flat panel. Most garage door panels which are made from a solid and
machinable material would have the same type of surface texture,
such as stucco wood grain or another pattern. But, this is not true
with metal panels. There, a surface design has to be added to the
panel.
[0008] A problem with doors, whether they are made of metal or
other material, such as vinyl or fiberglass, is that they require
expensive dies and molds, each time the surface design of the door
is changed. When designs are changed, on most occasions, extensive
labor is required to change the dies and molds. Even so, the
manufacturer is still limited to a certain number of designs or
patterns.
[0009] A recent trend in garage doors has been to make them
resemble the wooden doors which were manufactured a long time ago,
such as carriage house type doors or the like. Of course, wooden
doors, both in the past and those manufactured in accordance with
today's processes, have a limited number of designs, such as a
raised panel design, linear grooves, oriented horizontally or
vertically, or a flush door with a lay on or overlay to create a
Tudor or carriage house look, or any other antique type of look.
Such designs on garage doors can still be seen in some European
countries.
[0010] Many garage doors in the past were opened to the side via
side mounted hinges. Others were one piece doors lifted with a
spring mechanism. More recently, garage doors have been constructed
from a series of horizontal panels which are hinged together. This
can be done using a pivoting bracket instead of conventional
hinges. When the door is fully closed, the panels are aligned in a
single plane. The panels separate at the joints between individual
panels so that the door may be raised to open. To this end, the
door is mounted on rollers, fitted in roller guides that carry the
door vertically up and then horizontally into the interior space of
a building. Such doors, termed sectional doors, are used for
garages in residential buildings and have a variety of uses in
industrial and commercial settings as well.
[0011] Garage doors may be of a width sized for a single vehicle or
of a width for multiple vehicles. In those instances where the
garage door width is intended for more than a single vehicle, the
garage door may be formed from a single, extended horizontal panel
spanning the entire width of the opening, or from several
horizontal panels fitted end-to-end to span the horizontal width of
the opening.
[0012] Regardless of the makeup of the door itself, it is common
for the exterior surface of the panels of the door to take on
various appearances, such as smooth, embossed, textured, ribbed,
raised panel, inset panel, and many other designs, including
carriage house designs. Designs may be molded or stamped into the
panels. But, this can be costly, depending on the underlying
material used. More often, an overlay carrying the design is
adhered to the door panel, as a separate piece or structure.
[0013] The drawbacks to each of the foregoing overlap the various
product types, and no option currently available addresses all of
the problems of such sectional doors, including cost, weight,
weathering, insulation, ease of construction, and ease of use.
There exists a need for a sectional door product that can be
manufactured in a continuous line process, wherein the door panels
can have an unlimited variety of designs or patterns formed on the
outer surface of the panel.
SUMMARY OF THE INVENTION
[0014] In one embodiment, there is provided a panel for a sectional
door. The panel comprises an outer ply, comprising an extruded
thermoplastic material, forming an outer face of the door and a
sash frame comprising a thermoplastic material. A means is provided
for securing a sash frame to the outer ply. The outer ply and the
sash frame comprise thermoplastic materials which have
substantially the same rate of thermal expansion. A design can be
formed in or provided on the outer surface of the outer ply.
[0015] In accordance with another embodiment, a method of
manufacturing a panel for a sectional door is provided. The method
comprises providing an outer ply of an extruded thermoplastic
material and a sash frame of the same thermoplastic material. The
sash frame is secured to the outer ply. A desired design is formed
in an outer surface of the outer ply.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of an exterior face of a
sectional door, such as a garage door, according to the present
disclosure.
[0017] FIG. 2 is an enlarged rear elevational view of a single
panel of the door of FIG. 1.
[0018] FIG. 3 is an enlarged perspective view of a portion of the
single door panel of FIG. 2 made of an extruded thermoplastic
material, and including a sash frame.
[0019] FIGS. 4A-4D are side elevational views of garage door panels
illustrating various panel interlock configurations.
[0020] FIG. 5 is a front elevational view of a sash frame for a
door panel, with no exterior ply according to the present
disclosure.
[0021] FIG. 6 is a front elevational view of an external ply of the
door panel according to the present disclosure.
[0022] FIG. 7 is a front elevational view of a ribbed panel
according to the present disclosure.
[0023] FIG. 8 is a front elevational view of a raised panel
according to the present disclosure.
[0024] FIG. 9 is a front elevational view of a carriage house type
panel design according to the present disclosure.
[0025] FIG. 10 is a front elevational view of a vertical ribbed
panel according to another design of the present disclosure.
[0026] FIG. 11 is a side cross sectional view of a door panel
according to one embodiment of the present disclosure.
[0027] FIG. 12 is a side cross sectional view of another door panel
according to another embodiment of the present disclosure.
[0028] FIG. 13 is a top plan view in cross section of a portion of
a panel according to still another embodiment of the present
disclosure.
[0029] FIG. 14 is a reduced perspective view of the panel of FIG.
13.
[0030] FIG. 15 is a front elevational view of a door according to
the present disclosure.
[0031] FIG. 16 is a front elevational view of another door
according to the present disclosure.
[0032] FIG. 17 is a flow chart of a manufacturing process for a
door panel according to the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] The subject disclosure relates to the use of an extruded
thermoplastic material, such as polyvinyl chloride (PVC) or a PVC
composite as the material for the construction of a closure, such
as a sectional garage door. Use of a PVC material provides
advantages with regard to such features as: exterior design; weight
of the door; durability with regard to weather; resistance to mold
and mildew, boring insects and rust/rot; denting; maintenance; and
a custom finish capability in order to produce aesthetically
pleasing sectional doors, such as garage doors. If desired, the
entire sectional door, other than the hinges, can be made from the
chosen extruded thermoplastic material.
[0034] Sheets of cellular PVC material are available worldwide and
known for use on molding trims, siding, fascia and the like. Such
material is not solid but has a core made of fine cells similar to
weather foam but with smooth, solid exterior surfaces. It is termed
a cellular PVC material and is known in the art. Extruded cellular
PVC sheets are available from several manufacturers and are
available under different trade names and trademarks, such as Trim
Board, DuraBoard and the like. Another such material is available
under the Versatex brand name from Wolfpac Technologies of
Leetsdale, Pa. These sheets are available in various thicknesses,
such as 1/4 inch, 3/8 inch, 1/2 inch, 5/8 inch, 3/4 inch and 1 inch
(0.6315, 0.953, 1.27, 1.59, 1.91 and 2.54 cm). They are available
in lengths up to a maximum of 20 feet (6.1 m) long. Normally, these
sheets are made in 4 foot (1.22 m) widths and are provided with a
smooth plain surface or with a wood grained texture.
[0035] Although cellular PVC sheets are mainly available in a light
color, color can be impregnated in the PVC material in order to
eliminate finish painting of the panel. On the other hand, the
panels can be painted to any desired light and medium colors using
a vinyl-type adherent paint. The panels can also be painted with a
urethane type of process paint with UV inhibitor, which would
protect the surface of the panel from the rays of the sun.
[0036] Polyvinyl chloride as a garage door construction material
provides many advantages. Unlike garage doors constructed partially
or wholly from wood, thermoplastic garage doors are not subject to
rotting and resist mildew and fungus growth. In addition, the PVC
material as described herein has an excellent "R" value, which is
the insulation value of the door. Also, the PVC material exhibits
superior surface hardness, making it more resistant to denting and
other surface degradation.
[0037] Another advantage of using PVC material for the sectional
door disclosed herein is that the door can be produced in various
colors. If painted, the PVC composite door retains the painted
coating without requiring maintenance as often as other known
garage door materials, i.e., steel, wood or aluminum, for example.
In one known method of manufacture, the PVC material can be
extruded.
TABLE-US-00001 TABLE 1 Cellular Ponderosa ASTM Test Description
Unit PVC Pine ASTM D-2395 Density g/cc 0.62 0.39 ASTM D-2250 Shore
D Surface Hardness 0.71 0.53 ASTM D-1761 Screw Holding lb. 400 363
ASTM D-1761 Nail Holding lb. 0.61 0.83 ASTM D-638 Tensile Strength
psi. 2984 4940 ASTM D-570 Water Absorption % 0.4 74.6 ASTM D-662
Smoke 18.08 106.0 ASTM D-648 Heat Deflection Temperature F. 150 N/A
ASTM D-4726 Dimensional Stability % 1.7 N/A ASTM D-696 Coefficient
of Thermal in/in-F. 0.0000245 0.000021 Expansion ASTM D-518 Thermal
Conductivity BTU 0.420 1.20 UL E-84 Tunnel Test (Fire Rating) 14.31
99.0 (red oak)
[0038] Table 1 above provides a comparison of one type of extruded
cellular PVC material, which can be used for the sectional door
panels disclosed herein, to a conventional wood panel material.
Extruded cellular PVC material from other manufacturers would
likely have somewhat different properties. Also, other types of
wood, such as fir or cedar will likely have different properties
than the pine described above. Nevertheless, it can be seen that
the extruded cellular PVC material has advantageous properties when
compared to wood.
[0039] Extended cellular PVC material can be machined in the same
way as wood, using the same equipment. It is important to note that
cellular PVC provides excellent weather resistance, does not absorb
moisture, does not split or crack and is resistant to insect
damage. Moreover, it does not rot.
[0040] Cellular PVC sheets are flexible due to the nature of the
material. As such, use of this material for door panels requires
lateral reinforcement to stiffen the sheet and to provide rigidity
to the structure of the panel. For panels where the sheet is 1 inch
thick or thinner, the sheet can, in one embodiment, be glued onto a
sash frame. For example, a common size of minimum 8 foot wide
garage door made of PVC sheet material and held from each end
horizontally will deflect or bow a minimum of 3 inches (7.62 cm).
Without a reinforcement element, such as a metal beam (for example
steel or aluminum or the like), it would be impossible to construct
such a garage door from extended cellular PVC sheet material. It is
also known that the cellular PVC material can be reinforced with a
variety of reinforcing materials, such as, e.g., wood materials or
fibers, such as carbon or glass fibers or the like. For sake of
economy, wood material are preferred. A wood composite extruded
cellular PVC material is sold under the trademark PuraBoard--PW by
South Asia Plastics Group of Scarborough, Ontario, Canada. Perhaps
a narrow door made of a wood composite PVC material would not need
any type of metal reinforcing element. Nevertheless, for wider
doors used in industrial settings, perhaps even a wood material
reinforced extruded cellular PVC door would need one or more metal
reinforcing elements. It should be appreciated that since the wood
material is encapsulated by the thermoplastic material, such a door
would not be subject to environmental degradation as with
conventional wood doors.
[0041] While the sectional doors illustrated herein are described
with reference to use for personal dwellings, they may also be used
for other applications, such as warehouses, storage facilities,
commercial garages, and the like. They can also be used for
sectional doors on trucks or other commercial vehicles. In such
environments, characteristics with regard to fire rating, strength,
hardness, and the like become even more important. In addition,
when intended for commercial use, a company logo or other indicia
may be engraved directly into a door formed according to the
instant disclosure.
[0042] With reference to the Figures, FIG. 1 shows a sectional door
constructed from the PVC material referred to herein. In FIG. 1,
sectional door 10 which could be a garage door is constructed from
four (4) horizontal panels 12a, 12b, 12c, 12d, each constructed
from a cellular PVC material (whether reinforced or not). Of
course, any number of panels could be employed as may be required
for a particular application. Each of panels 12a, 12b, 12c, 12d can
be made of multiple PVC plies that are glued to form a single piece
structure. The cellular PVC material can be glued to itself by
means of a PVC cement, plumbing pipe glue or the like conventional
adhesive which may have a fast curing time. PVC material contracts
and expands a fair amount. However, when the entire panel is made
of plies of PVC material, such contraction and expansion will be
consistent. On the other hand, if the PVC material is only employed
for the purpose of providing the outer covering for the door panel,
a sheet of 1/4 inch (0.635 cm) thickness at a minimum can be
adhered or glued to an underlying substrate. While a door panel may
comprise a single, 1 inch (2.54 cm) thick, ply of PVC material,
this is not preferred as the door would then be too heavy. The
whole door may also require framing.
[0043] With respect to FIG. 2, a rear side of panel 12a is shown.
The same structure can be used for all panels of the door. However,
the exterior appearance of the panels may be varied along the
height or width of the door as may be desired. With reference now
also to FIG. 3, the panel 12a can include a PVC sheet, ply or
"skin" 13 forming the outer surface of the door, which would
exhibit a width in keeping with the size of the opening for the
garage door, and would have a thickness, at certain locations, of
about a minimum of one to two inches (1''-2'') (2.54-5.08 cm), but
may be thicker depending on the use. The skin 13 can comprise two
or more plies of material. Such plies are preferably thermally
compatible so they do not delaminate upon changes in temperature.
For the sake of convenience, it will be referred to herein as a
"ply", even if it includes more than one ply of material. An outer
ply of the door panel can be one-quarter to three-eighths inch
(1/4''-3/8'') thick (0.635-0.953 cm), while the inner reinforcing
member or beam or rail can be on the order of about one inch (1'')
thick (2.54 cm) or thicker. These two elements can be secured
together via a conventional PVC adhesive. The height of each panel
is also variable and depends upon the number of panels that will be
included in a door, i.e., two, three, four, or more. As was stated
hereinabove, however, each panel can have a substantially similar
construction.
[0044] With reference again to FIG. 2, there are shown horizontal
narrow rails 14, 14' which are placed on the upper and lower
perimeters of one side of the panel 12a for reinforcement. The
rails 14, 14' can be formed of the same PVC material as the skin 13
or from a similar material so that there are no thermal mismatch
problems. For example, the rails 14, 14' can comprise the composite
PVC material discussed above. In addition, vertical rails,
sometimes termed stiles, 16, 16' are placed on either side edge of
the panel on the same side as the horizontal rails 14, 14' also for
reinforcement. The horizontal rails 14, 14' and vertical rails 16,
16' can contact each other and can be secured together. Optionally,
one or more vertical reinforcement beams or rails 18 may be
included anywhere along the horizontal length of the panel, between
the rails 16 and 16' and spanning the height of the panel from top
rail 14 to bottom rail 14'. It is only the rails 14-18 that are
about one inch (1'') (2.54 cm) or so or thicker, as shown in FIG.
3. The several rails can be secured together by a conventional PVC
adhesive and can form a sash frame 11 in the embodiment
illustrated. Of course, other embodiments are also possible. The
outer ply 13 forming the exterior face of the door can, as
mentioned, be only one quarter to three-eighths inches
(1/4''-3/8'') thick (0.635-0.953 cm).
[0045] In one embodiment, the several rails are glued and mounted
to the inner surface of the ply 13 in FIG. 3. The purpose of the
rails is to frame the panel and provide support therefor. Other
means of fastening the rails 14-18 to the outer ply 13 can be used,
such as mechanical fasteners, including corrugated staples, screws,
rivets, bolts or the like. It should be appreciated that the entire
door panel 12a can be on the order of about two inches (2'') (5.08
cm) thick at the locations of the rails 14-18.
[0046] As mentioned, the rails may be adhered to the PVC ply 13
using any type of known fastening device, including but not limited
to drywall screws, nails designed for trim application, or other
fasteners. However, one preferred method of adhering the rails to
the panels is via the use of an adhesive. The adhesive may be, for
example, a polyvinyl acetate glue or a hot melt glue, among others.
Commercially available adhesives that are suitable for use to
adhere the rails to the PVC panels include known PVC cements or
other commercially available suitable adhesives. Use of an adhesive
has the practical effect of rendering the one or more plies of the
PVC skin 13 and the additional panel layers formed by the several
rails 14-18 as a one piece structure. A layer of adhesive 29 is
illustrated in FIG. 3 located between vertical rail or stile 16 and
bottom rail 14'. A suitable adhesive can cure very quickly and bond
so tightly that delamination is all but impossible. As was stated,
although mechanical fasteners such as nails or screws may be used,
the same are likely unnecessary when using an adhesive of the type
disclosed herein to connect the several sections of thermoplastic
material disclosed herein together to form the panels of the
door.
[0047] In construction, the thickness of each of the two or more
plies of each panel may be varied according to need. For example,
the skin 13 may be as thin as one-quarter (1/4) inch (0.635 cm) or
as thick as an inch (2.54 cm) or more. On the inside face of the
skin or outer ply, horizontal and vertical rails, which can be of
the same material as the panels, can be adhesively applied to frame
and reinforce the panel. These rails may be of any thickness
desired, for example about 1 to 2 inches (2.54-5.08 cm) thick. The
overall thickness of a panel 12a, then, including the thickness of
the rail and the several plies of the skin may be varied and
achieved using different thicknesses of plies and rails without
limitation. For example, three or more plies can be employed to
form a particularly strong door panel for larger width garage
openings. Thus, the overall thickness of the door panel may be
thicker than two inches (2'') (5.08 cm), in the area of the
reinforcing rails.
[0048] With continued reference to FIG. 3, it can be seen that the
top rail 14 and bottom rail 14' are provided, respectively, with a
longitudinally extending protrusion 20 and indentation 22. These
features enable adjacent panels to interlock with each other to
give the sectional door additional stiffness. In one embodiment,
one or more metal reinforcing elements, such as variously shaped
beams 24 and 26, can be employed to further stiffen the panel 12a.
Each of these can be secured to one or more of the rails 14-18 via
suitable fasteners 28 as shown in FIG. 3. The several rails 14-18
of the sash frame 11 also serve as supports to which conventional
hinges (not shown) can be fastened in order to link the several
door panels 12a-12d together. This can be done using conventional
lag screws or the like. These screws can be mounted directly into
the PVC material of the rails without cracking or splitting the
rails. The several rails 14-18 also provide surfaces for mounting
the hinges of the door (not illustrated) as well as the roller
brackets (not illustrated) which allow the door to slide on
suitable tracks.
[0049] One method for constructing the door illustrated in FIG. 3
is to provide the outer ply 13 and secure to it the sash frame 11.
However, the center reinforcing beam 18 can be applied after
securing the metal reinforcing members 24 in place on the beams 14
and 14' and before mounting the center metal reinforcing element 26
in place. To this end, the upper and lower reinforcing elements or
members 24 can be provided with cutouts to accommodate the beam 18
and allow it to be adhesively secured to the backside of the ply
13. Such beam 18 may not be necessary on narrower width doors.
[0050] Moreover, it should be appreciated that the respective
reinforcing elements 24 and 26 include elongated apertures 25. Such
apertures are advantageous because they allow relative movement
between the sash frame 11 and the reinforcing members 24 and 26.
Because these are made of different materials, they have different
thermal expansion and contraction rates. As mentioned, the
reinforcing members 24 and 26 can be made of steel or aluminum or
the like metal. Thus they must be attached or fastened in such a
way to the sash frame 11 as to allow a movement of the reinforcing
members and the sash frame in relation to each other, due to
contraction and expansion of the PVC material of the sash frame in
relation to the metallic material of the reinforcing members.
[0051] As with other styles of garage doors, the PVC panels
disclosed herein display a weathering joint feature so that in the
fully closed or fully opened position, the door appears to be one
sheet of material. FIGS. 4A-4D show different types of joint
structures that can be used to achieve this purpose. However, the
illustrated structures are in no way intended to limit the various
known configurations that could be used. FIG. 4A shows a structure
known as a shiplap configuration, FIG. 4B is a common
tongue-in-groove configuration, FIG. 4C is a finger protection
configuration, and FIG. 4D is another basic tongue-in-groove
configuration. As is apparent from FIG. 4A, two or more plies of
material 30, 32, 34 can be employed to form a panel 36 of the door.
FIG. 4C shows two plies 30'' and 32''. Alternatively, a single ply
may suffice for the door panel in some applications.
[0052] In each of FIGS. 4A-4D a top portion of the panel 37, 37',
etc. is the portion that would be found on the upper horizontal
surface of the sectional door panel, for example 14 in FIG. 2. This
portion would engage with the adjacent portion 38, 38' etc. located
on the lower horizontal surface of the sectional door panel just
above this panel, for example, in FIG. 1, panels 12a and 12b. As
two vertically adjacent panels are brought together and the lower
portion of one panel contacts the upper portion of the adjacent
panel, the weathering joint feature would be engaged as at 20 and
22 in FIG. 3. A variety of known joints is shown in FIGS.
4A-4D.
[0053] FIG. 5 illustrates the sash frame 11 by itself. FIG. 6
illustrates the outer, skin, cover or face ply 13 by itself. As
mentioned in connection with FIG. 4A, the skin 13 can include more
than one ply of material. For example, the cover or skin 13 can be
insulated with any suitable insulation material placed between the
sash 11 and the panel 13. A portion of a layer or ply of one
suitable known insulation material is identified by the numeral 27
in FIG. 6. Such insulation can be applied at the factory.
Alternatively, it can be added at a later date in the field on an
installed door. The insulation material should be chosen to have a
rate of thermal expansion similar to that of the panel 13 and sash
11 to forestall delamination. The panel can also be provided with
an inside skin 31 (FIG. 5) which can be as thin as craft paper or
can be a layer of a thin vinyl sheeting attached or glued to the
surface of the rails 14-18 comprising the sash frame 11.
[0054] Each panel may be configured to display a desired exterior
design. For example, with reference to FIGS. 7-10, available
sectional door panel designs popular in the garage door industry
include, but are certainly not limited to, a horizontal ribbed
panel 41 (FIG. 7), or a raised panel 42 (FIG. 8). Other panel
designs include a carriage door design 43 (FIG. 9) and a vertical
ribbed design 44 (FIG. 10). Also, textured, embossed, or debossed
designs may be easily produced according to the present
disclosure.
[0055] As noted above, with other garage door materials, creating
these designs in the panel surface may require the use of costly,
complicated, and heavy machinery, such as roll formers, hydraulic
presses and die formers. Alternatively, overlays may be made using
these techniques and then applied to the door surface. Often,
however, such overlays are made from a different material than the
door itself, creating an opportunity for thermal mismatch of the
door materials, which can to cause delamination. The present
disclosure pertains to a door in which the components of the panels
can be formed from a single type of material (other than the
reinforcing members and the hardware of the door), thereby
eliminating any thermal mismatch issues. As mentioned, any thermal
mismatch between the material of the reinforcing members 24 and 26
and the sash 11 can be accommodated via the slotted openings 25
shown in FIG. 3.
[0056] With reference now to FIG. 11, another door according to the
present disclosure can include two adjacent panels 50a and 50b,
each having an outer layer or ply 52, 52' and one or more
reinforcing members, beams or rails, which can extend horizontally,
such as 54, 54'. These can be connected to the ply 52 via an
adhesive layer (not shown). Mounted to the rails can be suitable
beam or channel-like reinforcing members 56, 56' made of a metallic
material. Also shown is a lower edge rail 57 secured to the upper
outer panel 52 and an upper edge rail 58 secured to the lower outer
panel 52'. These can be made of metal. Connecting the two panels
50a and 50b of the sectional door is a suitable hinge 60. Also
provided are respective metallic panel edge reinforcing members 61
and 62. Securing both the hinge and the metallic reinforcing
members to the respective reinforcing rails 57, 58 of the sash of
each door panel are suitable conventional fasteners 64.
[0057] Also, there can be provided between the panels 50a and 50b a
weather resistant joint 66, including a rubber seal 68 in the
joint. Such seals are known in the art. As mentioned, the joint can
be a tongue in groove joint or any other known type of joint. The
thickness of the outer ply 52, 52' can be on the order of 1/2 to 1
inch (1.27-2.54 cm), for example, 5/8 of an inch (1.59 cm). A slot
70 can be provided in the ply in order to accommodate a flange 72
of the respective reinforcing member 61 and 62. Such reinforcing
members can be roll formed to adopt the shape of the panel 50a,
50b. The slot 70 can be cut at a location on the edge of the ply
closer to the inside surface of the outer ply 52, 52', but with
enough material (for example, 1/8 of an inch (0.32 cm) thick)
allowing the exterior of the outer ply with the other side of the
cut being a minimum of 3/8 of an inch (0.95 cm) thick. This
thickness becomes important when vertical grooves (such as
illustrated in FIG. 10) are required so that the groove doesn't
become routed into the slot 70. The purpose for attaching the
reinforcing member 61 to panel 52 (or element 62 to panel 52') is
to allow the panel to expand and contract freely, laterally,
relative to the lengths of the reinforcing members. The metal
center reinforcing rail member 56 can have a reverse C-shaped
configuration, the flanges 74 of which will be accommodated in
slots 76 defined in the center rail or block of thermoplastic 54
that would be adhesively secured to the inside surface of the ply
50. When the thermoplastic ply 52 and the center rail 54 expand and
contract, the PVC material of the center rail will slide within the
C-channel of the metal reinforcing element 56 as required.
[0058] In one embodiment, the end rails can be made of metal. With
reference now to FIG. 13, an end rail 80 made of metal can include
a pocket or "channel" 81 defined by a pair of opposed flanges 82
and 83 which can accommodate a front ply or skin 84 of a door. Such
ply 84 is made of an extruded thermoplastic material. In one
embodiment, and with reference now to FIG. 14, the channel 82 can
be formed in the end rail 80 by notching a square shaped hole 86
cut only on three sides to form a tab to define a pocket-type
channel. The pocket can be provided with a cushion material 88
(FIG. 13), such as medium density rubber, to allow for relative
contraction and expansion between the thermoplastic panel 84 and
the metal end rail 80. The means for securing the end rail 80 to
the ply 84 is not illustrated in this embodiment, but can be along
the lines of the several designs discussed previously.
[0059] Another embodiment of a sectional door is illustrated in
FIG. 12. In this embodiment, an extruded thermoplastic outer ply or
layer 90 has a bottom edge 92 accommodated in a metal end rail 94.
To this end, the end rail 94 includes a vertically oriented channel
96 defined on its outer end. As is evident from a comparison of
FIGS. 11 and 12, the ply 90 can be thinner than the ply 50, since
the distal end of the end rail encloses the lower edge of the
panel, instead of being accommodated in a slot in the lower edge of
the panel. It should be appreciated that in all of these designs,
care must be taken to prevent water from becoming trapped in the
channel holding the lower edge of the panel. Therefore, in this
embodiment, one cannot use vertically oriented grooves on the
panel, such as the grooves illustrated in FIG. 10. Another
consideration for all of the designs illustrated herein is that the
relative movement or thermal expansion and contraction between any
metal reinforcing members (top or bottom rails or reinforcing
elements) and the thermoplastic plies of the door has to be
accommodated in order to allow for relatively free movement of the
outside facing door ply or skin 13, 52, 84 and 90 in the several
embodiments illustrated herein.
[0060] With reference now to FIG. 15, another embodiment of a door
design, among many others, according to the present disclosure is
there illustrated. In this embodiment, a door 100 includes a
plurality of panels, such as panels 102, 104, 106, 108, wherein
each of the panels has a different outer surface design. For
example, panel 102 is provided with a plurality of windows 110.
Panel 104 is provided with a pair of grooves 112 and 114 via
routing. These grooves continue onto panels 106 and 108 as well. A
similar spaced pair of grooves 116 and 118 is also provided.
Together, the two sets of grooves form two Xs on the outer surface
of the door 100. Dividing the two Xs from each other are a pair of
vertically oriented parallel grooves 120 and 122. Located on these
can be handles 124 (or designs which appear to be handles). The
overall appearance of the outer surface of the door is, therefore,
that of a carriage door. Note that an outer "framing" set of
grooves 126 can also be provided, to frame the entire door. The
outer surface of each panel 102-108 can be formed by suitable
milling or routing into the outer thermoplastic ply of each panel
of the door. Any desired design can be formed in the outer ply of
each panel by suitably programming the router.
[0061] Alternatively, the various designs on the door 100 can be
formed by overlay strips (which can be made of the same
thermoplastic as the outer ply or skin of each panel 102-108) which
can be adhesively secured to the outer ply. While this would
produce a more realistic design effect than routing grooves into
the skin or outer ply of each panel, it would be at a cost. Such a
design would be much more time consuming and result in a heavier
weight door. As an alternative to the foregoing, it is also
conceivable to sell a sectional door with a smooth outer surface
and provide on the inside surface of the sectional door a template
which would enable a homeowner, or after sale installer, to add
overlay strips to the outer surface of the door, by securing them
via fasteners extending from the inner surface of the door (at the
locations indicated by the template) through the skin layer and
into the overlay strips. In this way, the fasteners would not be
visible on the outer surface of the door. It should be appreciated
that adhesive could also be used together with, or in place of,
fasteners.
[0062] In fact, one can envision the sale of kits which have the
necessary template for each panel of the door and the various
components or strips which are to be added or secured in place to
the outer panel surfaces of the sectional door. Once a homeowner
has decided to redecorate the outer surface of his or her sectional
door, they would shop for a design. Having bought the desired
design, they would secure the templates in place on the back side
of each panel of the door and secure the necessary overlay strips
via fasteners extending through the panel at the locations
indicated by the template. Perhaps decorative hardware could be
secured to the front surface of the door in the same manner. This,
then, would give the homeowner a different look to their sectional
door, such as a garage door. Many such overlay strip designs and
templates could be produced, thereby giving the homeowner a wide
choice of possible designs.
[0063] With reference now to FIG. 16, a further embodiment of the
door 130 is there illustrated. In this embodiment, the door
comprises a plurality of panels 132, 134, 136, 138. Again, each
panel has a somewhat different design but the overall design is
that of another version of a carriage type door. Located on each
panel is at least one strip 140. Moreover, located on each panel is
a plurality of horizontally extending grooves 142. As with the
design of FIG. 15, the surface pattern on each panel can be
accomplished by forming the outer surface via routing or the
like.
[0064] A process of manufacturing such a thermoplastic door from,
for example, extruded PVC panels in a continuous manufacturing
process includes extruding cellular PVC door panels which can be
anywhere from 18 inches (45.72 cm) to 24 inches (61 cm) wide, for
example, in order to form the outer ply of each panel of the door.
The ply can be on the order of 3/8 inches (0.95 cm) thick. These
would then be cut to the desired size. The outer ply or skin can be
placed manually or automatically at the beginning of a continuous
process where a PVC cement or the like adhesive is applied to the
top perimeter of the sheet forming an inner surface of the door. A
sash frame made of the same extruded cellular PVC material (which
can be on the order of 1 inch (2.54 cm) thick) can be preassembled
(such as by cementing or fastening the various components together)
and cemented by a known PVC cement to the door panel sheet.
[0065] With reference now to FIG. 17, one process for manufacturing
a door panel according to the present disclosure includes ripping
or cutting rails from a larger sheet of thermoplastic material
(after one or more sheets of ply has been formed, such as by
extrusion) as shown at step 150. An exterior surface of outer
layer, ply or skin would be placed facing downwardly with the
interior surface of the several rails (made of extruded cellular
PVC material and cut to the desired size) of the sash frame facing
upward. However, this can be reversed so as to have the exterior
surface of panel facing upwardly. To do this, a jig may be required
to position the rails so that the panel will be placed on top of
the glued sash frame without having the sash frame misaligned with
the panel. This would take place at step 152. The panel can be
glued manually or automatically to the sash frame. The cemented
frame is placed on the cemented sheet. Any necessary metal
reinforcing elements (see FIG. 3) can be then secured to the sash
by means of fasteners and slotted holes, with the exception of the
reinforcement 26 of FIG. 3.
[0066] A linear motion hold down clamping system is then activated
on both sides of the panel and feeds the panel while it is being
cured. Thus, the door panel so formed can be fed through a
continuous moving hold down press as illustrated in step 154, at a
desired speed. That speed can be approximately 4 feet per minute
(1.2 m/s), or any other suitable speed. The panels will then be fed
at a set speed into a shaping and routing station, as illustrated
at step 156. At the same time, grooves can be routed into the outer
surface of the panel. For example, designs, such as illustrated in
FIGS. 8-10, or a door design such as is illustrated in FIGS. 15 and
16 can be formed in the panel. The design will be programmed via a
computer, such as a PLC. The edges of the panel can be shaped
according to the type of joint selected. FIGS. 4a-4d show several
different types of joints and FIG. 3 shows a further
embodiment.
[0067] A programmable CNC router can be employed to rout a specific
chosen program design on the panel from underneath. An electronic
monitor can be used so that manufacturing personnel can view the
design being routed onto the panel as it moves in the process. A
side cutter can be employed to shape the desired specific joint
shape (as is shown in FIGS. 4a-4d, for example). Ribs and grooves
can also be routed into the panel at the same time as the sides of
the panel are being shaped. If additional routing is desired, then
additional routing of the material can take place to complete the
design, i.e., such as with vertical grooves, as at step 158. As the
panel exits the continuous process extrusion line, the door panel
is considered to be completed unless it requires painting with a
different color than the original color of the thermoplastic
material, such the extruded cellular PVC discussed herein.
[0068] The PLC can be programmed so as to rout or engrave different
patterns in each of the panels (as in FIGS. 15 and 16) so that when
all the panels are put together, they will form the selected
design. The type of pattern can look like an overlay. However, an
add on or an overlay strip (not shown) of the same material can be
applied over a plain graphic to give a raised effect. The overlay
can also be of a different color when the ply contains an
impregnated solid color, such as beige or almond. The extruded
cellular PVC sheet is normally available in a white color. However,
two other colors are available, namely, almond or beige and sand
tone. These colors can be impregnated so that the entire thickness
of the PVC sheet is the desired color. Moreover, the outer ply of
the panel can be painted with an ultraviolet protective coating in
order to lessen harm to the thermoplastic material of the door due
to sun exposure.
[0069] For example, a white strip can be employed over a beige or
sandstone color door. Such add-ons can be applied at a later date
in the field by the home owner or a handyman fastening or gluing a
strip of material on the outside of the door panels. These add-ons
or overlays can be made from a strip of material (which can be on
the order of 1/4 inch or 3/8 inch thick (0.635-0.953 cm) ply). As
mentioned, such material can be glued or mechanically fastened from
the inside of the panel using fasteners, such as screws. To aid in
such fastening, a printed center line can be made by the PLC on the
interior surface of the panel to aid in securing one or more
additional layers or plies of material to the outer surface of the
door. At the routing station discussed in step 164, the necessary
cycles are completed.
[0070] Then it is determined whether painting of the door panel is
necessary at step 160. If so, it can be conducted as at step 162.
The panel is then fed to a paint drying area, as at step 164. With
continued reference to FIG. 17, after painting or if no painting is
needed, the material can be delivered to the process stage where
the reinforcing material is installed at step 166. At this time, a
suitable window, such as 134 shown in FIG. 15, can also be
installed in one or more of the panels of the door. Also, the
necessary hardware, such as, e.g., brackets for holding rollers or
the hinges illustrated in FIGS. 11 and 12, can be installed.
Moreover, handles, such as at 124, can be secured to the outer face
of a panel. As mentioned, at least some of the reinforcing elements
can be secured to the sash frame before it is secured to the outer
ply at step 152. Thus, the reinforcing members can be placed on the
lateral rails of the sash frame at the beginning of the assembly
process before the sash frame is cemented to the panel or
thereafter as the panel exits the process and before it is
assembled to the remaining panels to form the door. When the panel
is finished, it along with other panels, can be packaged, as at
step 168.
[0071] The door panels made from extruded cellular PVC do not
require conventional manufacturing techniques, nor do they require
overlays. Rather, conventional routing devices can be used to
create any desired design with ease and in a much less costly
manner. For example, a computer numerically controlled (CNC) router
or other similar router may be used to engrave a design on the
exterior surface of the panel. Alternatively, multiple routers may
be used together. In this regard, such routers are programmable to
create the desired design to suit panel width and height. For
ribbed designs, such features are generated in the same manner and
can be formed in the panel along with the routing of the weather
joint features at the top and bottom edges of the panel.
[0072] In another embodiment, the thermoplastic material sheet of
the panel can be extruded in such a way as to have the lateral
sides thereof extruded in a specific shape for panels which can be
mated to each other. In other words, with such a design, there may
not be any need to mechanically shape the top and bottom edges of
the panel in the process. Such an extrusion would deliver a long
strip of the desired panel height. Then, the panels would be cut to
the desired width.
[0073] The disclosed method of manufacturing and the thermoplastic
material used are advantageous from the perspective that designs
can be duplicated without the use of heavy and expensive equipment.
Moreover, an unlimited number of designs and patterns can be
obtained at relatively little cost. This is possible because of the
extruded thermoplastic material, such as the cellular PVC discussed
herein, and the use of a fast curing adhesive. These enable a
continuous manufacture of composite garage door panels having edges
formed with the necessary joints in order to provide a weather
tight seal between adjacent door panels. Thus, a relatively
maintenance free sectional door panel with any desired pattern on
its outer face is achieved in an advantageous manner. This can be
accomplished via a continuous manufacturing process.
[0074] The disclosure has been described with reference to the
preferred embodiments. Modifications and alterations will occur to
others upon reading and understanding this specification. It is
intended to include all such modifications and alterations insofar
as they come within the scope of the appended claims or the
equivalents thereof.
* * * * *