Door with assembly of stiles and rails

An entry door is shown and described. The entry door may include a first skin, a second skin, and at least one stile formed from a plurality of interconnected members attached together. The entry door may also include at least one rail formed from a plurality of interconnected members attached together, where the at least one rail and stile are positioned between and secured with the first and second skins forming a cavity between the first and second skins, and an insulative material positioned between the first and second skins generally filling the cavity.

FIELD OF INVENTION

The present invention relates generally to an entry door, and more particularly, to an entry door formed with an assembly of stiles and rails.

BACKGROUND

Entry doors for residences, business, and industrial facilities often suffer from shortcomings in their design. One popular design is a door formed from wood. Since wood is generally light and can be shaped and cut easily, wooden doors can be manipulated to meet a lot of differing needs and requirements. Wooden doors, however, are often more susceptible to harsh environmental conditions. Still further, wooden doors have a fixed insulative capacity that cannot generally be altered without significant costs and design issues.

Steel or metal doors, on the other hand, provide strength and the ability to withstand extreme environmental conditions. Due to the heavy material, the metal doors generally have a hollow cavity in order to substantially reduce the overall weight. Often this cavity is filled with a wood material, which similarly causes the door to have a fixed insulative capacity that cannot generally be altered without significant costs and design issues. The metal door with the cavity filled with wood can still be heavy and difficult to install.

Traditionally, the metal door was manufactured with two door skins if the top and bottom pieces were manufactured integral to the respective door skins or four pieces if the top and bottom pieces were not integral to one of the door skins. One traditional method of manufacturing the door is to weld the pieces together at the seams. The welded door provides great resistance to the harsh environment and can generally withstand fires, but suffers from being a time consuming and costly procedure as well as being unattractive.

The welded door is unattractive due to the welded seams that contain a variety of bumps and ridges from the welding process. Further, the welding process is generally unreliable and may cause material flexing and fitment issues due to the extreme heat required to weld the door together. Further still, the welded door is costly to produce because an acceptable door must be prepped for welding and then welded. Not only is welding expensive and time consuming, the unattractive seams that result must be sanded and polished to provide an acceptable finish. The sanding and polishing procedures are objectionable because they are both labor intensive and messy.

Further still, these types of entry doors are limited in the available points of contact between the door and applicable building structure. This may create additional gaps through which environmental conditions may enter, e.g., hot or cold air. The door may then not offer suitable insulation to the opening, which may increase heating and cooling costs.

Therefore, there is a need for an improved door that may be formed from skins and that can be manufactured in a more efficient and cost effective manner and that may be easier to install due to a lower weight. Further, there is a need for a door that may exhibit good protection from environmental conditions and that can provide additional insulative capacity. Further still, there is a need for an entry door that may be formed to contact additional components of the building structure to which it is attached to provide a better seal between the building structure and environment.

SUMMARY

An entry door is shown and described. The entry door may include a first skin, a second skin, and at least one stile formed from a plurality of interconnected members attached together. The entry door may also include at least one rail formed from a plurality of interconnected members attached together, where the at least one rail and stile are positioned between and secured with the first and second skins forming a cavity between the first and second skins, and an insulative material positioned between the first and second skins generally filling the cavity.

An entry door may include a first skin, a second skin, and a pair of stiles formed from a plurality of interconnected members attached together. The entry door may also include a pair of rails formed from a plurality of interconnected members attached together, where the pair of stiles and rails are positioned between and secured with the first and second skins forming a cavity between the first and second skins, and an edge member attached to at least one of the pair of stiles, where the edge member includes a generally perpendicular internal corner capable of engaging at least two surfaces of a jamb.

An entry door may include a jamb attachable to an opening in a building structure, the jamb having a width, a first skin, a second skin, and a pair of stiles formed from a plurality of interconnected members attached together. The entry door may also include a pair of rails formed from a plurality of interconnected members attached together, where the pair of stiles and rails are attached together, positioned between and secured with the first and second skins forming a cavity between the first and second skins whereby at least one of the pair of stiles is connected with the jamb, and where the first and second skins extend beyond the width of the jamb.

DETAILED DESCRIPTION

An entry door10capable of being attached to a building structure, or more specifically to any appropriate jamb frame12at an entrance to the building structure is shown inFIG. 1. The entry door10may be of any appropriate shape and size, the present teachings are not limited to the shape and size of the entry door10shown and described herein. These are merely exemplary embodiments of the entry door10. While the entry door10is shown and described as being a door to enter a structure, it may also be an internal door, closet door, or any other type of door; the present teachings are not limited to the use and type of door shown and described.

When terms such as “inner,” “outer,” “lower,” “upper,” “horizontal,” and “vertical” are used herein, reference is made to the entry door10of the present teachings when oriented as shown, for example, inFIG. 1. It should be understood that such terms are used in their relative senses and are intended to be are merely exemplary and not all-inclusive nor exclusive.

The entry door10may be secured with the jamb frame12using hinges20. The hinges20may be any suitable type of hinges as the present teachings are not limited to a specific type of hinge. The hinges20may be attached to the entry door10and the jamb frame12in any appropriate manner, such as by way of a non-limiting example using fasteners (not shown). Any type of fasteners may be used.

The entry door10may include a first skin24and a second skin28. Either of the first and second skins24,28may face an interior of the building structure whereby the other of the first or second skins24,28may face an exterior of the building structure. If the entry door10is utilized as an interior door, the first and second skins24,28may refer to any side of the entry door10. The first and second skins24,28may be formed of any appropriate material, including, by way of non-limiting examples, steel, fiberglass, aluminum or any other appropriate material. The first and second skins24,28may be formed of the same material, or in the alternative, the first and second skins24,28may be formed from different materials. By way of a non-limiting example, the first skin24may be steel or fiberglass and the second skin28may be the other of fiberglass or steel.

The first and second skins24,28may have any appropriate decorative finish or none at all. For example, the first skin24may include a plurality of decorative panels32formed therein, such as shown inFIG. 1. The first skin24may have generally the same decorative finish as the second skin28such that the second skin28includes similar decorative panels32formed therein. In the alternative, the first skin24and second skin28may have generally different decorative finishes. The present teachings are not limited to a specific decorative finish. By way of non-limiting examples, the first and second skins24,28may include any decorative finish like windows, textured wood grain, generally smooth finish, and the like. Further, the finish may be stainable to match interior trim or other appropriate components or paintable to match an exterior of a building or to be in compliance with homeowner's association guidelines.

The entry door10may further include a rail and stile structure40secured with the first and second skins24,28in any appropriate manner. By way of a non-limiting example, the rail and stile structure40may be adhered, welded, fastened or the like to both of the first and second skins24,28. The first skin24may be secured by a first method and the second skin28may be secured in a second manner whereby the first and second manners are different. Alternatively, the first and second skins24,28may be secured in the same manner.

The rail and stile structure40may be adhered to the first or second skins24,28using any appropriate adhesive, such as epoxies, urethanes, hot melts, silicones and the like or a combination of such. The rail and stile structure40may also be welded to the first or second skins24,28such as through sonic welding, heat welding, and the like. Still further, the rail and stile structure40may be fastened such as through fasteners, fastening devices, integrally formed fastening devices, monolithically formed fastening devices and the like.

The rail and stile structure40may be formed in any appropriate manner. Exemplary embodiments of the rail and stile structure40secured with the first and second skins24,28are shown in cross-section inFIGS. 2 and 3. The rail and stile structure40being secured with the first and second skins24,28may form at least a portion of the entry door10. The rail and stile structure40may be formed of any appropriate material, including, without limitation, fiberglass, plastic, and rubber. Further, the rail and stile structure40may be formed from a pultruded material such as polyurethane, or sheet molding compound fiberglass. The rail and stile structure40may serve as a frame like structure to the entry door10to which the first and second skins24,28may be attached. The rail and stile structure40may be of a configuration to provide the appropriate rigidity and structure to the entry door10.

The rail and stile structure40may include a plurality of components operatively attached to one another to which the first and second skins24,28may be secured. In an exemplary embodiment, the rail and stile structure40may include a pair of side stile assemblies42, top rail assembly44and bottom rail assembly46. The components may all be attached together in any suitable manner forming the rail and stile structure40. The side stile assemblies42may be a mirror image of one another, or may be of a different configuration. The present teachings are not limited to either configuration. In a non-limiting example, one of the side stile assemblies42may be a hinge stile while the other of the side stile assemblies42may be a lock stile. In such embodiments, the hinge stile may be connected with the hinges20and connected with the jamb frame12. The lock stile may be selectively secured with the jamb frame12upon closing of the entry door10and may include a lock (not shown) that may lock the entry door10with respect to the jamb frame12preventing further movement thereof.

More specifically, the rail and stile structure40may include at least the following components: a header50, such as shown inFIG. 11, an internal connection member56such as shown inFIG. 12, a side member62, such as shown inFIG. 13, a bottom member68such as shown inFIG. 14, and an edge member74such as shown inFIG. 15. While specific configurations of the header50, internal connection member56, side member62, bottom member68and edge member74are shown inFIGS. 2-9, the present teachings are not limited to such. Any appropriate configuration of the header50, internal connection member56, side member62, bottom member68and edge member74may be used without departing from the present teachings.

The side stile assemblies42may be formed by attaching the edge member74with at least one side member62and at least one internal connection member56. The side stile assemblies42may further include an end member76, which is described in more detail below. More specifically, and as shown in the embodiment ofFIGS. 3 and 9, the side stile assemblies42may be formed from attaching the edge member74between a pair of the side members62. Additionally, a pair of the internal connection members56may be attached to the side members62. Next, the edge member74may be attached to a portion of the end member76in any appropriate manner, such as through adhesives, fastening, engaging or any combination of such. It should be understood, however, that the side stile assemblies42may be formed in any appropriate configuration and the components thereof may be attached in any order. They are not limited to the order described above.

In the embodiments shown, the side members62may include at least one snap fit member80, the internal connection members56may include at least one snap fit member82and the edge member74may include at least one snap fit member84. The snap fit members80,82,84may have any appropriate configuration such that they may be selectively engaged together as appropriate. Specifically, each of the side members62may include a pair of male snap fit members80and a female snap fit member81; each of the internal connection members56may include a pair of female snap fit members82; and the edge member74may include a pair of male snap members84. The male snap fit members80of each of the side members62may engage the female snap members82of the internal connection members56. Similarly, the male snap fit members84of the edge member74may engage the female snap member81of the side members62. The snap fit members80,81,82and84may be engaged together such as through a manual hand operation, utilizing an appropriate machine, or a combination of such. Once the snap fit members80,81,82and84are selectively engaged, an adhesive may be used to fixedly secure the snap fit members80,81,82and84together. Any appropriate adhesive may be used without departing from the present teachings. Alternatively, the snap fit members80,81,82and84may be attached through any appropriate process, including, fastening, welding or the like.

The edge member74may be of a configuration that it includes a portion that matingly engages with a portion of the end member76. By way of a non-limiting example, the edge member74may include a first mating portion90—such as a female dovetail90as shown inFIG. 9and the end member76may include a second mating portion92—such as a male dovetail92also shown inFIG. 9. The first mating portion90may generally engage with the second mating portion92. As shown inFIG. 9, the male dovetail member90may matingly engage with the female dovetail member92. In the alternative, the edge member74may include a male mating member and the end member76may include a female mating member—the present teachings are not limited to a specific configuration. In addition, the first and second mating portions90,92may be further secured together through use of adhesives, fastening, or any other suitable process. By way of a non-limiting example, the first and second mating portions90,92may have adhesive applied in any appropriate manner and then the first and second mating portions90,92are matingly engaged.

The end member76may be formed from any appropriate material. By way of a non-limiting example, the end member76may be generally formed of any appropriate wood material such as oak, mahogany, fir, cherry, etc. The end member76being wood may further add rigidity to the side stile assembly42, and more specifically, the rail and stile structure40of the entry door10. One of the pair of side stile assemblies42may include the end member76, or alternatively, both of the pair of side stile assemblies42may include the end member76, i.e., either or both of the hinge stile or locking stile may include the end member76.

The end member76may include a generally perpendicular corner portion96. By way of a non-limiting example, the end member76may be rabbeted around exterior edges thereof to generally form the perpendicular corner96, which results in two surfaces96aand96b. The corner portion96may, when the entry door10is assembled, engage the door jamb12when the entry door10is attached to the building structure. The corner portion96being generally perpendicular may allow the entry door10, and more specifically, the surfaces96a,96bof the corner portion96to engage a corner of the door jamb12. This may, therefore, result in the corner portion96engaging two sides of the door jamb12, i.e., surfaces96aand96b, as opposed to prior art entry doors that only engage a single surface. In addition, weather-stripping99may be attached to the end member76, or more specifically, weather-stripping99may be attached to the surfaces96aand96bof the corner portion96. The weather-stripping99may be of any appropriate configuration and design, including, without limitation being a bead of weather-stripping. This may result in the weather-stripping99being positioned beyond prior art weather-stripping resulting in more direct exposure to the exterior. This placement of the weather-stripping99may result in better properties to prevent water leakage and air or light infiltration. Specifically, a gap100may be formed between the two beads of weather-stripping99on the corner96of the end member76. The gap100may form a cavity that may act as a weeping system for water infiltration as well as improve sound-deadening properties.

Further, the header50may include a corner portion97similar to that of the corner portion96. By way of a non-limiting example, the corner portion97may be rabbeted around exterior edges thereof, which results in two surfaces97aand97b. The corner portion97may, when the entry door10is assembled, engage the door jamb12when the entry door10is attached to the building structure. The corner portion97being generally perpendicular may allow the entry door10, and more specifically, the surfaces97a,97bof the corner portion97to engage a corner of the door jamb12. This may, therefore, result in the corner portion97engaging two sides of the door jamb12as opposed to prior art entry doors that only engage a single surface. In addition, weather-stripping101may be attached to the corner portion97of the header50, or more specifically, weather-stripping101may be attached to the surfaces97aand97bof the corner portion97. The weather-stripping101may be of any appropriate configuration and design, including, without limitation being a bead of weather-stripping. This may result in the weather-stripping101being positioned beyond prior art weather-stripping resulting in more direct exposure to the exterior. This placement of the weather-stripping101may result in better properties to prevent water leakage and air or light infiltration. Specifically, a gap103may be formed between the two beads of weather-stripping101on the corner portion97. The gap103may form a cavity that may act as a weeping system for water infiltration as well as improve sound-deadening properties. The weather-stripping99may be equivalent to the weather-stripping101or they may be of a different configuration or construction. The present teachings are not limited to a specific configuration of weather-stripping.

As the weather-stripping99,101may be attached to the corner portions96,97or more specifically, the surfaces96a,96b,97a,97b, respectively of the corner portions96,97this may result in an additional seal over the prior art entry doors. The additional seal may provide a better insulative result for the entry door10. The two seals may generally prevent more of the exterior environmental conditions from entering the building structure through the entry door10as well as generally preventing the interior environmental conditions from exiting through the entry door10. This may provide a superior seal.

The top rail assembly44may be formed from attaching the header50with at least one side member62and at least one internal connection member56. More specifically, and as shown in the embodiment ofFIG. 2, the top rail assembly44may be formed from attaching the header50between a pair of the side members62. Further, a pair of the internal connection members56may be attached to the side members62. As noted above, the internal connection members56may include a pair of the snap fit female members82and the side members62may each include the pair of snap fit male members80and the snap fit female member81. The header50may include at least one snap fit member94, such as by way of a non-limiting example, a pair of male snap fit members94capable of engaging the female snap fit members81of each of the side members62.

The snap fit members80,81,82and94may be engaged in any appropriate manner, such as shown inFIG. 2. The snap fit members80,81,82and94may be snap fit manually by hand, utilizing appropriate machinery or a combination of such. Once the snap fit members80,81,82and94are selectively engaged, an adhesive may be used to fixedly engage the snap fit members80,81,82and94together. Any appropriate adhesive may be used without departing from the present teachings. Alternatively, the snap fit members80,81,82and94may be fixed together through any appropriate process, including, without limitation, fastening, welding or the like. Attaching the snap fit members80,81,82and94as indicated above may form the top rail assembly44.

The bottom rail assembly46may formed from attaching the bottom member68with at least one side member62and at least one internal connection member56. More specifically, and as shown in the embodiment ofFIG. 2, the bottom rail assembly46may be formed from attaching the bottom member68between a pair of the side members62. Further, a pair of the internal connection members56may be attached to the side members62. The bottom rail assembly46or more specifically, the bottom member68may operatively engage a threshold96in any appropriate manner upon the entry door10being attached to the jamb frame12.

As noted above, the internal connection members56may include the pair of the snap fit female members82and the side members62may each include the pair of male members80and the snap fit female member81. The bottom member68may include at least one snap fit member104, such as by way of a non-limiting example, a pair of male snap fit members104capable of engaging the female snap fit members81of each of the side members62.

The snap fit members80,81,82and104may be selectively engaged in any appropriate manner, such as shown inFIG. 2. The snap fit members80,81,82and104may be snap fit manually by hand, utilizing appropriate machinery or a combination of such. Once the snap fit members80,81,82and104are engaged, an adhesive may be used to fixedly engage the snap fit members80,81,82and104together. Any appropriate adhesive may be used without departing from the present teachings. Alternatively, the snap fit members80,81,82and104may be attached through any appropriate process, including, without limitation, fastening, welding or the like. Attaching the snap fit members80,81,82and104may form the bottom rail assembly46.

While the order of the components forming the side stile assemblies42, top rail assembly44and bottom rail assembly46being assembled is described above generally in a specific order, the present teachings are not limited to such. The components may be assembled in any appropriate order. Further, steps may be skipped or combined without departing from the present teachings.

Once the side stile assemblies42, top rail assembly44and bottom rail assembly46are formed, they may be attached to one another in any appropriate manner. By way of a non-limiting example, the side stile assemblies42, top rail assembly44and bottom rail assembly46may be attached by using adhesives, fasteners, welding, or the like. Alternatively, they may be attached through an integral or monolithic connector formed thereon. This may form the rail and stile structure40, which as noted above may act as a frame structure for the entry door10. Once assembled, the first and second skins24,28may be attached to the rail and stile structure40in any appropriate manner.

The header50, internal connection members56, side members62, bottom member68, and edge member74may be a combination of components as shown inFIGS. 11-15. The components may be made of any appropriate material, including, without limitation, extruded plastic, pultruded fiberglass, polyurethane, rigid PVC, acetal, and the like. The components may interconnect with one another in any appropriate manner. The header50, internal connection members56, side members62, bottom member68, and edge member74and their corresponding snap fit members80,81,82,94and104may each be formed as a monolithic unit.

The rail and stile structure40being formed from the header50, internal connection members56, side members62, bottom member68, and edge members74may result in a generally hollow entry door10. Specifically, such components when attached may be generally spaced from one another. This may form a hollow portion108within the entry door10between the first and second skins24,28. The hollow portion108may be generally filled with an insulative material120. The entire hollow portion108may be filled with the insulative material120, or in the alternative, a portion of the hollow portion108may be filled with the insulative material120.

The insulative material120may be any appropriate material, including, without limitation, polyurethane foam, polyethylene foam, granular cellulose, honeycomb cellulose, fiberglass batting, and the like. When utilizing polyurethane foam, or any other foam insulation, it may be sprayed within the hollow portion108or the applicable portion thereof in any appropriate manner. Alternatively, the hollow portion108may be filled with a liquid insulation. The liquid insulation may be poured or sprayed in. Further, solid insulation may be inserted into the hollow portion108or the applicable portion thereof. The present teachings are not limited to a specific configuration of insulation. Including the insulative material120within the hollow portion108may result in the entry door10having a higher insulating factor than other prior art doors, including, without limitation wood doors. By way of a non-limiting example, adding the insulative material108within the hollow portion120may result in an entry door having an insulating factor of at least R−10.

Additional embodiments of an entry door according the present teachings are described below. In the descriptions, all of the details and components may not be fully described or shown. Rather, the features or components are described and, in some instances, differences with the above-described embodiments may be pointed out. Moreover, it should be appreciated that these additional embodiments may include elements or components utilized in the above-described embodiments although not shown or described. Thus, the descriptions of these additional embodiments are merely exemplary and not all-inclusive nor exclusive. Moreover, it should be appreciated that the features, components, elements and functionalities of the various embodiments may be combined or altered to achieve a desired entry door without departing from the spirit and scope of the present teachings.

An entry door200such as that shown inFIG. 19may include an overall thickness T2that greater than the thickness T1of the entry door10ofFIG. 3. The entry door200having a greater thickness may generate a larger hollow portion227. The larger hollow portion227may have included therein a greater amount of insulative material232. Increasing the amount of insulative material232in the entry door200may increase the insulating factor of the entry door200.

The thickness of the entry door200may be increased by utilizing longer internal connection members256than those of the entry door10. Utilizing longer internal connection members256with the rail and stile structure240may increase the distance between the first and second skins24,28. This may then increase the amount of available open area between the first and second skins24,28, or more specifically, increases the available hollow portion227. More insulative material232may be inserted between the first and second skins24,28. This may result in the entry door200having better insulative properties, including having a higher insulating factor.

Further, the thicker entry door200may include end members76similar to the entry door10. This may allow the thicker entry door200to fit on a standard rabbeted jamb frame12. This may be accomplished by an offsetting rabbet around the exterior edges of the entry door200. This may provide the entry door200with an offset edge resulting in four 90 degree corners—specifically three outside corners and one inside corner—as opposed to two 90 degree corners in prior art versions. These additional corners may provide additional surface area for an extra bead of weather-stripping and may further block a significant amount of light, air and noise infiltration. This placement of the weather-stripping may result in better properties to prevent water leakage and air or light infiltration. The gap between the two beads of weather-stripping may provide a cavity that acts as a weeping system for water infiltration as well as improve sound-deadening properties as further described above.

Although the embodiments of the present invention have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present invention is not to be limited to just the embodiments disclosed, but that the invention described herein is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter. The claims as follows are intended to include all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof.