Abstract:
An access door is provided which may be easily installed. The door utilizes a mounting tape which is affixed between the door frame and the surface which supports the door as well as acting as a seal. The mounting tape allows installation by a single individual. The door may be further held in position by a minimal number of screws after being attached initially using the mounting tape. A core surround member may also be part of the door. The core surround covers a gap between the door and the door frame from view.

Description:
[0001]    This application claims the benefit of U.S. provisional patent application No. 60/409,763 filed on Sep. 11, 2002 the entirety of which is hereby incorporated by reference. 
     
    
     
       BACKGROUND OF INVENTION  
         [0002]    The present invention concerns a door apparatus used in conjunction with horse trailers, utility trailers and/or recreational vehicles. Typical doors used in these applications employ common attachment means, namely a large number of screws which extend into a jamb around the opening in a wall or other surface. This common type of door takes a long period of time to install due to the amount of screws involved. Additionally a number of the screw heads are visible after installation.  
           [0003]    Alternatively, a clamp ring is used for installation of the door. With this method the door is placed in the rough opening of the wall and held in place by one individual while another installs a mounting device from the interior using screws that go through the clamp ring into the jambs of the door. As the screws are drawn tight the unit sandwiches the wall locking it in place. Use of either of these known apparatus also requires caulking around the edge of the door to provide a seal between the door and the wall or surface into which the door is mounted.  
           [0004]    An improved door apparatus is desired which uses fewer screws, thus reducing installation time and can be installed by a single individual. In addition, the presence of the screws should not be obvious after installation. Finally, there should be no need to caulk the door after installation is complete.  
         SUMMARY OF INVENTION  
         [0005]    The present apparatus and method overcomes the shortcomings in the prior art. The present door minimizes the need for screw installation and caulk sealing. The installation may be made directly through the door jamb, without the use of a clamp ring. The door provides a flush appearance with the rest of the compartment enclosed by the door. Additionally there is no visible gap between the door core and door mainframe.  
           [0006]    The design of the door frame is such that it does not have a blind stop for core and it hugs the rough opening of the mounting surface. The door frame is designed so that no additional protrusions extend into the clear opening other than what is required. The blind stop for an optional cage is only applied at the lock side of the frame and only when a cage is present. This results in a gain of close to 2.54 centimeters (1 inch) width and 1.27 centimeters (0.5 inch)″ to 2.54 centimeters (1 inch) in height over traditional configurations.  
           [0007]    In one version a vehicle door assembly, easily attachable to a door jamb, is provided which includes a peripheral frame attachable to the door jamb, a door member movable on hinges between a closed position within the peripheral frame and an open position, and mounting tape affixed between the peripheral frame and door jamb to hold said peripheral frame in place and to seal spaces between the peripheral frame and the door jamb.  
           [0008]    In another version a vehicle door assembly providing a gap-free appearance is provided which includes a peripheral frame, a door member movable on hinges between a closed position within the peripheral frame and an open position, and a core surround affixed to said door member, said core surround covering a gap between said door member and peripheral frame when said door member is in a closed position.  
           [0009]    These and other versions of the invention are described in more detail within the following description and drawings. 
       
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0010]    [0010]FIG. 1 a  is a front view of a first embodiment of the door;  
         [0011]    [0011]FIG. 1 b  is a front view of a second embodiment of the door;  
         [0012]    [0012]FIG. 1 c  is a front view of a third embodiment of the door;  
         [0013]    [0013]FIG. 1 d  is a front view of a fourth embodiment of the door;  
         [0014]    [0014]FIG. 2 is a first cutaway view of the door;  
         [0015]    [0015]FIG. 3 is a second cutaway view of the door;  
         [0016]    [0016]FIG. 4 is a detailed view of the core surround;  
         [0017]    [0017]FIG. 5 is a detailed view of the core surround and seal;  
         [0018]    [0018]FIG. 6 a  is a detailed view of the hinge;  
         [0019]    [0019]FIG. 6 b  is a detailed view of the main hinge;  
         [0020]    [0020]FIG. 7 a  is a cutaway view of a frame splice plate;  
         [0021]    [0021]FIG. 7 b  is a side view of two spliced frame members;  
         [0022]    [0022]FIG. 7 c  is a cutaway view of a frame member and splice plate;  
         [0023]    [0023]FIG. 8 is a cutaway view of the core surround;  
         [0024]    [0024]FIG. 9 is a horizontal cutaway view of an alternative embodiment of the door including a cage;  
         [0025]    [0025]FIG. 10 is a vertical cutaway view of an alternative embodiment of the door including a cage;  
         [0026]    [0026]FIG. 11 is a cutaway view of a hinge leaf used with a cage system. 
     
    
     DETAILED DESCRIPTION  
       [0027]    As described in more detail below and shown in FIGS.  1 - 3 , a door  20  is provided which includes a frame  30 , core  40 , core surround  50 , skin  42 , and hinges  60 . The door  20  may be provided in either a square edge configuration shown in FIG. 1 a  or round edge configuration shown in FIG. 1 b . FIGS. 1 c  and  1   d  show additional “Feed Door”embodiments. These embodiments may include windows and/or doors within the core, varied types and positions of handles for opening the access door and cage systems.  
         [0028]    Referring to FIG. 2, the door  20  includes a frame  30  which is placed within an open passage defined by one or a series of door jambs  18 . The frame  30  is screwed into the jamb  18  with a minimum number of screws. Chart  1  shows the typical number of screws used to attach the frame. This number is fewer than typical doors because of the mounting tape used to hold the door in place as described below. The frame  30  is made of a number of frame members  32 .  
         [0029]    Each frame member  32  may be an aluminum extrusion. The frame member  32  may include a base  34  and a plurality of legs. In a preferred embodiment of the frame member  32 , three legs  35 - 37  are included. Referring to FIG. 5, a first exterior leg  35  may extend from one side of the base  34 . A second leg  36 , considered an interior leg, extends in the same direction as the majority of the first leg  35  and may have a generally equivalent length in that direction compared to the first leg  35 . A third leg  37 , considered an exterior leg, is located at the opposite side of the base  34  and extends in the same direction as the first  35  and second legs  36 . The third leg  37  may be longer than the first  35  and second legs  36 . The interior leg  36  is located between the first  35  and third legs  37 , both considered exterior legs. In an alternate embodiment of the invention the frame member  32  does not include leg  36 .  
         [0030]    The extra length of the third leg  37  allows the frame  30  to overlap the door jamb  18 , thus providing a more aesthetic appearance. The frame members  32  are preferably made from extruded aluminum, although other materials such as steel or plastic may be used. The frame  30  functions both as a support for the door  20  and as means to cover the door jamb  18  and any other interior components of the wall or surface to which the door  20  is applied. Referring to FIGS. 7 a - c , multiple frame members  32  may be joined together using a splicing piece  38 . Referring to FIG. 8, the frame member  32  may also include one or more screw bosses  39  as part of the extrusion for the passage of mounting screws  70 . Screw bosses  39  may be used in rectangular embodiments of the frame  30 . Referring back to FIG. 2 the frame members  32  are oriented such that the three legs  35 - 37  point towards door jamb sections  18 . The two shorter legs  35 - 36  may abut the jamb while the third leg  37 , which is longer, may overlap the exterior side of the jamb  18 . Additional apertures may be included in the frame  32  for the passage of a handle latch and screws for mounting the hinges.  
         [0031]    Caulk and screws used in traditional doors may be replaced by the use of a two sided tape  46  between the frame  30  and door jamb  18 . Referring to FIG. 5, tape  46  may be applied to the frame member  32  and then, as the door  20  is installed, affixed to the jamb  18  or a member of the structure adjacent to the jamb  18 . Preferably the tape  46  is applied to all four sides of the door frame  30 . The tape  46  allows the door  20  to be installed by a single individual. Once pressed in place the door  20  is effectively installed and can be operated when supported solely by the tape  46 . However, it is preferred that additional screws are used for greater structural integrity.  
         [0032]    Referring to FIGS. 2 and 3, the door includes a core  40  which is sandwiched by two skins  42  and  44 . The core  40  has a general rectangular shape and may be manufactured from an expanded polystyrene (EPS) foam. As a substitute an injected foam may be used in place of EPS. The core  40  is sized according to the preferred size of the overall door  20 . The core  40  is sandwiched by skins  42  and  44  which may be flat sheets having a rectangular shape. The skins  42  and  44  are typically oversized in comparison to the core  40 , thus the core  40  is not visible when the door  20  is observed head on or from behind. The skins  42  and  44  are preferably manufactured from a smooth aluminum which in turn may be painted. The skins  42  and  44  may also be manufactured from fiberglass. The door may include one fiberglass skin and one aluminum skin. The core may be surrounded around its edges by a steel stile  76 . The core  40  may extend to the end of the stile  76  or there may be a gap between the stile  76  and core  40 . Multiple stile pieces  76  may be spliced together. The skins  42  and  44  may be hot melt laminated to the core  40 .  
         [0033]    The sides of the core  40  are shielded from view by a number of core surrounds  50 . The core surrounds  50  serve a second purpose of covering the gap between the core  40  and skin  42  and  44  combination and the frame  30  of the door  20 . Referring to FIG. 4, in a preferred embodiment of the door  20  the core surround  50  has and “L” shape with a leg protruding from each end or corner of the “L”. The two portions  54  and  55  of the core surround  50  forming the “L”are generally perpendicular to each other. The leg  51  at the uppermost end of the “L” extends outward perpendicularly from the uppermost portion  54  and in a direction opposite from the lowermost portion  55  of the “L”. The second leg  52  extends in the same direction as the first leg  51  and from the corner of the “L”. The third leg  53  extends in a direction generally parallel to the uppermost portion  54  of the “L”. Preferably the core surround  50  is also formed from extruded aluminum. Referring to FIG. 3, the two legs  51  and  52  which point in the same direction are oriented to go over the side of the core  40  and skin  42  and  44  combination or stile  76  and as a result the core  40  or stile  76  is hidden from plain view. The lowermost portion  55  of the “L”extends to cover the gap between the door core  40  and skins  42  and  44  and the frame portion  30  of the door  20  when the door  20  is in a closed position. The core surround  50  may also include one or more screw bosses as part of the extrusion for the passage of mounting screws.  
         [0034]    Referring to FIG. 5, a seal  80  is provided between the core surround  50  and the frame  30  of the door  20 . The seal  80  preferably has a bulb shape, and thus provides a cushion as the door  20  is closed. The seal  80  is formed of a polymer such as Ethylene Propylene Terpolymer (EPDM) which is generally flexible. Preferably, the seal  80  extends around all four sides of the door  20 . The seal  20  functions to prevent the migration of air, moisture or fluids through the door  20  when the door  20  is in a closed position. The seal  80  is affixed to the interior surface of the lowermost “L”portion  55  of the core surround  50 . The seal  80  has a width which is less that the width of the lowermost “L”portion  55  of the core surround  50 , thus the seal  80  is not visible when the door  20  is viewed head-on. The seal  80  may be an elongated member which extends along the full perimeter of all four sides of the door  20 . Alternatively, the seal  80  may consist of more that one individual member, each having the same shape. The seal  80  is configured in a way such that a flat section of the bulb shape abuts the surface of the core surround  50 . An arcuate portion of the seal  80  is designed to contact the frame  30 , and to be compressed in the process. The seal  80  may be affixed to the core surround  50  using tape.  
         [0035]    Referring to FIGS. 2, 6 a  and  6   b , one or more hinges  60  are attached to both the core surround  50  and a frame member  32 , allowing the door core  40  and skins  42  and  44  to be rotated between an open and closed position. Each individual hinge  60  includes a main hinge  62  which may be affixed to the frame  30  and one or more leaf hinges  64  which may be attached to the core surround  50 . The main hinge  62  and leaf hinge(s)  64  are held together using a hinge pin  66 . Washers  68  may be provided between points of contact to minimize friction and wear upon the hinges  60 .Referring to FIG. 6 a  a typical hinge  60  is shown having three leaf hinges  64 . FIG. 6 b  shows a main hinge  62  having areas of reduced thickness  67  and a stop portion  69 .  
         [0036]    Referring to FIG. 1 c  an embodiment including a window  95  is shown. The window opening is generally cut into the door core by a router and the window  95  is then dropped into place. The window  95  uses a clamp ring to hold it in place.  
         [0037]    [0037]FIGS. 9 and 10 shows an embodiment including a cage system  81 . The cage system  81  consists of an outer extruded aluminum tubular frame  83  that is generally rectangular in shape with rounded corners. The size of the cage system  81  is dictated by the size of door. Running vertically within the outer frame are a series of rectangular bars  84 . Spacing is such that an animal can not push their head out of the unit when the cage system  81  is in the closed position. The cage system  81  is held in the closed position by the hinges on one side and a spring loaded bolt  85  on the other. The bolt  85  is mounted internal of the cage bar with an external trip mechanism. The bolt  85  is always in the closed position unless a force is applied to the trip mechanism of the bolt to retract it. The force could be applied to a pull wire or to a tubular handle  86  that wraps the vertical bar. The cage system  81  is prevented from over-rotating by a blind-stop  87  that is applied to the lip of the frame  30 . This door with cage system  81  is available in both square and radius configurations but the cage system  81  always has radiused corners so as not to injure the animals. The cage system  81  uses an alternate hinge configuration that substitutes one of the door leaf components with a revised version that will mate to the cage system  81 . The cage system  81  can open and close with the core or can be left in a closed position when the core is opened to prevent an animal from pushing it&#39;s head out the opening. With the core in the open position the cage system can be opened and closed independently.  
         [0038]    [0038]FIG. 1 d ,  9  and  10  shows an embodiment which uses a modified version of the core surround  50  with sliding  89  and fixed glass panels  90  and a center mullion  91  that incorporates a handle  92  with a remote trip bolt. The benefit of this design is a large area of glazing that allows for maximum lite and a center handle  92  that allows better control of the door when opening and closing the unit. The core surround is similar in design to that previously described, but adds a series of legs that act as tracks for the operable glass and mounting surfaces for the fixed glass. The fixed glass is glazed in place with tape or wet glazing and a glazing bead  93  is used to dress out the final appearance. The operable panels ride on plastic inserts  94  that aid in operation of the glass panel and prevent metal to glass contact and rattling of the glass. The operable panel can be opened or closed and locked in the closed position by a locking handle. The mullion acts as a support for the fixed glass and a mounting for the handle  92 . With this design the handle  92  is located generally near the center of the door and allows for better control of the door when opening and closing. Additionally it lowers the handle from traditional locations so that it is more assessable to people of shorter stature. The center location is made possible by the use of an external handle that is linked to an internal cam and cable that when operated trips a slide bolt at the edge of the door. Additionally the design allows for a clean streamlined look. This embodiment is formed in the radius corner versions only.  
         [0039]    Additional components necessary for the operation of a door are also included as part of the invention such as a handle latch upon the core and skins portion and corresponding latch plate upon the frame. The handle may include a lock.  
         [0040]    Although the invention has been shown and described with reference to certain preferred and alternate embodiments, the invention is not limited to these specific embodiments. Minor variations and insubstantial differences in the various combinations of materials and methods of application may occur to those of ordinary skill in the art while remaining within the scope of the invention as claimed and equivalents. Use of the term “or”herein is the inclusive, and not the exclusive use.