Door sill system, apparatus and methods for a door assembly

A system, device, kit, assembly and methods for a frame assembly, including a door sill as shown and described. The assembly may be a door frame assembly and may, by way of example, be a door jamb and/or a door mullion including a door sill. Some inventions of the present disclosure may be considered a door sill having a deck.

FIELD OF TECHNOLOGY

The present disclosure relates generally to doors and door assemblies having a door sill for entranceways, for example, for a building and, more particularly, to a door sill system, device, apparatus, and/or methods for a door sill assembly for a residence/facility.

BACKGROUND

A door sill takes constant and repeated traffic, weathering and abuse. Some parts of a door sill may age faster or slower than others and/or may be the focal point of more traffic flow. Important variables in door sill applications are a secure fit, durability and expense. In some attempts, door sills have been made one piece to be more durable. However, one piece door sills remain expensive, may still wear in certain areas more than others, may not provide a desirable fit over time, or become damaged in certain areas of the sill. If an owner wants to make the door sill more aesthetically pleasing when damage occurs, the one piece door sill requires full installation and repair, adding a new full unit, not a desirable option when door sills still have a cost barrier. Therefore, traditional sills are typically too expensive for aesthetic replacement of the entire unit due to damage to one portion of the sill, and a better fit, cost and option for replacement are still needed.

Thus, the Applicant recognized there remains a need for a cost effective, durable door sill that resists foot traffic, weathering and long-term exposure to moisture and, in some embodiments, allow replacement of a damaged part or replacement of the entire sill economically.

SUMMARY

The present disclosure is directed in one embodiment to a system, device, method and/or kit for a door sill assembly for a doorway.

In some embodiments, a door sill having a deck, may include a molded base component and a deck component fitting with the molded base component. A base component may include a base portion and a cap portion. The base portion and the cap portion may be integrally formed with one another in some examples. The cap portion may extend from the base portion.

The base portion may include a cap surface. The cap surface may extend along a top plane of the base portion for forming a seal with a door panel. The base portion may include a first end having a first wall and a second end having a second wall.

A deck support surface may extend along a second plane. The deck support surface may include recesses and a set of support platforms to form a discontinuous planar support.

The base portion may include a lip at the base portion second end that extends beyond the base portion second end wall. The lip may also include a terminating end.

The deck component may fit with the molded base component, for example, along a discontinuous planar support. The deck component may include a first end, a second end, a medial section between the first end and the second end, a deck top, and a deck bottom.

A top surface on the deck top may include a set of raised treads.

The deck component may include a projection located toward the first end. The projection may extend into one of the recesses.

In one example, a supported segment of the deck along the medial section may be supported by at least one of the support platforms. The at least one of the support platforms may be located in between one of the recesses.

Embodiments may include a lip cap toward the second end of the deck component. The lip cap may include a downwardly oriented segment that mates with a terminal end of the lip. A turn segment may mate with an underside of the lip. A lip cap may substantially cover the lip at the terminating end. The lip cap may secure the deck component with the molded base component by way of the lip cap and the projection, forming a securing tension.

In some embodiments, a door sill may include a sill extender cavity. The sill extender cavity may include a first connector feature. The sill extender cavity may include a second connector feature.

Some embodiments may include a terminating point separated apart from the second end wall by an opening. The opening may be defined on one side by the second end wall, on a top side by the turn segment, and on an opposite side by the second connector, with a space on a bottom side so that the second connector and the second end wall are spaced apart from one another.

A door sill according to examples of the present disclosure may include cap support ribs in the base portion. The door sill may, in other examples, include a caulking surface on the underside of the base portion. The caulking surface may be integral with the base portion.

In one example, a molded base component may be an injection molded base component.

In one example, the deck component may be an extruded aluminum deck component.

Embodiments may include a door sill where a deck component is removable from a molded base component. A second deck component may be configured to be replaceable with the deck component, such that the second deck component may mate with the molded base component.

The inventions of the present disclosure may be considered a method for a door sill for a doorway by way of any of the embodiments disclosed.

The inventions of the present disclosure may be considered a door sill having replaceable portions according to any of the embodiments disclosed herein. One of the replaceable portions may be a deck portion.

One example may include a kit for a door sill according to any of the embodiments disclosed herein. In one example of a kit, the kit may include a door sill having a deck component and a second deck component for replacing the deck component.

These and other aspects of the inventions of the present disclosure will become apparent to those skilled in the art after a reading of the following description of embodiments when considered with the drawings.

DESCRIPTION OF EMBODIMENTS

A door frame often includes one or more frame members. A plurality of frame members may include any combination of a header, a sill, mullion components, jamb components, and/or a trim profile. A header may be generally placed toward the top of a door assembly. Mullions and jambs components may be generally placed at opposing sides of a door assembly. Frame assemblies may also include hinges for connecting door panels to at least one of the frame members. The frame assembly may also include locking hardware that enables the door to be secured to as least one of the frame members and/or to another frame member. Locking hardware, by way of example, may include latches and deadbolts. Toward the bottom of a doorway typically is a door sill assembly.

Referring now to the drawings in general, it will be understood that the illustrations are for the purpose of describing a preferred embodiment of the inventions and are not intended to limit the inventions thereto. Shown throughoutFIGS. 1-4, and referencing a door sill10, in some embodiments, a door sill10may include a base component20and a deck component40for fitting with the base component20. The base component20may be a molded base component.

A base component20may include a base portion22and a cap portion24. The base portion22and the cap portion24may be integrally formed with one another in some examples. The cap portion24may extend from the base portion22. The cap portion24may include a cap surface26and a back15. The cap surface26may extend along a top plane P1of the cap/base portion22/24for forming a seal with a door panel.

The base component20may include a first end23having a first wall23′ and a second end25having a second wall25′. The base component may include one or more recesses27between the first end23and the second end25. The base component20may include one or more support platforms29. The support platforms29may be located between the first end23and the second end25. In some examples, one or more of the support platforms29may form a discontinuous substantially planar support along plane P2.

In other embodiments, a supported segment of a deck component40, along a medial section46of the deck component may be supported by at least one of the support platforms29. The at least one of the support platforms29may be located in between one or two of the recesses27.

The base portion24may include a lip30at the base portion second end25. The lip30may extend beyond the base portion second end wall25′. The lip30may also include a terminating end32. The lip30may form a shelf toward the terminating end32. The shelf may be an unsupported shelf or partially unsupported shelf in this embodiment, extending beyond second wall25′.

A deck component40may fit with the base component20. In some example, deck component40may fit with the base component20along a discontinuous planar support along P2. The deck component40may include, in some examples, a first end42, a second end44, a medial section46between the first end42and the second end44, a deck top43, and a deck bottom45. A deck top surface on the deck top43may include a set of raised treads51.

The deck component40may include a projection60located toward the first end42. The projection60may extend into one of the recesses27. The projection60may be configured to be secured in recess27. The projection60may include a barb along one or more points of a projection length.

A deck surface may extend parallel to a second plane P2.

In some examples a door sill for a door assembly including support platforms may include a medial support29C, a distal support29D, and a proximal support29B. The door sill for a door assembly may including a base support29A. There may be a recess between the proximal support and the medial support. There may be a recess between the medial support and the distal support. A top portion of the base support29A and a top portion of the proximal support29B each may include a wedge-shaped corner for guiding entry of the projection into the jointly formed recess formed between the supports. The supports may be dispersed to provide a discontinuous support along variable points along the support surface in the plane P2to minimize materials and cost while also maximizing sturdiness and support for the deck portion. An alternating arrangement of supports and recesses may provide such an arrangement.

Embodiments including a deck component40, may include a lip cap64toward the second end44of the deck component. The lip cap64may partially surround lip30. The lip cap64may include a downwardly oriented segment65that mates with a terminal end of the lip32. A turn segment68may mate with an underside of the lip30. A lip cap64may substantially cover the lip30at the terminating end32. The lip cap64may secure the deck component40with the base component20by way of the lip cap64and a securing of the projection60, forming a securing tension when both the lip cap64and projection60are fitted into place.

In some embodiments, a door sill10may include a sill extender70(location shown inFIG. 2). The sill extender70may lengthen the deck sill through connector to a first connector feature75. The sill extender70may connect to a second connector feature76. Sill extender70may extend in substantially the same plane P2and provide a longer length to the door sill10. Some embodiments may include an upper cavity75′ and a lower cavity76′, the upper cavity75′ and lower cavity76′ separated apart from one another by the downwardly oriented segment65. The lower cavity75′ may be defined on one side by the second end wall25′, on a top side by the turn segment68, and on an opposite side by the second connector feature76, with an opening on a bottom side so that the second connector feature76and the end wall25′ are spaced apart from one another. The first connector feature75may include a curved surface and an opposite rounded surface forming the upper cavity75′.

A door sill10, according to examples of the present disclosure, may also include one or more support ribs72. The door sill may, in other examples, include a caulking surface74on the underside of the base portion24. The caulking surface74may be integral with the base portion24.

In one example, a molded base component20may be an injection molded polymer base component.

In one example, the deck component40may be an extruded aluminum deck component. In an example including a molded polymer base component and an extruded aluminum deck component, structured according to any of the embodiments disclosed, the door sill10maintains a secure fit with a door panel, minimizes materials needed for construction of the sill, is durable and damage resistant and is cost effective, reducing production cost of the door sill10.

Some examples may include where a cap surface26is a sealed surface. The cap surface26may be, in some embodiments a non-adjustable surface. The cap surface26may include integrally formed treads.

In other examples, the door sill10may be considered a one-piece fixed sill with an aluminum deck secured thereto. In other examples, the door sill10may be considered a two-piece door sill.

Some embodiments may include wherein a deck component40is removable from a base component20, in some instances with base component20remaining installed. In some instances, deck component40may be interchangeable with a replacement deck component40.

The inventions of the present disclosure may be considered a method for a door sill10for a doorway by way of any of the embodiments disclosed. The inventions also include a method for an economical door sill10.