DOOR PANEL

Abstract: The invention relates to a flexible, bump-resistant door leaf, especially for overhead sliding doors, comprising a plurality of flexible panels (2) and, between any two of neighbouring panels (2), a flexible link element (4) extending along essentially the entire width of the door leaf. The link element comprises mating convex and concave sliding surfaces (36, 38) which engage with each other and together serve as a knee joint when mutually rotating the neighbouring panels (2). The concave sliding surface (38) encloses the convex sliding surface (36) through such a restricted angle that said link element (4) in itself permits an unimpeded vertical separation of the two neighbouring panels (2) but counteracts a mutual horizontal displacement of the panels. At each end of the link element (4) there is arranged an end coupling means (6) which prevents separation of the ends of neighbouring panels (2). Preferably, there is no panel-joining element in addition to the end coupling means (6).

Description: DOOR PANEL The present invention relates to a door panel or door leaf of the type comprising a plurality of succes¬ sive, mutually rotatable, separate panels. The inventive door leaf may be used for, for instance, but not exclu¬ sively, an overhead sliding door whose door leaf is mov¬ able between an essentially vertical closed position and an essentially horizontal open position. Traditionally, as shown in, for example, Fig. 1 of US 5,148,850 as mentioned below, neighbouring panels of such door leaves for overhead sliding doors are rotatably connected to each other by means of a plurality of sepa¬ rate hinges which are distributed over the width of the door leaf and which are normally made of metal and whose hinge plates are attached by screwing, riveting or in some other way to the inner panel surfaces of the door leaf in order to rotatably join the panels. The axis of rotation as defined by each hinge is positioned in or in the immediate vicinity of the plane that coincides with the inner boundary surface of the door leaf. This traditional solution having a plurality of fixedly mounted hinges between neighbouring panels suf¬ fers from the drawback that the hinges and the panels are in many cases broken when bumped into or subjected to some other impact. This results in a costly and time-con¬ suming exchange of components and in the door becoming useless for some time. A further disadvantage of using such hinges is that the panels themselves must be suffi¬ ciently strong to permit the attachment of the hinges and to resist the stress in these attachments during opera¬ tion. Since the total weight of the door leaf thus will be considerable, the speed at which the door can be open¬ ed and closed is restricted. One more disadvantage of using such traditionally hinges is that the hinge attach- ments will be impaired in course of time and cause noise during opening and closing. One more drawback is that the mounting of all hinges is complicated and time-consuming. Wear and lubricating problems may also arise. Attempts have been made to eliminate at least some of these disadvantages of the above described, tradi¬ tional construction with separate hinges. Thus, US 4,924,932 discloses a door leaf comprising a plurality of successive, separate panels and, between any two neighbouring panels, a link element continuously extending along essentially the entire width of the door leaf, said link element defining an axis of rotation around which the two neighbouring panels are adapted to rotate relative to one another, and including a male sec¬ tional element arranged on one of the neighbouring panels and having a convex surface concentric with the axis of rotation, and a female sectional element arranged on the other one of the neighbouring panels and having a concave surface mating the convex surface and concentric with the axis of rotation. The link element of this prior art door leaf is distinguished in that the link element in itself functions as a vertically joining hinge. This joining hinge function is achieved by the concave surface of the female sectional element enclosing the convex surface of the male sectional element through about 270° such that the sectional elements hook into each other. When assem¬ bling such a link element between two neighbouring panels, the panels must be held almost perpendicular to each other to make it possible to insert the female sec¬ tional element into the male sectional element. After this insertion and after having rotated the two panels in the direction of a mutually parallel position, the male sectional element is locked in the female sectional ele¬ ment and the link element functions as a vertically join¬ ing hinge, which extends continuously in the transverse direction of the door leaf. US 4,924,932 explicitly states that this construction aims at preventing every possibility of the sectional elements being moved apart. In the construction according to US 4,924,932, the same problem remains regarding lack of impact resistance, as in the traditional solution with separate hinges. If the force of impact is sufficiently high, the continuous link element will break, which like in the case of sepa¬ rate hinges implies that the door will become useless for some time and that extensive repair work will be neces¬ sary. EP-B1-0 304 642 shows (Figs 8 and 9) a construction having essentially the same function as the one in the above-mentioned US-4,924,932. US 5,148,850 describes a door leaf comprising a plu¬ rality of successive, separate panels and, between any two neighbouring panels, a link element continuously extending along essentially the entire width of the door leaf and arranged to join the neighbouring panels. The continuous link element consists of an elongate rubber strip or the like, which extends along essentially the entire width of the door leaf and is attached along the inner surface of each panel. The elongate rubber strip functions as a continuous hinge, as well as a sealing element. The central portion of the rubber strip defines the axis of rotation of the two neighbouring panels, said axis of rotation, like in the above-mentioned traditional solutions with separate hinges, thus being positioned at the inner surface of the door leaf. Between opposite lon¬ gitudinal edge surfaces of two neighbouring panels there is a female sectional element arranged on one panel and formed with an elongate groove, as well as a ridge arranged on the other panel and received in the groove of the female sectional element. The surface of the ridge never abuts against the surface of the groove, and there¬ fore these mating sectional elements do not constitute any link or sliding surfaces. These mating surfaces are separated from each other, when the panels are angled around the axis of rotation defined by the rubber strip, and therefore do not define an axis of rotation for the panels as in the above-mentioned US 4,924,932. Moreover, the link sectional elements and the panels are made in a stiff, flexurally rigid design. US 2,300,265 discloses an overhead sliding door comprising a plurality of successive panels, whose ends are rotatably united by means of hook-type hinges. The adjoining edges of the panels in the transverse direction are so designed that they keep the panels in one and the same plane along the entire width of the door and simul- taneously permit the panels to turn in a predetermined direction relative to each other, such that the door can be moved through a 90° bend from a vertical closed posi¬ tion to a horizontal open position. The adjoining edges of the neighbouring panels are almost designed as turn- able tongue-and-groove joints. The object of the invention is to provide a door leaf which does not suffer from the above-mentioned draw¬ backs of the prior-art technique. More specifically, the object of the invention is to provide a door leaf: - which is bump resistant or impact resistant and is not permanently damaged or deformed after being bumped into or subjected to an impact, - which can resist load due to wind pressure - which is burglarproof, - which has a long life, - which can be operated at high speed, - which is silent-running, - which can be designed with good heat insulation proper¬ ties, - which is easy to mount, and - which is easy to provide with windows and the like. These objects are achieved by a door leaf designed according to claim 1. The inventive door leaf thus comprises a plurality of successive, separate panels and, between any two neighbouring panels, a link element extending over essen¬ tially the entire width of the door leaf and defining an axis of rotation, around which the two neighbouring panels are adapted to rotate relative to one another, said link element including a male sectional element arranged on one of the neighbouring panels and having a convex surface concentric with the axis of rotation, and a female sectional element arranged on the other one of the neighbouring panels and having a concave surface, which mates the convex surface and is concentric with the axis of rotation. The impact-resistant door leaf accord- ing to the invention is characterised in that said convex and concave surfaces constitute sliding surfaces, which engage with each other and together serve as a knee joint when mutually rotating the neighbouring panels around the axis of rotation, that the concave sliding surface of the female sec¬ tional element encloses the convex sliding surface of the male sectional element through such a restricted angle that the link element in itself permits an unimpeded ver¬ tical separation of the two neighbouring panels, but counteracts a mutual horizontal displacement of the panels perpendicular to the axis of rotation, that, at each end of the link element, there is arranged an end coupling means preventing separation of the ends of neighbouring panels, and that the link element and the panels are made of flexible material. The terms "vertical" and "horizontal" in the above- mentioned expressions "prevents an unimpeded vertical separation" and "counteracts a mutual horizontal dis- placement" should be interpreted in a wide sense, the term "vertical" generally meaning the extent of the door leaf perpendicular to the direction of the link element, and "horizontal" generally meaning the direction perpen¬ dicular to the door leaf and the link element. The invention is distinguished relative to prior-art solutions by a joining function at the side edges of any two neighbouring panels, while the hinge function - which is responsible for mutually guiding the panels and for defining the axis of rotation - is present and continuous over essentially the entire width of the door leaf and in itself permits an unimpeded vertical separation of the two neighbouring panels. The end coupling means serve the traditional purpose of joining the panels and have the function, which is new to the invention, of ensuring that also when subjected to impact, two portions with an intact hinge function remain, causing the link element to be automatically reset after being bumped into or sub¬ jected to a similar impact. The axis of rotation of the link element is, accord¬ ing to the invention, defined by and concentric with the convex and concave sliding surfaces of the link element, and, neighbouring panels, when subjected to impact, should, according to the invention, be able to divide essentially unimpededly. This does not necessarily imply that the panels are not allowed to be interconnected somehow between the ends of the link element. According to a preferred embodiment of the invention, there is along the link element no joining means in addition to the above-mentioned end coupling means, which prevent separation of but the ends of neighbouring panels. Owing to the fact that the separate panels of the door leaf along essentially their entire width are not connected to any vertically joining hinges, the door leaf will be highly resistant to impact, since the transverse, ver¬ tically not joining link element can divide, when bumped into or subjected to any other impact, without any hinges breaking. The division of the link element is possible owing to the link element and the panels being manufactured of flexible material and the link element in itself having no joining hinge function, but a "knee joint function" only. When subjected to impact, one or more panels can therefore bulge in the direction of impact, and be sepa¬ rated from neighbouring panels a distance whose length depends on the amount of the force of impact. If the link element, when subjected to impact, divides in this man¬ ner, it will be reset on the one hand owing to the arrangement of the end coupling means which at each end of the link element prevent separation of the ends of neighbouring panels and, on the other hand, owing to the link element and the panels being flexible transversely of the plane of the door leaf. Thus, the link element is intact at both ends even when subjected to impact, i.e. the male sectional element and the female sectional ele¬ ment are substantially correctly positioned relative to each other at the ends of the link element. A division of the link element between the ends will ensure, owing to said flexibility, that the link element is automatically reset if being bumped into or subjected to a similar im¬ pact. Also the special knee joint construction between the panels with its rounded engaging surfaces contributes to this resetting function. These and other preferred embodiments of the inven- tion are stated in the accompanying claims. The invention will now be described in more detail by means of embodiments, reference being made to the accompanying drawings. Fig. 1 is a front view of the lower part of a door leaf according to one embodiment of the invention. Fig. 2 is a cross-sectional view, taken along line II-II in Fig. 1, of a panel and the associated link ele¬ ments. Fig. 3 constitutes perspective views of a male sec- tional element and a female sectional element included in the link elements shown in Figs 1 and 2. Figs 4A and 4B are cross-sectional views illustrat¬ ing a knee joint function. Figs 5B and 5A are cross-sectional views of a modi- fied link element fitted with a sealing strip. Fig. 6 is a cross-sectional view of a panel accord¬ ing to a second embodiment of the invention. Figs 7A-7C are a side view, a horizontal sectional view and a vertical sectional view of a panel core. Fig. 7D is a cross-sectional view of an outer element. Fig. 7E is a cross-sectional view of a reinforcing sec- tional element. Figs 8A-8E schematically illustrate a method for making a panel based on the parts in Figs 7A-7E. Fig. 1 illustrates a lower part of a vertically extended door leaf composed of horizontal, rectangular panels 2, between which there are arranged continuous, elongate link elements 4 according to the invention. Each link element 4 defines an axis of rotation A around which neighbouring panels 2 can rotate in relation to each other. As shown in the Figure, the length of the link elements 4 essentially equals the width of the door leaf. The link element according to the invention can be designed to be continuous or consist of a plurality of successive parts, which optionally can be positioned at a relatively small distance from each other in the longitu- dinal direction of the link element. According to the invention, there is arranged at the opposite ends of each link element 4 a means for joining the corresponding two neighbouring panels 2. In the embodiment illustrated, each such joining means consists of a hinge, whose hinge pin coincides with the axis of rotation A. Each hinge comprises two hinge plates 6 which are each screwed to a reinforcing sectional element 8 attached to and extending along the side edge of the respective panel 2. The hinge plates are rotatably mounted on a hinge pin 10, which is connected to a guide means 12. The guide means 12, which are adapted to be guided by and slide along guides (not shown) positioned on both sides of the door leaf, can preferably be such flexible guide means as described in Applicant's Swedish patent application entitled "Door edge guiding arrangement", which has the same filing date as the present application and to which reference is made for more details regarding the flexibi- lity of the guide means 12. Specifically, the engagement of the guide means 12 with the guide is such as to allow a rotary motion of the guide means 12 relative to the guide in a plane perpendicular to the longitudinal direc- tion of the guide. Reference is now made to Fig. 2, which is a cross- sectional view of the lowest but one panel 2 in Fig. 1. The panel 2 is composed of two outer elements 20 attached to a panel core 22. An upper edge 24 and a lower edge 26 of each outer element 20 extend over the longitudinal edge surface 28 of the core 22 so as to form, together with the upper edge 24 and the lower edge 26, respec¬ tively, of the opposite outer element 20, an upper and a lower groove 30 and 32, respectively, which thus extend along the entire width of the panel 2. From one end of the panel 2, a male sectional ele¬ ment 4A and a female sectional element 4B of the appear¬ ance illustrated in Fig. 3 are inserted in the grooves 30, 32 of the panel 2, thereby forming the link element 4. The link sectional elements 4A, 4B are each provided with a lug 34 to be held in the respective groove 30, 32. The male sectional element 4A has a convex sliding sur¬ face 36, which in the illustrated embodiment describes a cylindrical surface through essentially 270°. The female sectional element 4B has a mating concave sliding surface 38, which describes but a smaller angle. As is evident from Fig. 4A, which illustrates the appearance of the mounted link element 4 when the door is closed, the concave sliding surface 38 of the female sectional ele- ment 4B is composed of, starting from the vertical line V, a portion facing the outside of the door leaf and describing an angle of about 90°, and a shorter portion facing the inside of the door and describing an angle of about 45°. Thanks to the 90° outer portion not extending beyond the horizontal line H, this portion will not pro¬ duce a vertically joining effect. Thanks to the inner portion extending through 45° only, the link element 4 can, as illustrated in Fig. 4B, be rotated to a requisite extent, without the female sectional element 4B striking against the panel that supports the male sectional ele¬ ment 4A. The outer portion of the concave sliding surface 38 could, however, extend through a smaller angle than 90°. The link element shown in Figs 5A and 5B is essen¬ tially identical with the link element in Figs 4A and 4B, but is supplemented with a sealing element 40 attached to the outer part of the female sectional element 4A and consisting of a continuous, elastic sealing strip, whose opposite longitudinal edges 42 constitute lips which, in the closed position of the door (Fig. 5A) seal against the exteriors of the panels. Fig. 6 shows a second embodiment of the invention. In this embodiment, the male sectional element 4A and the female sectional element 4B are integrated with the actual panel 2. The panel 2 can suitably (but not exclu¬ sively) be extruded as a closed casing, which is then divided into suitable lengths. The wall of the casing then constitutes two opposite parallel main walls 50, which are joined by integrated end walls 52 and 54 designed as shown in Fig. 6, thereby forming a male sec¬ tional element 4A and a female sectional element 4B, respectively. Those parts of the casing which form the sliding surfaces 36, 38 can optionally be made to have other properties than the rest of the casing, for example of a more durable material than the rest of the casing and/or be made with a greater thickness of the material as shown in Fig. 6. In the manufacturing process or later, the interior of the casing is filled with a suit¬ able filling 56, for example a core of expanded styrene foam which is introduced later, or polyurethane foam which is foamed inside the casing to the final shape. Moreover, those parts of the casing which form the slid¬ ing surfaces 36, 38 can consist of different materials in the thickness direction of the casing, for example by applying foils to the casing, by spraying, chemical reac¬ tions etc. According to the invention, the panel 2 is, like the link element 4, made of flexible material to make it pos- sible for the link element 4 to divide if being bumped into or subjected to any other impact. A method of making such a flexible panel will now be described with reference to Figs 7 and 8. Figs 7A-7C are a side view, a horizontal sectional view and a vertical sectional view of a panel core 22 of the type included in the panel shown in Fig. 2. The panel core 22 is, at each terminal edge surface 60, provided with a narrower portion 62 extending along the height of the entire core 22. As material for the panel core 22, use can be made of, for instance, blown polystyrene, such as Styrofoam™, which has closed cells that cannot take up moisture, which is advantageous in moist surroundings. Fig. 7D is a cross-sectional view of a substantially U-shaped outer element 20, which should constitute the outer layer of the finished panel. The outer element 20 can be made of polycarbonate or the like. Fig. 7E is a cross-sectional view of a reinforcing sectional element 8 of the type which is used in Fig. 1 at each panel termi¬ nal edge and to which the hinge plates 6 are attached. The sectional element 8 is of substantially I-shaped cross-section and has, at one flange, a groove 64 adapted to receive the hinge plates 6 and, at its other flange, two serrated securing portions 66, whose mutual distance conforms with the panel thickness at the narrower end portion 62 of the core 22. The method shown in Figs 8A-E can be used for assem¬ bly of the panel parts in Figs 7A-E. In a first step, (Fig. 8A), a first U-shaped outer element 20 of the type illustrated in Fig. 7D is arranged on a base 70. In a second step (Fig. 8B), a binder 74 of some suitable type, such as a hot-setting agent, is applied to the entire main surface of the outer element 20. In a third step (Fig. 8C), a panel core 22 of the type shown in Figs 7A-7C is arranged on the outer element 20 provided with the binder. In a fourth and a fifth step (Figs 8D and 8E) , a binder 74 and a second outer element 20 are applied to the opposite main surface of the panel core 22. Subsequently, a reinforcing sectional element 8 is mounted on each panel terminal edge 60, the serrated securing portions 66 being fitted into the spaces between the outer element 20 and the narrower portion 62 of the panel core 22. The thus-completed panels 2 are then provided with link sectional elements 4A and 4B according to Figs 2 and 3 and are assembled at their terminal edges by means of the hinge plates 6, which are screwed into the grooves 64 of the reinforcing sectional elements 8 and are joined with the hinge pins 10 connected to the guide means 12. As indicated by dashed lines at reference numeral 80 in Figs 7A and 7B, the panel cores 22 can be formed with through recesses for making panels with windows. The outer elements 20 can then be made of some suitable transparent material. Furthermore, it is possible to colour the outer elements 20 and/or the panel cores 22 so as to obtain the desired appearance of the door. A colouring effect can also be achieved by using a coloured binder 74. A further possibility is the arranging of a metal foil, for example having a logotype, between the core 22 and a transparent outer element 20. If required, the panel 2 can be equipped with rein¬ forcing elements, on the one hand for the purpose of enhancing the resistance of the panels to load due to wind pressure, and on the other hand for the purpose of preventing too great a slack if the panels extend hori¬ zontally between the guides in the open state of the door. Such reinforcing elements may consist of, for instance, glass fibre elements of high tensile strength, thin metal strips or the like, arranged over the length of the panel on both main surfaces of the core. By arranging these elements at a distance from the centre of the panel core, they will impart flexural rigidity to the panel. For example, in Fig. 8B and Fig. 8E, respectively, such reinforcing elements can be inserted between the binder 74 and the outer element 20.

Claims: CLAIMS 1. A bump-resistant door leaf, comprising a plura- lity of successive, separate panels (2) and, between any two neighbouring panels (2), a link element (4) extending over essentially the entire width of the door leaf and defining an axis of rotation (A), around which the two neighbouring panels (2) are adapted to rotate relative to one another, said link element (4) including a male sec¬ tional element (4A) arranged on one of the neighbouring panels and having a convex surface (36) concentric with the axis of rotation (A), and a female sectional element (4B) arranged on the other one of the neighbouring panels and having a concave surface (38), which mates said con¬ vex surface (36) and is concentric with the axis of rota¬ tion (A) c h a r a c t e r i s e d in that said convex and concave surfaces (36, 38) con¬ stitute sliding surfaces, which engage with each other and together serve as a knee joint when mutually rotating the neighbouring panels around the axis of rotation (A), that the concave sliding surface (38) of said female member (4B) encloses the convex sliding surface (36) of said male member (4A) through such a restricted angle that the link element (4) in itself permits an unimpeded vertical separation of the two neighbouring panels (2) , but counteracts a mutual horizontal displacement of the panels perpendicular to the axis of rotation (A), that, at each end of the link element (4), there is arranged an end coupling means (6, 10) preventing separa¬ tion of the ends of neighbouring panels (2), and that said link element (4) and said panels (2) are made of flexible material. 2. The bump-resistant door leaf as claimed in claim 1, c h a r a c t e r i s e d in that along the link element (4) between the end coupling means (6, 10) there is no hinge-forming means providing any essential joining of the neighbouring panels. 3. The bump-resistant door leaf as claimed in claim 1, c h a r a c t e r i s e d in that the male sec- 5 tional element (4A) and the female sectional element (4B) each consist of a separate sectional element which is attached (30, 34) to a longitudinal edge surface of the respective panel (2) . 4. The bump-resistant door leaf as claimed in 0 claim 3, c h a r a c t e r i s e d in that the male sec¬ tional element (4A) and the female sectional element (4B) are provided with attachment means (34) on their side facing away from the axis of rotation (A), and that said longitudinal edge surface of each panel (2) is formed 5 with a longitudinal groove (30, 32) into which said attachment means (34) is inserted for attaching the respective separate sectional element (4A, 4B). 5. The bump-resistant door leaf as claimed in claim 1, c h a r a c t e r i s e d in that the male sec- 20 tional element (4A) and the female sectional element (4B) are formed in one piece (50, 52, 54) with the respective panel (2) . 6. The bump-resistant door leaf as claimed in claim 5, c h a r a c t e r i s e d in that the convex 25 sliding surface (36) of the male sectional element (4A) and the concave sliding surface (38) of the female sec¬ tional element (4B) are made of a material other than that of the remaining panel. 7. The bump-resistant door leaf as claimed in 30 claim 4 or 5, c h a r a c t e r i s e d in that each panel (2) is composed of an extruded flexible casing (50, 52, 54) surrounding a core (56), said casing forming opposite main walls (50) of said panel, a male sectional element (52) of the above-mentioned type at one longitu- • 35 dinal edge of said panel, and a female sectional element ( 54) of the above-mentioned type at the opposite longitu¬ dinal edge of said panel. 8. The bump-resistant door leaf as claimed in any one of the preceding claims, c h a r a c t e r i s e d in that the end coupling means arranged at each end of the link element (4) is a hinge, whose hinge plates (6) are fixedly connected to the terminal edges of the neigh¬ bouring panels (2) and whose hinge pin (10) coincides with the above-mentioned axis of rotation (A) of the link element (4). 9. The bump-resistant door leaf as claimed in claim 8, c h a r a c t e r i s e d in that said hinge is connected to a guide means (12) which is adapted to engage with and run along a guide when opening or closing the door, said engagement between the guide means (12) and the guide being such as to permit a rotary motion of said guide means (12) relative to said guide in a plane perpendicular to the longitudinal direction of said guide. 10. The bump-resistant door leaf as claimed in any one of the preceding claims, c h a r a c t e r i s e d in that, seen in the direction of the axis of rotation (A), the convex sliding surface (36) of said male sectional element (4A) describes an angle greater than 180°, and the concave sliding surface (38) of said female sectional element (4B) describes an angle smaller than 180°.

Inventors: BERTILSSON HANS-INGE, EKSTRAND MARIE INGELA CHRISTIN, LARSSON NILS HAAKAN IVAR, MANNS CARL HUGO, PAALSSON KENT INGE, BERTILSSON, HANS-INGE, EKSTRAND, MARIE, INGELA, CHRISTINA, LARSSON, NILS, HAAKAN, IVAR, MANNS, CARL, HUGO, PAALSSON, KENT, INGE
Applicants: BERTILSSON HANS INGE, EKSTRAND MARIE INGELA CHRISTIN, LARSSON NILS HAAKAN IVAR, MANNS CARL HUGO, NOMAFA AB, PAALSSON KENT INGE, BERTILSSON, HANS-INGE, EKSTRAND, MARIE, INGELA, CHRISTINA, LARSSON, NILS, HAAKAN, IVAR, MANNS, CARL, HUGO, PAALSSON, KENT, INGE
Application year: 1995
Main classification: E05D15
IPC codes: E05D15, E06B3