GB2276902A

GB2276902A - Door core with moulded-on edge

Info

Publication number: GB2276902A
Application number: GB9307291A
Authority: GB
Inventors: Victor Paul Ferguson; Wayne Victor Paul Ferguson; Arthur David Ellis
Original assignee: PANEL EDGE PRODUCTS Ltd
Current assignee: PANEL EDGE PRODUCTS Ltd
Priority date: 1993-04-07
Filing date: 1993-04-07
Publication date: 1994-10-12
Anticipated expiration: 2013-04-07
Also published as: GB2276902B; GB9307291D0

Abstract

A door 10 having plastics edging moulded onto a core 20 to provide an L-shaped moulding 30 of which an upright limb 31 is T-shaped in cross-section and the bottom limb 32 is U-shaped in cross-section. The moulding may provide a lock mounting and further mouldings may provide hinge mountings. <IMAGE>

Description

DOORS This invention concerns doors (and like openable closures hereinafter referred to as "doors").

Doors are known which comprise a substantially rectangular body having nominally horizontal top and bottom edges at opposite ends thereof, and two nominally vertical edges one of which is intended to receive hinges or like mountings and is hereinafter called "the mounting edges" and the other of which is intended to receive door furniture (such as a lock, latch, handle or push-plate) and is hereinafter called "the opening edge".

Doors are known in which the body comprises a core incorporating edging strips at the vertical edges of the body, which core is covered with facings such as veneers, so as to cover or alternatively leave exposed the sides of the parallel edging strips.

Doors commonly give rise to problems in use caused by impact damage, and to problems in manufacture, storage and installation because of the need to make them in a range of specific widths.

To enable such problems to be reduced the present invention provides a door comprising a body having top, bottom, mounting and opening edges around an internal core, and characterised in that the bottom and opening edges are defined by an L-shaped edge moulding of plastics material cast onto the core.

The core is preferably left completely exposed at the top and mounting edges to reduce costs of manufacture and to facilitate the top and mounting margins the door being cut back to reduce the size of the door. However, hinge mountings of plastics material may be cast into the body to interrupt the mounting edge of the core. Top mountings of plastics material (e.g. for a door closer) may interrupt the top edge of the core.

A lock mounting of plastics material may be cast in the door so as to be integral with the upright limb of the L-shaped moulding; and, optionally, said lock mounting may be hollow to provide a lock-reception socket.

The upright limb of the L-shaped moulding and the opening edge of the core preferably interengage at a stepped interface. The upright limb is preferably Tshaped in horizontal cross-section.

The bottom limb of the L-shaped moulding preferably embraces the bottom end of the core, and is preferably Ushaped in vertical cross-section. The limbs of the Ushape preferably extend upwards to serve as kick plates at each side of the bottom portion of the door, e.g. by at least 15cm up to 30cm, preferably between 10 and 20cm.

The door may incorporate an inset panel or pane in a surround of plastics material. The surround preferably comprises a first moulding insertable into an opening in the body to provide a seating for the panel or pane, and a second moulding securable to the first moulding or the body to serve as bead retaining the panel or pane in the first moulding.

The mouldings are preferably of polyurethane material.

The invention will be described further, by way of example, with reference to the accompanying diagrammatic drawings, wherein FIGURE 1 shows one side of a door of the invention in elevation; FIGURES 2 to 6 show sections of the door on the line 11-11 to VI-VI respectively in FIGURE 1, and FIGURES 7 and 8 show diagrammatic sections through parts of a mould used in manufacturing the door.

The door shown in FIGURE 1 comprises a body 10 which has a top edge 11, a bottom edge 12, a mounting edge 13 and an opening edge 14, the peripheral surfaces of which edges, in use, confront surfaces of a frame 15 and floor 16 defining an opening in which the door is hung; and comprises a glazed window 17 in the body 10.

Referring to FIGURES 2 to 6, the body 10 comprises a core 20, of fibreboard in this example, but other forms of core materials and structures e.g. chipboard, blockboard, cellular foamed rigid plastics material honeycombed material and like timber substitutes or timber may be employed, and in this example the core 20 is covered on each face with a laminate 21 e.g. of timber, timber substitute, plastics or metal.

Along the opening edge 14 the margin 27 of the core is machined to produce a groove 22 (FIGURES 2 and 7), and along the bottom edge 12 both sides of the margin 26 of the core is machined to leave a central tongue 23 of core material (FIGURES 3 and 8).

The core 20 has an opening formed therein for the window 17, and the edges of the core surrounding the opening are machined to provide a groove in the core between walls 28 and 29 at each side of the core, as shown in FIGURE 4.

Portions of the margins of the core 20 may be further machined to provide recesses which open at the edges of the core; and in this example, a lock-mounting recess for a lock mounting 24 is shown in FIGURE 5 and one of three hinge mounting recesses for hinge mountings 25 is shown in FIGURE 6.

The body 10 is provided with an L-shaped moulding 30 of polyurethane material which extends along the bottom and opening edges 12 and 14. The moulding 30 is cast onto the core 20 in a mould 40 (FIGURES 7 and 8) so that the polyurethane material becomes bonded or strongly adhered to the core. In this example the moulding is formed so that side surfaces thereof are co-planar with the faces or sides of the body 10, and so that the lock mounting 24 is integral with the moulding.

The mould 40 comprises a rigid base 41 in which the core 20 is located, a removable rigid closure 44 and a shaped liner 42 which is preferably formed from a flexible material and is clamped to the sides of the body 10 to define, with the shaped margins 26 and 27, a moulding chamber 43 into which liquid or fluid material is pumped to set or harden to form the moulding 30. A similar moulding process may be employed to form other mouldings, e.g. the hinge mountings 25, in recesses such as the hinge mounting recesses.

As can be seen from FIGURES 2 and 3, the upstanding limb 31 of the moulding 30 is substantially of T-shaped horizontal cross section, whereas the horizontal bottom limb 32 of the moulding 30 is substantially U-shaped in vertical cross section, so that the interfaces between the limbs 31, 32 and the margins are geometrically shaped to provide mechanical support for the moulding 30. The walls 33 and 34 provided by the bottom limb 32 extend upwards to serve as kick-plates for the door.

Referring to FIGURE 4, the window 17 includes a pane 35 set in a surround which comprises a first moulding 36 and a second moulding 37 both formed from polyurethane material. The first moulding 36 provides a seating for the pane 35 and is inserted (or moulded) in the opening so as to engage in the groove in the core between the walls 28 and 29. The second moulding 37 serves as a glazing bead and is secured by fasteners 38 to retain the pane in the surround and to further secure the surround to the core.

The invention is not confined to details of the foregoing example and many variations and modifications are possible within the scope of the invention. For example, the bottom surface 39 of the moulding 30 may be provided with formations such as a sealing blade or rebate, especially for external doors; and the opening edge may be rounded or rebated, especially for sliding or meeting doors. The lock mounting 24 may be moulded to provide a socket for a lock (not shown), by means of an extension of, or an insert in, the liner 42.

The limbs of the moulding 30 may have any suitable cross-sectional configuration. For example, for a sliding door, both limbs may be of T-shaped cross section.

The other edges 11 and 13 may have an elastomeric or plastics covering moulded thereon, but preferably, if they are required to be covered, the covering is applied after the door has been cut to size by trimming of the margins of the core along these edges.

The invention further includes and provides a door having any novel part, feature, or element disclosed herein or in the accompanying drawings; and a method of making a door including any novel step or expedient disclosed herein. For example, the invention further provides a door having moulded-in plastics mountings for door gear or furniture such as locking or latching means, hinges or runners. The invention further provides a door having a moulded-on polyurethane edging incorporating portions of different cross-section. The invention further provides a door having a bottom portion provided by a moulding moulded onto a body of the door so as to provide a kick-plate at each side of the door.

The terms and expressions used herein, are by way of example, and represent and may be replaced or supplemented by equivalent or analogous terms or expressions.

Claims

1. A door comprising a body having a core provided with moulded-on polyurethane edging incorporating portions of different cross-section.

2. A door comprising a body having top, bottom, mounting and opening edges around an internal core, and characterised in that the bottom and opening edges are defined by an L-shaped edge moulding of plastics material cast onto the core.

3. A door as claimed in Claim 2 wherein the core is left completely exposed at the top and mounting edges to reduce costs of manufacture and to facilitate the top and mounting margins the door being cut back to reduce the size of the door.

4. A door as claimed in Claim 2 or 3 wherein hinge mountings of plastics material are cast into the body to interrupt the mounting edge of the core.

5. A door as claimed in Claim 2, 3 or 4 wherein top mountings of plastics materials interrupt the top edge of the core.

6. A door as claimed in any one of Claims 2 to 5 wherein a lock mounting of plastics material is cast in the door so as to be integral with the upright limb of the L-shaped moulding.

7. A door as claimed in Claim 6 wherein said lock mounting is hollow to provide a lock-reception socket.

8. A door as claimed in any one of Claims 2 to 7 wherein the upright limb of the L-shaped moulding and the opening edge of the core interengage at a stepped interface.

9. A door as claimed in Claim 8 wherein the upright limb is T-shaped in horizontal cross-section.

10. A door as claimed in any one of Claims 2 to 9 wherein the bottom limb of the L-shaped moulding embraces the bottom end of the core, and is U-shaped in vertical crosssection.

11. A door as claimed in Claim 10 wherein the limbs of the U-shape extend upwards to serve as kick plates at each side of the bottom portion of the door.

12. A door as claimed in any preceding claim wherein the door incorporates an inset panel or pane in a surround of plastics material.

13. A door as claimed in Claim 12 wherein the surround comprises a first moulding insertable into an opening in the body to provide a seating for the panel or pane, and a second moulding securable to the first moulding or the body to serve as bead retaining the panel or pane in the first moulding.

14. A door as claimed in Claim 13 wherein the mouldings are of polyurethane material.

15. A door as claimed in Claim 1 having moulded-in plastics mountings for door gear or furniture such as locking or latching means, hinges or runners.

16. A door as claimed in Claim 1 having a bottom portion provided by the moulding moulded onto a body of the door so as to provide a kick-plate at each side of the door.

17. A door substantially as hereinbefore described with reference to FIGURE 1, or FIGURE 1 as modified by or further detailed in any one or more of FIGURES 2 to 6; or made by a method substantially as hereinbefore described with reference to FIGURES 7 and 8.