Internal doors

Abstract: The invention provides a method of forming a door pressed from medium or high density fibre-board opposing door forms having elevated surrounding perimeter door portions and including providing elongate depressions of timber-like appearance of box-like disposition within the outer perimeter portions of the door which define and surround and within which are disposed elevated panels, together with a door formed thereby, wherein after pressing, each fibre-board door form is subject to treatment to release elevated panels at the level of the elongate timber-like depressions therearound, whereafter the facing two sets of door forms (13,14) are pressed together with spacers (50) of a solid and of a spacing nature in accordance with customary practice, together with edging spacers and wherein, before or after such formation and adhesion together, the edges of the door forms from which the panels are removed are provided at said depressed level with plastics edging strips (9) on the opposing edges of each face of the door forms on the two sides (9) thereof and the upper and lower edge thereof for the support within the doors of glass panels (7).

Description: This invention relates to internal doors of the kind currently formed on a very large scale from pressed fibre-board usually from medium density fibre-board, but sometimes from high density fibre-board, for use as doors to internal rooms of dwelling houses and office suites and also for example, to wardrobes and similar internal cupboard arrangements. There is a very large market for such doors in view of the high quality which is achievable by producing doors formed from two opposed pressed medium density fibre-board sides or forms, interconnected by spacing members and edge members. The doors can be primed and painted using various techniques to provide appropriate colouring or wood texture and shading, and currently have great popularity and commercial success. A standard feature of many such pressed doors is that they are presented to outward appearance as though they have formed elevated panels in accordance with traditional panelled door construction, which are in fact formed by elongate depressions forming a box-like timber-like structure around the elevated apparent panels of the door, and surrounded by what is in appearance the elevated edging timber of the doors. The market requirements are such that at times it is considered desirable in marketing terms that the panels, normally of a solid apparently wooden construction, should incorporate glazed panels of a clear or translucent nature, or of a mirror nature. This requirement has previously been obtained by a technique, which usually includes cutting out, after manufacture of the door assembly, at the elevated edges of the surrounding elevated outer edging "timbers", the relevant depressed elongate timber-like areas of the door and the included elevated panel or panels, and inserting in its place a framework or "cassette" of wood or plastics material to support glazed panels and to engage within the aperture formed in the prefabricated door. Typically such cassettes would not only include the surrounding supports for the glazing panel which would be attached, for example by adherence, to the edges of the door from which the recessed elongate parts and the elevated panel or panels have been removed, but also glazing-bars for attachment to the glazing and/or disposal above the glazing to simulate smaller glazing pieces or panes, such pieces providing, as required for appearance, 4, 6, 8 or 12 rectangular pane doors for example. Whilst such arrangements enable the provision of doors with glazed portions, the arrangement is necessarily such that often the surrounds of the glazed panels in particular, but also sometimes the separating plastics glazing bars delineating the individual glazed panels, protrude above the plane of the elevated parts of the door on each side thereof. This protrusion has a disadvantage in terms of aesthetic appearance, and also requires during the manufacture, storage, and distribution of such doors, additional temporary spacing members, at additional cost, to ensure, when stacking glazed doors one upon the other for example that no detrimental or damaging contact between parts of doors come into contact to avoid any frictional or compressive damage to any of them. It is an object of the present invention to overcome or at least substantially reduce the above-mentioned problems. In accordance with one aspect of the present invention there is provided a method of forming a door pressed from medium or high density fibre-board opposing door forms having elevated surrounding perimeter door portions and including providing elongate depressions of timber-like appearance of box-like disposition within the outer perimeter portions of the door which define and surround and within which are disposed elevated panels, wherein after pressing, each fibre-board door form is subject to treatment to release elevated panels at the level of the elongate timber-like depressions therearound, whereafter the facing two sets of door forms are pressed together with spacers of a solid and of a spacing nature in accordance with customary practice, together with edging spacers and wherein, before or after such formation and adhesion together, the edges of the door forms from which the panels are removed are provided at said depressed level with plastics edging strips on the opposing edges of each face of the door forms on the two sides thereof and the upper and lower edge thereof for the support within the doors of glass panels. In accordance with another aspect of the present invention there is provided a door pressed from medium or high density fibre-board opposing door forms including elongate depressions of timber-like appearance disposed around the door or parts thereof within an elevated outer periphery portion of the door, wherein at the level of the depressed elongate timber-like panel surrounds a number of elevated door panels have been released, the facing two sets of door forms having spacers of a solid and of a spacing nature in accordance with customary practice, together with edging members, wherein the edges of the door forms from which the panels are removed have plastics edging strips disposed on the opposing edges of each face of the door forms to support glazing therein. The upper edge member of the door may be provided with an appropriately dimensioned slot to enable the glazing panel to be inserted therein for subsequent engagement with the plastics edging strips provided at the two sides and base of the edges of the removed door panels. The plastics edge strip may comprise generally concave, such as U-shaped, strips arranged to fit jointly around the edges of the two half door forms cut edges with appropriate cut edges at the corners thereof of a push-in fit to support the glazing panel inserted from the upper edge of the door. Parts of the base of the U-shaped strips may be cut away for example along the upper edge of the glazed panel, to enable insertion of the pane of glass therethrough. The extrusion of the U-shaped plastics strip may incorporate a co-extruded softer plastics portion at the base of the U within which the edges of the glazing panel at its base are disposed to provide a softer resilient support for the edging panel. In addition tongues of softer plastics material may be arranged to protrude from the side walls of the U-shaped member to provide additionally resilient support for both sides of the glazing panel for example. In one alternative arrangement the plastic edge strip may comprise separate resilient plastics elongate glazing clips, attached to opposed edges of the depressed portions of the panel to be glazed. These resilient clips may incorporate inwardly extending fingers to grip firmly but resiliently the glazing panel to be inserted, and configured to cover the edge of each opposed fibre-board door wall so as to engage firmly around the edge and within the wall of each form. An appropriate mouth recession may be provided along the length of each of these plastics clips (disposed in use within each form) so as to be able to receive the edges of a locating cross-piece strip down the sides and along the lower edge of the opening within the door on opposite parts of the door members, which will limit the possibility of movement for the glass panel vertically and horizontally when inserted from an overhead opening slot in the upper edge of the door, both in a vertical and horizontal direction. Whilst the plastics elongate glazing clips in this case may be of such configuration as to provide movement of the glass panel therewithin, subject to the restraining effect of the inwardly protruding fingers thereof, and the cross-piece strip connected therebetween limits vertical and horizontal movements of that glass panel, the dimensions of the glazing bars may be such as to conform tightly and accurately to the glazed opening movement of the glass. In another alternative, the clips for the opposed side edges may differ slightly, one clip on one side having a recess along its length, and the other clip (where movement within the door is to be prevented) incorporating a matching protrusion, to replace the cross-piece strip. It will be appreciated that the incorporated glass panel may of course have applied to it the usual plastics glazing bars secured to the surface of the glass on each side thereof to provide the usual separation of the glazing into apparent separate small rectangular or other shaped portions, of as many number as required. Where glazing clips are used, the glazing may be carried out prior to actual formation of the door, and at the same time the glazing bars may be applied by an appropriate jig. The edge strips for each glass panel may be separate for each edge of the aperture, or may be a single strip appropriately notched for corners of the aperture. It is possible, by means of the present invention, to provide during its basic formation, a door incorporating two sides of an appropriately pressed medium density fibre-board door forms with the necessary solid and card separation, and with an appropriate necked formation around the inner edges of the depressed elongate portions surrounding the raised door panels, such that the panels may be "punched" out prior to formation of the door, whereby the door either before or after bonding of the forms with all of internal and edge supports may be provided with glazed panel edging strips and glazing therein at a level below the elevated edge portions of the door. In order that the invention may be more readily understood three embodiments thereof will now be described by way of example with reference to the accompanying drawings in which:- Figure 1 illustrates schematically a known door of the kind to which the invention relates; Figure 2 shows a section of part of the door of Figure 1; Figure 3 shows a section of part of a known form of glazing applied to the door of Figures 1 and 2; Figure 4 illustrates schematically a glazed door to which the invention has been applied; Figure 5 shows a section of part of a door form from which the door of Figure 4 may be formed; Figure 6 shows in section, one form of resilient plastic glazing edging strip for use with a door of the invention; Figure 7 shows in section part of the door of Figure 4 with the edging strip of Figure 6 in situ; Figure 8 shows in section an alternative resilient plastics edging strip or clip for use with the invention; Figure 9 shows in section part of the door of Figure 4 with the edging clip of Figure 8 in situ; Figure 10 illustrates in schematic view the upper edge of a door according to the present invention; Figure 11 shows in section another alternative form of resilient plastics edging clips; and Figure 12 shows in section part of the door of Figure 4 with the edging clip of Figure 11 in situ. Referring now to the drawings it will be seen that Figures 1 and 2 show a door 10 of known kind pressed from medium density fibre-board which comprises a surrounding elevated portion 4 with internal solid support 50, elongate depressed portions 3 of timber-like appearance both horizontally and vertically which define therewith four elevated panel portions 5 with internal solid support 51 within the face of the door, giving the manifest appearance of a panelled door and producible in varying panel types, such as 2, 4 or 6 panels; Depressed areas 3 have a contoured finish to give the appearance of timber beading holding the panels 5 in place. In the arrangement of Figure 3, in known manner, the door has been cut at the edge of the outer elevated portion 4, to remove the depressed area 3 and panel portion 5, and enable the provision of a glass insert 7 held in position, at the elevated level of the outer elevated portion 4 by timber or UPVC glazing beads 53 protruding outwardly even beyond the elevated portions 4. The glass may typically be 4mm thick toughened glass. Glazing bars 49 (one shown) of UPVC are adhered to both sides of the glass 7 to give the appearance of a multi-panned glass panel. Figure 4 illustrates schematically the door of Figure 1 which has been modified in known manner and as described in relation to Figure 3, by the cutting away of all but the substantial elevated edging 4 of the door and its replacement by a sheet of plain glass 7 insertable through a slot 8 at the upper edge of the door (see Figure 8) to which has been attached adhesively a plurality of glazing bars 49 on both sides to separate the glazing into a multiplicity of rectangular glazed portions 11; Referring now generally to aspects of the drawings illustrating the invention, it will be seen that a medium density fibre-board form pressing of the kind generally illustrated in Figure 2,1 is provided (Figure 5) with a neck 2 at the lowest point of the depression 3 between the elevated parts 4, 5 of the door between essentially the outer edges thereof 4, and the inner panel 5 thereof. After pressing the door form, it will be appreciated that, with the neck 2 it is possible to "punch" the panel 5 from the door at the neck 2 formed at the lowest point of the depression 3 between the edge 4 of the door and the panel 5 to remove the panel 5 therefrom. This aspect of the invention enables the production from a pair of forms of the general configuration shown in Figure 2 to enable the provision of a glazed panel as illustrated for example in Figures 7 and 9. It will be appreciated that in different embodiments of the invention, only some panels of a door need be removed leaving some solid door panels in the finished door with only some panels of the door replaced by glazing in accordance with the invention. Subsequent to the removal of the relevant internal panels 5 of the door as provided by subjecting the arrangement of Figure 5 to a removal process, the door may then be passed through its necessary forming stages with internal solid support 50 around the edge portions 4 of the door, and wherever else is required, together with supporting transverse strips of card or corrugated card (not shown) elsewhere in the door. As part of such forming, the door is provided by adherence with edge members 54. Thereafter in accordance with one embodiment of the invention, the resilient plastics strip 9 of Figures 4, 6 and 7 may be applied around the edges of the two side parts 13, 14 of the panel door 10 on the two vertical sides and the lower edge. At the upper edge the base of the strip 9 is cut away, and an appropriately sized glazing panel 7 inserted from an appropriate slot 37 in the top surface 54 of the door 10 such that it engages upon the softer resilient plastics material 34 at the base of the lower plastics edging strip, and is held by inwardly protruding strips 15 of the upper softer plastics material. In the usual manner, artificial glazing bars 49 may then be added to the glass panel 7 to provide the usual required sub-division of the glass panel into desirable rectangular portions, which firmly locate the glass in place. In the alternative arrangement which is illustrated in Figures 8 and 9 separate resilient plastics clips 38, 59 are located around each of the two edges of the cut depressed portions 45, 46 of the door side forms 13, 14, each of these conforming internally to the configuration and dimensions of the relevant door sides as it reduces from the outer extension to the inner depression of the pressed door panel. End portions and clipping portions 16, 17 therewith fit over the edges of the edges of the depressed portions for firm location of the individual strips with their respective door panel portions. It will be observed that inwardly of the two door sides, the strip is provided with two glass engaging inwardly protruding fingers 18, and there is provided an elongate recessed tongue 46 adapted to receive one side of a locating cross piece strip 39, 59 which is arranged to close the space within which the glazing panel may fit. With the arrangement of Figures 8 and 9 it is possible to apply the clips 38 and 59, and cross piece 39, and the glass pane, and even by appropriate jigging, glazing bars, before bonding the door forms together. As can be seen from Figure 9, the glazing panel 7 fits closely within the two resilient plastics clips 38, 59 being held by the two inwardly extending tongues 18 thereof, and is located to prevent longitudinal movement of the glazed panel 7 further into the body of the door by means of the closure strips 39 which locate within the elongate depressions 46 within the clips of plastic 38, 59. In case of breakage the broken glass panel may be removed and a new one provided via the slot 37 in the upper surface of the completed door. Glazing bars 49, as mentioned above, if not already fitted, can now be added to the glazed panel 7 to sub-divide it, on both sides, into appropriately shaped and dimensioned rectangular glazing portions. Figures 11 and 12 illustrate an embodiment of the invention using a variation of the glazing clip 38 of Figures 8 and 9 to obviate the need for the cross-piece strip 39. In this case the lower parts of clips 60 and 61 are slightly different, clip 60 having an elongate recess 62 and clip 61 a matching elongate protrusion 63. As shown in Figure 12 these features prevent movement of the glass within the door. Where such movement is not to be prevented, such as along the upper edge of a glazing panel, both sides of the edge may be provided with clips 60. It will be appreciated that by means of the invention we have enabled the preparation of a glazed door from formed and opposed pressed medium density fibre-board panels which can be prepared for and even provided with glazing during their formation, complete with the insertion of edge supporting resilient plastics strips therefor and glazing panel which only thereafter require the addition of glazing bars to separate the panel into the market required rectangular portions considered so appropriate for such glazed doors. It is to be understood that the foregoing is merely exemplary of preglazed doors in accordance with the invention and that modifications can readily be made thereto without departing from the true scope of the invention.

Claims: A method of forming a door pressed from medium or high density fibre-board opposing door forms having elevated surrounding perimeter door portions and including providing elongate depressions of timber-like appearance of box-like disposition within the outer perimeter portions of the door which define and surround and within which are disposed elevated panels, wherein after pressing, each fibre-board door form is subject to treatment to release elevated panels at the level of the elongate timber-like depressions therearound, whereafter the facing two sets of door forms are pressed together with spacers of a solid and of a spacing nature in accordance with customary practice, together with edging spacers and wherein, before or after such formation and adhesion together, the edges of the door forms from which the panels are removed are provided at said depressed level with plastics edging strips on the opposing edges of each face of the door forms on the two sides thereof and the upper and lower edge thereof for the support within the doors of glass panels. A door (10) pressed from medium or high density fibre-board opposing door forms (13,14) including elongate depressions (3) of timber-like appearance disposed around the door or parts thereof within an elevated outer periphery portion (4) of the door, wherein at the level of the depressed elongate timber-like panel surrounds a number of elevated door panels (5) have been released, the facing two sets of door forms (13,14) having spacers of a solid and of a spacing nature (50) in accordance with customary practice, together with edging members (45,46) wherein the edges of the door forms from which the panels are removed have plastics edging strips (9) disposed on the opposing edges of each face of the door forms to support glazing (7) therein. A door as claimed in Claim 2 wherein the upper edge thereof is provided with an appropriately dimensioned slot to enable the glazing panel to be inserted therein for subsequent engagement with the plastics edging strips provided at the two sides and base of the edges of the removed door panels. A door as claimed in Claim 2 or 3 wherein the plastics edge strip comprises generally concave, such as U-shaped, strips arranged to fit jointly around the edges of the two half door forms cut edges with appropriate cut edges at the corners thereof of a push-in fit to support the glazing panel inserted from the upper edge of the door. A door as claimed in Claim 4 wherein parts of the base of the U-strips are cut away along the upper edge of the glazed panel, to enable insertion of the pane of glass therethrough. A door as claimed in any one of Claims 2 to 5 wherein the extrusion of the U-shaped plastics strip incorporates a co-extruded softer plastics portion at the base of the U within which the edges of the glazing panel at its base are disposed to provide a softer resilient support for the edging panel. A door as claimed in Claim 6 wherein tongues of softer plastics material are arranged to protrude from the side walls of the U-shaped member to provide additionally resilient support for both sides of the glazing panel for example. A door as claimed in Claims 2 to 5 wherein the plastic edge strip may comprise separate resilient plastics elongate glazing clips, attached to opposed edges of the depressed portions of the panel to be glazed. A door as claimed in Claim 8 wherein the resilient clips may incorporate inwardly extending fingers to grip firmly but resiliently the glazing panel to be inserted, and configured to cover the edge of each opposed fibre-board door wall so as to engage firmly around the edge and within the wall of each form. A door as claimed in Claim 8 or 9 wherein a mouth recession is provided along the length of each of the plastics clips, disposed in use within each form, so as to be able to receive the edges of a locating cross-piece strip down the sides and along the lower edge of the opening within the door on opposite parts of the door members, which will limit the possibility of movement for the glass panel vertically and horizontally when inserted from an overhead opening slot in the upper edge of the door, both in a vertical and horizontal direction. A door as claimed in Claim 2 to 5 wherein the clips for the opposed side edges differ slightly, one clip on one side having a recess along its length, and the other clip, where movement within the door is to be prevented, incorporating a matching protrusion, to replace the cross-piece strip.

Inventors: ZEBEDEE ALAN ROGER, ZEBEDEE, ALAN ROGER
Applicants: JRM DOORS LIMITED
Application year: 1996
Main classification: E06B3
IPC codes: E06B3