A door slab assemble structure for the partly hollow door skin and glass

Abstract: A door slab assemble structure for the partly hollow door skin and glass, especially, is composed of glass and a Sheet Molding Compound's embossed grain door skin with double-layers grooves. It has three types of assembling including two, four, and eight door skins. The feature of the two sheet door slabs is making two partly hollow door skin which have the left-right integral edge to be glued together with the reinforcement wood inside the door left and right, top and bottom rail, and hollow area's sealing stuffs. Besides, to locate the glass through the insertion between glaze bead and the hollow area's sealing stuffs. The sealing stuffs for joining the door skins could be wood, PVC (Polyvinyl Chloride), PE (Polyethylene), PP (Polypropylene), resin, particle board or foam plastics. Insides the door, it is filled with polyurethane foam plastics, and is assembled with glass to form a glazed door with glass on the middle area. The feature of the four sheet door slabs structure is to set two crossed convex ribs on each of the long ribs and short ribs end of the four sheet "L" type door skin, and through the connection between the metal sheet of corner fixing and crossed ribs, to fix two "L" type slabs, and thus form a partly hollow door skin. Further, by gluing together with the reinforcement wood inside both door left and right, top and bottom rail, and hollow area's sealing stuffs, to form a partly hollow door slab. The door width of this invention is changeable by cutting the length of "L" type short rib whose concept is taken form the structure of two sheet door skins. The feature of the right sheet door slab's structure is to use eight crossed and vertical door skins which all have flush skins on the edge to form a rectangular frame. On the left side and the right side of the frame, it can be taken a metal sheet inserting with sealing stuffs for location totally sixteen metal sheets on the two sides. Then glue the crossed and the vertical door skin on the rectangular frame to form a partly hollow door skin. On the same way, the hollow area's sealing stuffs can be fixed with glass and PVC foam profile.

Description: The invention relates to a door slab with a hollow area for a lite assembly comprising a pair of door skins with integral vertical convex left and right flanges and sealing means for the hollow area receiving a glass panel and sealing means for the top and bottom of the door skins the sealing means are provided with at least one groove. Drawbacks of prior arts: The prior arts include Patent No. 4,327,535., Patent No. 4,720,951; and US Patent No. 4,850,168. At present, the assemble structures of existing partly hollow door skin are two sheet door skins and eight sheet door skins; wherein the former structure is described in US Patent No. 4,327,535. It is made by the following steps. First, to assemble the perimeter of door skin with sealing stuffs. Second, to assemble the sealing stuffs and glass together on the hollow area, then, to insert with the convex part of door skin to formulate a hollow and close space inside the door skin, then filling with polyurethane foam plastics to form a partly hollow door skin with glass. The other one, US Patent No. 4,720,951, taking a pair of door skins which are produced by SMC (Sheet Molding Compound) technical, to fix the hollow area's long rib together with the insulating glass during compression process to replace with the hollow area's sealing stuffs disclosed in US Patent No. 4,327,535. Therefore, it can save time and material expense while assembling. This US Patent's perimeter is still assembled through the insertion among four scaling stuffs. The inner part is also fill with foam plastics to form a door skin. To conclude the three patents mentioned above. It still has some drawbacks. Describing as follows 1. The insulating glass is inserted with door skin during production and can not be replaced. This causes the problem that once the glass is fragile during production or transport, the whole door skin will be out of use. 2. To fix glass with convex rib disclosed in US Patent No. 4,720,951 will have problem, too. Only one specific size of glass can not satisfy various customers requirements (now exists single, double and three layers); though, US Patent No. 4,850,168 has certain improvement on this point, however, it add a sealing stuff on the convex area make the appearance lack of beauty. 3. US Patent No. 4,850,168 replaces the perimeter sealing stuffs assembly with the integral edge structure. This will cause the height of the door skin fix and can not be changed. 4. The length and width of glass is not changeable too. This will also limit the width of door skin. There is another existing eight sheets door skin's assembly, that is as same as US Patent No. 4,546,585. This technical is adopted two up and down crossed stuffs and two left and right vertical stuffs to be assembled together for the formation of partly hollow door slab. This structure will provide the advantage for being capable of producing different width door slabs to meet the customer's requirements, by changing the length of up and down crossed stuffs. However, this structure will also produce some drawbacks as follows: The assembly type is time consuming. Also, the strength resulted from lock action between the vertical and crossed stuffs is inferior to single door skin. Furthermore, if the size is not controlled so accurate, the connecting part between vertical stuff and crossed stuff will cause certain gap.- deleted) This invention focus on the improvement of the existing partly hollow door slab assembly. Through researches and tests, we create the novel assemble mode of this invention including two sheets', four sheets' and eight sheets' assembly. This improvement is achieved by a door slab as claimed in claim 1. Preferred embodiments of the invention are described in the subclaims. DESCRIPTION OF THE DRAWINGS Fig. 1: Perspective of two sheet door skins SMC door skin 1, 2. Fig. 2: Vertical section view of two sheet door skins top and bottom rails of door skin 6. Fig. 3: Crossed section view of two sheet door skins SMC skin 1, 2. Left side and right side integral edge 3, 4 of SMC door skin. Hollow area's sealing stuff of door skin 5. PU foam plastics 7. Glaze bead 8. Glass 9. Inner reinforcement wood 23. Fig. 4: Perspective section view of two sheet door skins SMC door skin 1. Left side and right side integral edge 4 of SMC door skin. Top and bottom rails of door skin 6. PU foam plastics 7. Glaze bead 8. Glass 9. Inner reinforcement wood 23. Fig. 5: Perspective explosive drawing of two sheet door skins "L" SMC door skins 10, 11, 12, 13. Corner fixing metal sheet 15. Two crossed convex ribs of "L" long rib 16. Two crossed convex ribs of "L" short ribs 17. Fig. 6: Vertical section view of four sheet door skins. Top and bottom rails of door skin 6. Corner fixing metal sheet 15. Fig. 7: Cross section view of four sheet door skins. Left side and right side integral edges of SMC door skins 3, 4. Hollow area's sealing stuff of door skin 5. PU foam plastics 7. Glaze bead 8. Glass 9. "L" SMC door skins 10, 11, 12, 13. Inner reinforcement wood 23. Fig. 8: Perspective section view of four sheet door skins "L" SMC door skins 11, 12. Corner fixing metal sheet 15. Two cross convex ribs of "L" long ribs 16. Two cross convex ribs of "L" short ribs 17. Fig. 9: Perspective drawing of eight sheet door skins Door skin of top cross stuff 18. Door skin of bottom cross stuff 19. Door skin of left side and right side vertical stuff 20, 21. Fig. 10: Vertical section view of eight sheet door skins. Top and bottom rail of door skin 6. Door skin of top cross stuff 18. Door skin of bottom cross stuff 19. Fig. 11: Cross section view of eight sheet door skins. Hollow area's sealing stuff of door skin 5. PU foam plastics 7. Glaze bead 8. Glass 9. Left and right stiles 14. Door skin of left and right side vertical stuff 20, 21. Metal sheet for corner fixing 22. Fig. 12: Assembling view of metal sheet and sealing stuff of eight sheet door skins. Top and bottom rails of door skins 6. Left and right stiles 14. Metal sheet for corner fixing 22. Fig. 13: Perspective section view of eight sheet door skins. Glazed area's sealing stuff of door skin 5. PU foam plastics 7. Glaze bead 8. Glass 9. Here will describe the features in detail: 1. Two sheet door skin assembly (Fig.1 ∼ Fig.4): It comprises: a pair of SMC door skins 1, 2 whose center is a hollow rectangle, and has an convex integral edge 3, 4, on the left and right skin edges as a feature. While two sheet door skins insert with each other from left to right, there is a corner sealing stuffs 23 on left side and right side each, to glue together with the top and bottom rail 6 and hollow areas' sealing stuffs 5 of door skin to form a partly hollow door slab with a close space. In the inner part, it is filled with polyurethane foam plastics 7, and a filler is put on the inlet to get a solid core door skin, wherein the opposite corner stuff 23 and door skins integral edge 3, 4 is departed from 3mm to strengthen the whole door skin and to reinforce the strength for hinge installment. The solid door skin with partial hollow area is assembled wherein the hollow areas' sealing stuffs 5 can set glass 9, which fixed by glaze bead 8. At the bottom, glaze bead 8 has a plug-in convex rib to be inserted in the groove of hollow area's sealing stuff 5 for joint tightly.The features of two sheet door skin assembly are stated as follows: (1) To base on the most popular door skin size making it constant, and using integral edge easily for assembling. Besides, it saves left aide and right side stiles. (2) Top and bottom rail can be cut to change the door slab height. (3) Glaze bead can be replaced. Also, if the insulating glass fragile, it can be replaced, too. Different glaze beads can fit with different glass thickness to meet with the diversity of market. 2. Four sheet door shin assembling (Fig.5∼Fig.8): It is consisted of four "L" type sheets. No.10, 11, 12, and 13 of SMC door skin. Both the long and short rib edges of OAK wood grain door skin have two crossed convex ribs each, wherein the two crossed convex ribs 17 of "L" short rib and the two crossed convex ribs 16 of "L" long rib are fixed tightly with the two grooves of corner fixing metal sheet 15. to form a partly hollow door skin. The left side and right side edges of four sheet "L" door skins each is designed a pair of inserting convex ribs 3, 4 to be glued and inserted together while in door skin assembling. Each left and right of door skin inner parts is glued with a corner stuff 23 whose integral edge is 3mm departed not close to each other. The door slab's top and bottom rail 6, hollow area's sealing stuff 5 and the preceding four sheet "L" door skins are glued together to form a partly hollow door slab. To fill the PU foamed plastics into the door skin and seal the inlet to form a door slab. This invention have the function of door skin width changeable by following the concept of two sheet door skins assembling and cutting the length of "L" short rib of "L" door skin.The inserting fixed mode of insulating glass of the four sheet door skin assembling is as same as those of the preceding two sheet door skin assembling is as same as those of the preceding two sheet door skins, and produce the same function. Advantages are as follows: (1) "L" type structure can be reassembled by cutting the "L" short rib to change the door skin width and fulfill the customer's needs. (2) The metal sheet fixed on the corner can increase the door skin strength and reduce the angle matching error. 3. Eight sheets door skin assembling (Fig.9∼Fig.13): It has 90 degree edges of corner fixing metal sheet 22 can be inserted to the left side and right side stiles 14, the top and bottom rail 6, and the grooves of hollow area's sealing stuffs 5, for door skin. Totally, 16 metal sheets both sides be used for fixing to be a door frame. Then, making the four sheet door skins with long strip OAK wood grain and flush skin edges, which is consisted of two sheet crossed stuffs 18, 19 and two sheet vertical stuffs, to be glued on the door frame to form a partly hollow door skin. Inside the door is filled with PU foam plastics, and is sealed on the inlet with filling stuff. The hollow area's sealing stuffs can be laid in and fixed the glass tightly the insertion between plug-in convex rib of glaze bead and the groove of hollow area's sealing stuffs. The glass described forth can be single, double or three layers. Through different sizes of glaze beads which can be fixed the glass by the same structure, and formed a novel functional door slab assemble structure with partial hollow door skin and glass. The advantage of the eight sheet door skin assembling of this invention are the following: (1) It is consisted of eight sheets of vertical and crossed stuffs, and can be cut for different width and length for various of requirements. (2) The door skin body will be strong enough by the metal sheets, and will not be deformed after using for a long time. (3) It is more easily to assemble than traditional ways. Therefore, this invention can save the labor hour and down the cost.

Claims: A door slab with a hollow area for a lite assembly comprising a pair of door skins with integral vertical convex left and right flanges (3,4), sealing means (5) for the hollow area receiving a glass panel and sealing means (6) for the top and bottom of the door skins the sealing means for the hollow area being provided with at least one groove, the door slab being obtainable by inserting the left and right flanges (3,4) of the door skins (1,2) within each other for assembling the door slab, the sealing means (5,6) and the door skins (1,2) being glued together, characterised in that a glaze bead is inserted (8) by means of a convex rib into the at least one groove of the sealing means for the hollow area for fixing the glass panel (9), wherein different glaze beads are insertable in the at least one groove, to fit with different glass thickness, and the interior of the assembled door slab is filled with polyurethane foam plastics and afterwards sealed with a plug. A door slab according to claim 1, characterised in that the door skins (1,2) each are comprised by two "L"-shaped parts (10,11,12,13), the respective ends of the "L"- shaped parts (10,11,12,13) being provided with ribs (16,17), wherein two crossed convex ribs (17) of a "L"-short leg and two crossed convex ribs (16) of a "L" - long leg are in engagement with two grooves of a corner fixing metal sheet (15) and there is provided an inner corner sealing stuff (23) and the left and right side each glued with the door skin inner parts . A door slab according to claim 1, characterised in that the door skins (1,2) each are comprised by four parts (18,19,20,21), consisting of two horizontal parts (18,19) and two vertical parts (20,21), wherein the vertical flanges (3,4) are substituted by separate stiles (14) with grooves, the sealing means (5,6) being provided with grooves, too, and all mentioned grooves are arranged to engage with 90 degree edges of comer fixing metal sheets (22) and the stiles (14) are also glued with the door skins (1,2) A door slab according to one or more of claims 1 to 5, characterised in that the door skins (1,2) are composed of sheet molding compounds with oak wood grain and the sealing means for joining the door skins (1,2) could be wood, PVC, PE, PP, resin, particle board or foam plastics

Inventors: WANG CHEN KUEI YUNG, WANG CHEN, KUEI YUNG
Applicants: NAN YA PLASTICS CORP TAIPEI TA, NAN YA PLASTICS CORP., TAIPEI TAIWAN
Application year: 1997
Main classification: E06B3
IPC codes: E06B3