EP1430197A1

EP1430197A1 - A door panel

Info

Publication number: EP1430197A1
Application number: EP02777235A
Authority: EP
Inventors: Mark Stevens
Original assignee: WARD BUILDING COMPONENTS Ltd
Current assignee: Kingspan Holdings IRL Ltd
Priority date: 2001-09-26
Filing date: 2002-09-25
Publication date: 2004-06-23
Also published as: GB2380219A; WO2003029593A1; GB2380219B; PL367355A1; GB0222362D0; IE20020774A1

Abstract

A door panel (2) comprises an external sheet (l0), an internal liner sheet (ll), and an insulting core (12) therebetween. The sheets (10, 11) are insulated from one another. Each panel (2) has two ends with different profiles. The internal liner sheet (ll) has a hinge receiver (20) on one edge defining a recess (21) for receiving a barrel (23) of a conventional hinge (3). The hinge (3) has an upper leaf (25) which is screwed to the liner (11) of an upper panel (2) and a lower leaf (26) which is screwed to the liner (11) of a lower panel (2). The hinge receiver (20) comprises a lower portion (30) which extends in the direction of the external sheet (10) and a return leg (31) which extends towards the inside of the door panel. The leg (31) extends generally perpendicular to the plane of the inside of the door panel to correctly locate the hinge (3), on assembly. The leg (31) has a downturned formation (32) which engages, on assembly with the barrel (23) of the hinge (2) for alignment of the hinge barrel (23) in the hinge recess (21). The lower portion (30) of the hinge receiver in this case has a bend (35) between a first entry section (36) and a second section (37) extending to the return leg (31). The entry section (36) extends at an angle α of approximately 55°; with respect to the inside face of the liner sheet. The hinge receiver ensures that a hinge (2) is located precisely whilst allowing adjacent panels (2) to butt together for precise location of the panels (2), on assembly. This ensures that the correct geometry at the joint between the panels (2) is maintained as the door opens. The liner arrangement (10, 11) ensures that there is a close fit at the inner joint, when closed, to prevent entry of fingers, and that as the door opens, the gap remains sufficiently tight to prevent finger entry.

Description

"A DOOR PANEL"

Introduction

The invention relates to door panels and in particular to a roll-up door comprising a number of elongate door panels which are hingedly interconnected along adjacent edges extending transversely of the door.

Door panels for such doors are generally are of composite construction comprising an outer facing sheet and an inner liner sheet with an insulating core therebetween.

The sheets are usually of metal and the core is typically of polyurethane foam.

Several door panel constructions which claim to substantially prevent a users fingers becoming entrapped between adjacent panels on the outer facing side of the door are known. In general all such panels use the same principle of a nose of a female edge sweeping over an approximation to an arc as the door opens and closes.

Conventional door panels however are not generally finger safe on the inner liner side of the door. There is a risk of a users fingers becoming entrapped between the inner hinge joint between adjacent panels.

There are in general three different types of joint used on the inner lower side of conventional door panels.

In one conventional construction adjacent panels abut on the liner side with a straight edge butt joint and hinges of conventional construction are used to connect the adjacent panels. One problem with this construction is that the positioning of the hinge is variable depending on the operator who assembles the door. If the hinges are not positioned with a very high degree of accuracy, which requires considerable operator skill, there will be a variation in the gap between the adjacent panels across the joint. This can lead to problems of user finger entrapment not only on the liner side but also potentially on the outer facing side of the door. In addition, as there is no finger safety feature on the inside liner face the inner joint can open to an extent where entrapment of fingers can occur.

It is also known to provide a straight butt joint between adjacent panels with a specialist complex hinge. However, as the hinges are spaced-apart transversely there are gaps between the hinges in which a users fingers may become entrapped, especially if the hinges are mis-aligned on assembly.

A third known construction provides a gap between the inner faces of adjacent panels to allow hinges to face inwardly i.e. with the hinge axis within an area bounded by the inner and outer faces of the panel. While this arrangement assists in locating a hinge considerable operated skill is still required to ensure that the hinges are not mis-aligned with potential finger trapping consequences. In addition, the area in which the hinge is located is often sufficiently large to accommodate a finger. This gap tightens as the door closes posing a potential finger trapping hazard.

There is therefore a need for an improved construction of door panel in which potential finger trapping hazards on the inner liner side of the door are eliminated whilst still ensuring that finger entrapment hazards are avoided on the outer side of the door.

In addition, to be effective in use a door panel should have thermal insulating properties.

Statements of Invention

According to the invention there is provided a door panel comprising:-

an external sheet;

an internal liner sheet; an insulating core between the external sheet and internal liner sheet;

the internal liner sheet having a hinge receiver on one edge defining a recess for receiving a barrel portion of a hinge, the hinge receiver having an abutment portion;

the internal liner sheet having a projecting nose on an opposite edge, the nose projecting towards the abutment portion of the hinge receiver of an adjacent panel, on assembly;

the external sheet and the internal sheet being substantially insulated from one another.

In one embodiment of the invention, the nose is engageable with the abutment portion of the hinge receiver of an adjacent panel, on assembly.

Preferably the hinge receiver comprises a leg which extends towards the inside of the door panel, the leg defining the abutment portion.

In a preferred embodiment the hinge receiver comprises a lower portion which extends in the direction of the external sheet and a return leg which extends towards the inside of the door panel.

Preferably the leg extends generally perpendicular to the plane of the inside of the door panel.

In one embodiment the leg comprises a downturned formation for engagement, on assembly with portion of a hinge. Preferably the lower portion of the hinge receiver extends at the angle of from 55° to 42° ideally approximately 55° with respect to the inside face of the lower sheet. In one arrangement the lower portion of the hinge receiver has a bend between a first entry section and a second section extending to the return leg.

Preferably the hinge receiver is formed by profiling the inner liner.

In one embodiment the hinge receiver has a thickness which is greater than the thickness of the liner sheet. In this case preferably the hinge receiver is formed by folding the liner sheet back in itself to form a double skin liner section.

In a preferred embodiment the nose of the internal liner sheet is pointed to make point contact with the abutment face of the hinge receiver of an adjacent panel, on assembly.

It is preferred that the inner liner and external sheet of a panel are not in contact with one another over the length thereof. The metal facing sheets of the panel are profiled inwardly at the joint. The most effective insulation is gained when no continuous conductive path is provided from one facing sheet to the other. This is best effected by spacing them apart, with an interposed insulating element.

Preferably the panel includes a seal for sealing the joint between adjacent panels, on assembly. The seal is typically housed in a recess between the inner liner and the external sheet of the panel. The seal may be of an elastomeric sealant material, usually a preform.

The seal may comprise a weather seal and an air seal. Preferably the weather seal is retained in place by compression between the inner and outer sheets. The air seal is preferably fixed in place. The air seal may be adhesively bonded to the panel.

The invention also provides a door comprising a number of panels of the invention. Brief Description of Drawings

The invention will be more clearly understood from the following description thereof given by way of example only with reference to the drawings, in which: -

Fig 1 is a perspective view of a door according to the invention, in use;

Fig 2 is a side elevational view of the door, in use;

Fig 3 is a cut-away view of a joint between adjacent panels of the door;

Fig 4 is a cross sectional view of adjacent panels with the panels in a vertical closed position;

Fig 5 is a cross sectional view of adjacent panels where the door is being moved between open and closed positions;

Fig. 6 is a cross sectional view of adjacent panels of another embodiment of the invention, with the panels in a vertical closed position;

Fig. 7 is a cross sectional view of the adjacent panels of Fig. 6 in which the door is being moved between open and closed positions;

Figs 8 and 9 are cross sectional views of adjacent alternative panels in an open and closed position respectively;

Figs 10 and 11 are cross sectional views of adjacent panels according to another embodiment in open and closed positions;

Figs 12 and 13 are cross sectional views of adjacent panels according to a further embodiment in open and closed positions; Figs 14 and 15 are cross sectional views of adjacent panels according to another embodiment in open and closed positions;

Figs 16 and 17 are cross sectional views of adjacent panels according to a further embodiment in open and closed positions;

Figs 18 and 19 are cross sectional views of adjacent panels according to another embodiment in open and closed positions; and

Figs 20 and 21 are cross sectional views of adjacent panels according to a further embodiment in open and closed positions.

Detailed Description

Referring to the drawings and initially to Figs 1 to 5 there is illustrated a door 1 comprising a number of transverse panels 2 which are hingedly interconnected by hinges 3. The door 1 is used in an opening 4 in a garage 5 or the like. The panels 2 are rolled up to open the door and are rolled down into a vertical orientation to close the door.

Each door panel 2 is a composite panel comprising an external sheet 10, usually of metal, an internal sheet 11, also usually of metal, and an insulating core 12 of polyurethane foam or the like therebetween. Typically, the sheets 10, 11 are of faced steel which is profiled by roll forming. However, they may also be extruded from a suitable material such as Aluminium. The external sheet 10 includes inturned legs 14 at the upper and lower ends of the panel. The internal sheet 11 also has an inturned leg 15 at the lower end of the panel. The sheets 10, 11 are insulated from one another by the insulating core 12. Each panel 2 has two ends with different profiles. For ease of description these will be referred to as upper and lower ends 18, 19 respectively, however this is an arbitrary designation and depends on the orientation of the panels on assembly and in use. In Figs 3 to 5 portions of adjacent panels are shown to illustrate and describe the j oint therebetween.

The internal liner sheet 11 has a hinge receiver 20 on one edge defining a recess 21 for receiving a barrel 23 of a conventional hinge 3. The hinge 3 has an upper leaf 25 which is screwed to the liner 11 of an upper panel 2 and a lower leaf 26 which is screwed to the liner 11 of a lower panel 2.

The hinge receiver 20 comprises a lower portion 30 which extends in the direction of the external sheet 10 and a return leg 31 which extends towards the inside of the door panel. The leg 31 extends generally perpendicular to the plane of the inside of the door panel to correctly locate the hinge 3, on assembly. The leg 31 in this case has a downturned formation 32 which engages, on assembly with the barrel 23 of the hinge 2 for alignment of the hinge barrel 23 in the hinge recess 21.

The lower portion 30 of the hinge receiver in this case has a bend 35 between a first entry section 36 and a second section 37 extending to the return leg 31. The entry section 36 extends at an angle α of from 55° to 42° with respect to the inside face of the liner sheet 11. Preferably, for optimum hinging whilst preventing finger entrapment in the hinge recess the angle is approximately 55°. The segmented angled face is to give retention to the hinge whilst allowing an exit angle which will not trap fingers. For example, if the hinge was retained in a square channel, the portion of the leg 30 which was parallel to leg 31 would meet the liner face much closer to the hinge, reducing the finger clearance to the point where it could trap.

The range of angles indicated above means that the fingers will not trap and the hinge can still be fixed through the standard holes. The face 30 is kinked to ensure that it does not project into the outer face. The hinge receiver 20 is in this case formed by turning the liner sheet back on itself, to form a double thickness of liner. This has the advantage of stiffening the hinge receiver 20, especially the horizontal leg 31 thereof. It also provides improved pull out strength for the hinge screw which is screwed through a number of plys, in this case two plys of the sheet 11 and one ply of the external sheet 10. The strengthened horizontal leg 31 between hinges 2 may be used as a handle for closing the door from the inside.

The lower end of the internal liner sheet 11 has a nose 39 which projects towards the return leg 31 of the hinge receiver 20 of an adjacent panel, on assembly. The nose 39 engages the horizontal plane defined by the return leg 31 of the hinge receiver 20 in point contact with a planar face ensuring positive engagement.

The external sheet 10 has a male profile portion 45 on one edge and a female profile portion 46 on an opposite edge which are arranged for finger safe engagement. A user's fingers cannot become entrapped between the external skins 10 of adjacent panels as the door is being moved between open and closed positions.

It will be noted that the external sheet 10 and internal liner sheet 11 are not in contact. This ensures that there is no cold bridge and a door formed by a number of panels hinged together has thereby improved thermal insulation properties.

A seal, in this case a single weather seal 40 is located in a recess between the inner and outer sheets 10, 11. The seal may be of elastomeric material, solid or foamed and may comprise more than one element (core and skin) . The seal may be a simple rectangular section or a more complex shape and may seal by pressing through its own elastic properties against the inner leg of the nose of the outer skin, by being compressed between the inner and outer skins 10, 11 or by being trapped between the nose of the outer skin of the lower panel and the horizontal portion of the outer skin of the upper panel. Whatever the configuration, the seal forms a weather seal when closed (i.e. prevents significant air leakage and entry by driving rain), and is configured to ensure that it does not become dislodged or adopt an incorrect shape through the normal use of the door. The seal in the configuration of the foam filled panel also acts to prevent chemical leakage during the manufacturing process. Various different configurations of seal are illustrated in the drawings.

Referring to Figs. 6 and 7 there is illustrated a door panel according to another preferred embodiment of the invention in which parts similar to those of the panel described above are assigned the same reference numerals. In this case fixing screws 51, 52 for the upper leaf 25 and the lower leaf 26 respectively of the hinge 3 are illustrated. It will be noted that the upper screw 51 is engaged for positive fixing with three plys, namely two plys of the internal liner sheet 11 and one ply of the external sheet 10. The lower screw 52 extends through two adjacent plys of the internal liner sheet 11 and one ply of the external sheet 10. This ensures positive secure fixing of the hinge.

In this case the internal liner sheet 11 is formed with an open loop 50 in the generally horizontal leg 31 of the profile to give added strength to the profile, to assist in locating the hinge, and for ease of manufacture. The barrel 23 of the hinge 3 is accommodated in the hinge recess 21 without a requirement for an engagement formation of the type illustrated as 32 in Figs. 1 to 5. Thus, the forming of the hinge receiver portion of the inner sheet 11 is simpler.

The seal is a two part seal comprising a weather seal 55 and an air seal 56. The air seal 56 is generally of rectangular shape and is typically of expanded polyvinylchloride having a closed cell structure and coated on one face with a pressure sensitive adhesive. The seal is compressed, on fitting, to provide a weather seal against air passage and filling the void which would exist without its presence, preventing the formation of condensation. The weather seal 55 is also of generally rectangular shape and is typically of a polyurethane (flexible polyether/polyurethane and a glass fibre cord) with a polyethylene outer skin. The weather seal 55 is typically non-adhesive and held in place by compression between the legs 14, 15 of the inner and outer sheets 10, 11.

The edges forming the joint are designed to allow easy, accurate roll forming. They are also designed to use a "standard" profile hinge. The two layers of metal facing projecting into the foam core at each edge, combined with the inner face give good purchase for the hinge fasteners, making the use of auxiliary plates unnecessary. The use of simple seals facilitates manufacture.

Referring to Figs 8 and 9 there is illustrated a door panel according to another embodiment of the invention. This configuration has an open loop 50 in the horizontal portion of the profile to give strength to the profile, locate the hinge and allow easy manufacture. The seal 60 is of a different shape.

Referring to Figs 10 and 11 there is illustrated a door panel according to another embodiment of the invention. This configuration is similar to Figs 6 and 7 except that the liner is modified to allow the use of a smaller seal 65. It also allows easier access to the foam into the edge detail during manufacture.

Referring to Figs 12 and 13 there is illustrated a door panel according to another embodiment of the invention. This configuration has similar features to those of Figs 8 to 11 except that the hinge barrel is housed in a curved recess 67.

Referring to Figs 14 and 15 there is illustrated a door panel according to another embodiment of the invention. This configuration is similar to Figs 6 and 7 but with a different seal configuration 70.

Referring to Figs 16 and 17 there is illustrated a door panel according to another embodiment of the invention. This configuration is similar to Figs 8 and 9 but with a different seal configuration 75. Referring to Figs 18 and 19 there is illustrated a door panel according to another embodiment of the invention. This configuration is similar to Figs 6 and 7 but with a different seal configuration 80.

Referring to Figs 20 and 21 there is illustrated a door panel according to another embodiment of the invention. This configuration is similar to Figs 8 and 9 but with a different seal configuration 80.

The hinge receiver ensures that a hinge is located precisely whilst allowing adjacent panels to butt together for precise location of the panels, on assembly. This ensures that the correct geometry at the joint between the panels is maintained as the door opens. The liner arrangement ensures that there is a close fit at the inner joint, when closed, to prevent entry of fingers, and that as the door opens, the gap remains sufficiently tight to prevent finger entry. On closing, a finger pressing on either the inner or outer joints is excluded.

Many variations on the invention will be readily apparent and accordingly the invention is not limited to the embodiments hereinbefore described which may be varied in construction or detail.

Claims

1. A door panel comprising :-

an external sheet;

an internal liner sheet;

an insulating core between the external sheet and internal liner sheet;

2. A panel as claimed in claim 1 wherein the nose is engageable with the abutment portion of the hinge receiver of an adjacent panel, on assembly.

3. A door panel as claimed in claim 1 or 2 wherein the hinge receiver comprises a leg which extends towards the inside of the door panel, the leg defining the abutment portion.

4. A door panel as claimed in any preceding claim wherein the hinge receiver comprises a lower portion which extends in the direction of the external sheet and a return leg which extends towards the inside of the door panel.

5. A door panel as claimed in claim 3 or 4 wherein the leg extends generally perpendicular to the plane of the inside of the door panel.

6. A door panel as claimed in any of claims 3 to 5 wherein the leg comprises a downturned formation for engagement, on assembly with portion of a hinge.

7. A door panel as claimed in any of claims 4 to 6 wherein the lower portion of the hinge receiver extends at the angle of from 55° to 42° with respect to the inside face of the lower sheet.

8. A door panel as claimed in claim 7 wherein the angle is approximately 55°.

9. A door panel as claimed in claim 7 or 8 wherein the lower portion of the hinge receiver has a bend between a first entry section and a second section extending to the return leg.

10. A door panel as claimed in any preceding claim wherein the hinge receiver is formed by profiling the inner liner.

11. A door panel as claimed in any preceding claim wherein the hinge receiver has a thickness which is greater than the thickness of the liner sheet.

12. A door panel as claimed in claim 11 wherein the hinge receiver is formed by folding the liner sheet back in itself to form a double skin liner section.

13. A door panel as claimed in any preceding claim wherein the nose of the internal liner sheet is pointed to make point contact with the abutment face of the hinge receiver of an adjacent panel, on assembly.

14. A door panel as claimed in any preceding claim wherein the inner liner and external sheet of a panel are substantially not in contact with one another over the length thereof.

15. A door panel as claimed in any preceding claim wherein the panel includes a seal for sealing the joint between adjacent panels, on assembly.

16. A door panel as claimed in claim 15 wherein the seal is housed in a recess between the inner liner and the external sheet of the panel.

17. A door panel as claimed in claim 15 or 16 wherein the seal is of an elastomeric sealant material.

18. A door panel as claimed in any of claims 15 to 17 wherein the seal comprises a preform.

19. A door panel as claimed in any of claims 15 to 18 wherein the seal comprises a weather seal and an air seal.

20. A door panel as claimed in claim 19 wherein the weather seal is retained in place by compression between the inner and outer sheets.

21. A door panel as claimed in claim 19 or 20 wherein the air seal is fixed in place.

22. A door panel as claimed in claim 21 wherein the air seal is adhesively bonded to the panel.

23. A door panel substantially as hereinbefore described.

24. A door comprising a number of panels as claimed in any preceding claim.