Patent Publication Number: US-11655668-B2

Title: Seamless multi-panel door

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This continuation application claims priority to and the benefit of the filing date of U.S. patent application Ser. No. 14/725,652, filed May 29, 2015, and entitled “SEAMLESS MULTI-PANEL DOOR,” which is hereby incorporated by reference herein in its entirety for all purposes. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to a multi-panel door, and, more particularly, to a multi-panel door having a seamless exterior appearance. 
     BACKGROUND 
     Multi-panel doors of the type used for closing a large opening in a building, such as a garage door, have long been manufactured using a plurality of substantially identical panels. The plurality of panels are typically hingedly or pivotally connected together to permit relative hinging movement between adjacent panels when the door is moved between a closed, vertical position, and an open, horizontal position. 
     Such multi-panel doors are commonly referred to as upward opening sectional doors and often include panels formed of a shell or casing, such as a molded or stamped piece of metal, fiberglass, or plastic, and an insulating core. In some cases, the multi-panel door includes windows positioned within one or more of the panels to allow users to view through a portion of the door. Due to the lightweight shell and core used to form the panels, multi-panel doors often require cumbersome, external framing structures to hold the windows in place. Thus, it is often difficult to create a seamless appearance on a multi-panel door that includes one or more windows. In addition, the windows and framing structures of such doors often provide for a limited viewing area through the door. 
     SUMMARY 
     In some embodiments, a multi-panel door includes a plurality of panel frames and a plurality of sheets of material that, when coupled to the panel frames, create an external surface of the door that has a seamless appearance when viewed from a distance. In some embodiments, the multi-panel door includes translucent sheets of material to provide a viewing area that covers a large portion of the door to give the door the appearance of a full, seamless viewing area. 
     According to a first aspect, there is provided a panel of a sectional door, the panel including a panel frame comprising a top frame member, a bottom frame member, a first side frame member and a second side frame member. The frame members include a rear surface and a front surface with the front surface having a ledge extending therefrom. The panel includes a sheet of material coupled to the front surface such that a bottom edge of the sheet rests on the ledge and a front surface of the sheet is unobstructed by the panel frame. 
     According to some embodiments, the panel includes an adhesive positioned between the front surface of the panel frame members and the sheet. 
     In yet other embodiments, the bottom edge of the sheet directly contacts the ledge. 
     In still other embodiments, the sheet is at least partially translucent. 
     In other embodiments, the sheet is at least partially opaque. 
     In yet another embodiment, the sheet is tempered glass. 
     According to some embodiments, the tempered glass includes flame-polished edges. 
     In still other embodiments, the sheet is at least partially translucent. 
     In yet another embodiment, the sheet is polycarbonate. 
     In other embodiments, the panel frame members are aluminum extrusions. 
     According to a second aspect, there is provided a multi-panel door having a plurality of panel frames, wherein each panel frame of the plurality of panel frames includes an inward facing surface, an outward facing surface, and a ledge extending from the outward facing surfaces. The multi-panel door includes a plurality of glass panels coupled to the outward facing surfaces of the plurality of panel frames, wherein a lower edge of the plurality of glass panels rests on the ledge. 
     In yet another embodiment, the ledge extends from the panel outward facing surface at a right angle. 
     In other embodiments, an outward facing surface of the plurality of glass panels is unobstructed by the plurality of panel frames. 
     In yet another embodiment, a color of the ledge matches a color of the plurality of glass panels. 
     According to another embodiment, an adhesive is positioned between the plurality of glass panels and the plurality of panel frames. 
     In still other embodiments, a double-sided tape positioned between the plurality of glass panels and the plurality of panel frames. 
     According to a third aspect, there is provided a method of manufacturing a panel of a sectional door. The method includes providing a panel frame comprising an outward facing surface and a ledge that protrudes from the outward facing surface and providing an at least partially translucent sheet comprising an inward facing surface and an outward facing surface. The method further includes coupling the inward facing surface of the at least partially translucent sheet to the outward facing surface of the panel frame so that a bottom edge of the at least partially translucent sheet rests on the ledge and so that an outward facing surface of the at least partially translucent sheet is unobstructed by the panel frame. 
     According to some embodiments, the method further includes placing an adhesive between the inward facing surface of the at least partially translucent sheet and the outward facing surface of the panel frame. 
     In yet another embodiment, the method further includes aligning a bottom edge of the at least partially translucent sheet with the ledge to position the at least partially translucent sheet on the panel frame. 
     In still another embodiment, the method includes coating the ledge so that a color of the ledge substantially matches a color of the at least partially translucent sheet. 
     In yet another embodiment, the method further includes placing a second sheet adjacent to the at least partially translucent sheet on the panel frame. 
     For a more complete understanding of the present invention, including additional features, objects and advantages thereof, reference is now made to the following detailed description taken in conjunction with the drawings, in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view of an embodiment of a multi-panel door having three panels in accordance with this disclosure. 
         FIG.  2    is a partial exploded view of the multi-panel door of  FIG.  1   . 
         FIG.  3    is a rear view of the multi-panel door of  FIG.  1   . 
         FIG.  4    is a cross section view of the top panel of the multi-panel door of  FIG.  1   . 
         FIG.  5    is a cross section view of the intermediate panel of the multi-panel door of  FIG.  1   . 
         FIG.  6    is a cross section view of a hinged connection between the top panel and the intermediate panel of  FIG.  1   . 
         FIG.  7    is a flow diagram illustrating a method of manufacturing the multi-panel door of  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION 
     In the description which follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawings may not be to scale and certain features may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness. 
       FIG.  1    is a perspective view of an embodiment of a multi-panel, upward-acting, sectional door  100  having a seamless exterior appearance. The multi-panel door  100  includes a plurality of panels  102  that form a front face  104  of the door  100  and enclose an opening  106  in a building  108  or other structure. In the embodiment illustrated in  FIG.  1   , for example, the door  100  includes three panels  102 , namely, a top panel  110 , an intermediate panel  112  and a bottom panel  114 , that enclose an opening  106  defined by two jambs  116  and  118 , a header  120  and a driveway  122 . In some embodiments, the panels  102  are hingedly connected and mounted on conventional track and rollers (not shown) within the building to enable movement of the door  100  between the vertical position shown in  FIG.  1   , and a horizontal (i.e., overhead) position. In other embodiments, the door  100  may include any number of panels  102  and may be located in any suitable opening  106 . 
     In  FIGS.  1 - 3   , each panel  102  of the door  100  includes a frame  160 ,  162  or  164  (see  FIGS.  2  and  3   ) and at least one sheet  126  of material coupled to the frame  160 ,  162  or  164 . The sheets  126  of material are coupled to the panel frame  160 ,  162  or  164  such that an outer surface  128  of each sheet  126  is unobstructed by the panel frames  160 ,  162  or  164 . In some embodiments, the unobstructed sheets  126  give the multi-panel door  100  a seamless exterior appearance when the door  100  is in the closed position, as will be described in more detail below. 
     The sheets  126  of material may be made of any suitable material and may be opaque, translucent, semi-translucent, transparent, semi-transparent or a combination of any of the foregoing. For example, in some embodiments the sheets  126  are made of semi-translucent black, white, bronze or mirror silver glass. In other embodiments, the sheets  126  are made of an opaque metal material. In yet other embodiments, the sheets  126  are made of tempered glass that has flame-polished edges to prevent chipping or cracking. In some embodiments, the sheets  126  are partially translucent, partially opaque or a combination of partially translucent and partially opaque. 
     The sheets  126  may also have any suitable thickness. In some embodiments, for example, the sheets  126  are ⅛ inch thick. In other embodiments, the sheets  126  are thicker or thinner than ⅛ inch. For example, in some embodiments the sheets  126  are a glass material that is ¼ inch thick. In some embodiments, the sheets  126  have a height and width that are substantially equal to the height and width of the corresponding panel frame  160 ,  162  or  164 . In other embodiments, multiple sheets  126  couple to each of the panel frames  160 ,  162  or  164  and the sheets  126  have a combined height and width that is substantially equal to the height and width of the corresponding panel frame  160 ,  162  or  164 . 
     The sheets  126  may also have any suitable color. For example, in some embodiments the sheets  126  have an anodized bronze or anodized brown color. In yet other embodiments, the sheets  126  have a semi-transparent black, white or mirror silver color. 
     As discussed above, in some embodiments the sheets  126  are coupled to the frames  160 ,  162  or  164  such that the frames  160 ,  162  and  164  do not obstruct an outer surface  128  of the sheets  126 . As will be described in more detail below, in some embodiments, a ledge  132  (see  FIGS.  3 - 7   ) of each panel frame  160 ,  162  and  164  is positioned below the sheets  126  and is partially exposed on the front face  104  of the door  100 . As such, in some embodiments the ledge  132  of each panel frame  160 ,  162  and  164  is painted, coated, or otherwise configured to have a color that is similar to the coloring of the sheets  126 . Thus, in some embodiments the entire front face  104  of the multi-panel door  100  has a substantially uniform color to give the door  100  a seamless appearance. 
     Referring now to  FIG.  2   , in some embodiments each panel frame  160 ,  162  and  164  includes an upper frame member  134 , a lower frame member  136 , a first side member  138  and a second side member  140 . In some embodiments, the upper frame member  134 , the lower frame member  136 , the first side member  138  and the second side member  140  are metal extrusions that are coupled to form a rectangular panel frame  160 ,  162  and  164 , as illustrated in the embodiment of  FIG.  2   . In some embodiments, the panel frame  160 ,  162  or  164  also includes one or more intermediate frame members  142 . For example, in the embodiment illustrated in  FIG.  2    each frame  160 ,  162  and  164  includes an intermediate frame member  142  that couples the upper frame member  134  to the lower frame member  136  and divides the frames  160 ,  162  and  164  into two equal sections. While the panel frames  160 ,  162  and  164  illustrated in  FIG.  2    are rectangular in shape, the panel frames  160 ,  162  and  164  may be any suitable shape in other embodiments. 
     Each member  134 ,  136 ,  138 ,  140  and  142  of the panel frames  160 ,  162  and  164  includes an inner surface  144  (see  FIGS.  4 - 6   ) that faces an interior portion of the space enclosed by the door  100 , such as the interior portion of a garage, and an exterior surface  148  that faces away from the space enclosed by the door  100 . The lower frame member  136  of each frame  160 ,  162  and  164  includes the ledge  132  ( FIGS.  3 - 7   ) that extends from the exterior surface  148  of the lower frame member  136 . In some embodiments, the exterior surfaces  148  of the frame members  134 ,  136 ,  138 ,  140  and  142  of each panel frame  160 ,  162  and  164  are substantially co-planar when the door  100  is in the vertical position, as illustrated in  FIG.  1   , with the exception of the ledges  132  that protrude from the exterior surfaces  148 , as best illustrated in  FIGS.  4 ,  5  and  6   . In some embodiments, the sheets  126  are substantially planar pieces of material that are also substantially coplanar when adhered to the frame members  134 ,  136 ,  138 ,  140  and  142  of each panel frame  160 ,  162  and  164 . 
     Referring again to  FIG.  2   , a coupling mechanism  150  is positioned on the exterior surfaces  148  of the frame members  134 ,  136 ,  138 ,  140  and  142  to adhere the sheets  126  to the exterior surfaces  148  of the frame members  134 ,  136 ,  138 ,  140  and  142 . In some embodiments, the coupling mechanism  150  is a layer of adhesive, a layer of double-sided tape or some other coupling object. In some embodiments, the coupling mechanism  150  is a double-sided tape, such as 4991 VHB tape made by 3M Company of Maplewood, Minn. In other embodiments, the coupling mechanism  150  is an adhesive, such as Adseal 4549 silicone based adhesive made by AdChem Corporation of Riverhead, N.Y. The coupling mechanism  150  may be any suitable adhesive, double-sided tape or other coupling mechanism in other embodiments. 
     In some embodiments, the coupling mechanism  150  is positioned on the outer surfaces  128  of the frame members  134 ,  136 ,  138 ,  140  and  142  and on a top surface  152  ( FIGS.  4 - 7   ) of the ledges  132 . In yet other embodiments, the coupling mechanism  150  is not positioned on the ledges  132  but is only positioned on the outer surfaces  128  of the frame members  134 ,  136 ,  138 ,  140  and  142 . 
     In the embodiment illustrated in  FIG.  2   , two sheets  126  of material are coupled to each panel frame  160 ,  162  and  164  by way of the coupling mechanism  150 . In other embodiments, any number of sheets  126  can be coupled to each panel frame  160 ,  162  and  164  by way of the coupling mechanism  150 . 
       FIG.  3    is a rear view of the door of  FIG.  1   . In the embodiment illustrated in  FIG.  3   , the positioning of the panel frames  160 ,  162  and  164  behind the sheets  126  of material is illustrated. In some embodiments, a majority of the inner surface  130  of the sheets  126  is unobstructed by the panel frames  160 ,  162  and  164  so that the door  100  has a principally transparent or translucent appearance when the sheets  126  are made of a transparent or translucent material. In some embodiments, for example, more than seventy percent of the inner surface  130  of the sheets  126  is unobstructed by the panel frames  160 ,  162  or  164 . In other embodiments, more than sixty percent of the inner surface  130  of the sheets  126  is unobstructed by the panel frames  160 ,  162  or  164 . In yet other embodiments, more than fifty percent of the inner surface  130  of the sheets  126  is unobstructed by the panel frames  160 ,  162  or  164 . 
       FIGS.  4  and  5    illustrate cross-section views of the top and intermediate panels  110  and  112 , respectively, of the door  100  of  FIG.  1   . The bottom panel  114  is a mirror image of the top panel  110  and thus is not individually illustrated herein in the interest of conciseness. Referring specifically to  FIG.  4   , in some embodiments the top panel frame  160  includes a large, or “heavy-duty,” upper frame member  134  and a small, or “light duty,” lower frame member  136 . In some embodiments, the upper frame member  134  is substantially rectangular in shape and generally has a cross-section profile configured to provide structural strength to a top portion  178  of the top panel frame  160 . 
     The upper frame member  134  includes an exterior surface  148  that is substantially planar and provides a surface to which the coupling mechanism  150  can be adhered. In some embodiments, the coupling mechanism  150  covers only a portion of the exterior surface  148  of the upper frame member  134 , as illustrated in  FIG.  4   . In other embodiments, the coupling mechanism  150  covers all or substantially all of the exterior surface  148  of the upper frame member  134 . 
     In some embodiments, the upper frame member  134  also includes one or more openings  180  to receive an end cap (not shown) or other device to protect the upper frame member  134 . 
     The lower frame member  136  also includes a planar exterior surface  148  to which a coupling mechanism  150  can be adhered. The planar, exterior surface  148  faces an exterior of the door and is substantially parallel to the exterior surface  148  of the upper frame member  134 . The lower frame member  136  also includes a sealing member receptacle  166  and a groove  168  that helps to seal the upper panel  110  to the intermediate panel  112 , as discussed in more detail below in connection with  FIG.  6   . 
     As described above, the lower frame member  136  of each of the panel frames  160 ,  162  and  164  includes a ledge  132  to support at least part of the weight of the sheet(s)  126 . The ledge  132  extends from the exterior surface  148  of the lower frame member  136  and includes a top surface  152  that supports the sheet  126 . In some embodiments, the top surface  152  directly contacts a lower edge  154  of the sheet  126 . In other embodiments, the top surface  152  contacts another element, such as an adhesive or double-sided tape (not shown), that is placed between the sheet  126  and the ledge  132 . 
     In some embodiments, the ledge  132  extends perpendicularly from the exterior surface  148  of the lower frame member  136  a distance that corresponds to the combined thickness of the sheet  126  and the coupling mechanism  150 . As such, in some embodiments the ledge  132  and the outer surface  128  of the sheet  126  are substantially aligned when the sheet  126  is coupled to the respective panel frame  160 ,  162  or  164 . As discussed above, in some embodiments the ledge  132  of each panel frame  160 ,  162  and  164  is visible at the front face  104  of the door  100  when the door  100  is in the fully closed position, as illustrated in  FIG.  1   . 
     Referring now to  FIG.  5   , in some embodiments the intermediate frame member  142  includes a small, or “light duty,” upper frame member  134  and a small, or “light duty,” lower frame member  136 . As discussed above, each of the upper and lower frame members  134  and  136  include a planar exterior surface  148  that provides a surface to which the coupling member  150  is adhered. The upper and lower frame members  134  and  136  each include a sealing member receptacle  166  used to seal adjacent panels  110 ,  112  and  114 . In addition, the upper frame member  134  includes a tongue protrusion  170  while the lower frame member  136  includes a groove  168  that are each used to further seal adjacent panels  110 ,  112  and  114 , as described in more detail below. 
     The lower frame member  136  also includes a ledge  132  that protrudes from the exterior surface  148  to support the sheet  126 . In some embodiments, the ledge  132  protrudes perpendicularly from the exterior surface  148  and supports the lower edge  154  of the sheet  126  on the top surface  152  of the ledge  132 . 
       FIG.  6    illustrates a hinged connection  172  between the top panel  110  and the intermediate panel  112  of  FIG.  1   . A hinged connection between the intermediate panel  112  and the bottom panel  114  may be substantially similar to the hinged connection  172 . In addition, a hinged connection between adjacent intermediate panels  112  (in an embodiment in which the door  100  includes multiple intermediate panels  112 ) may also be substantially similar to the hinged connection  172 . 
     In some embodiments, the top panel frame  160  is hingedly coupled to the intermediate panel frame  162  by one or more hinge members  174 . In some embodiments, the frame members  134  and  136  include sealing features to prevent water, air, insects or another elements from passing between the top and intermediate panels  110  and  112  when the door  100  is in the closed position. In some embodiments, for example, the lower frame member  136  of the top panel  110  includes a groove  168  and the upper frame member  134  of the intermediate panel frame  162  includes a corresponding tongue protrusion  170  configured to reside within the groove  168  when the door  100  is in the closed position. In some embodiments, the interaction between the groove  168  and the tongue protrusion  170  when the door  100  is in the closed position substantially prevents entry of water and light between the top and intermediate panels  110  and  112 . 
     In addition, in some embodiments one or more of the lower frame member  136  of the top panel  110  and the upper frame member  134  of the intermediate panel  112  includes a resilient sealing member  176  located in the respective sealing member receptacle  166 . In some embodiments, the resilient sealing member  176  is compressed when the door  100  is in the closed position to further seal the top and intermediate panels  110  and  112  to each other. 
       FIG.  7    illustrates an embodiment of a method  200  for manufacturing a panel  110 ,  112  or  114  for use on a seamless, multi-panel door  100 . In some embodiments, the method  200  begins and a panel frame  160 ,  162  or  164  that includes an upper frame member  134 , a lower frame member  136 , a first side frame member  138 , a second side frame member  140 , and one or more intermediate frame members  142  is provided, as illustrated at block  202 . The frame members  134 ,  136 ,  138 ,  140  and  142  include an exterior surface  148  and the lower frame member  136  includes a ledge  132  that protrudes from the exterior surface  148  of the lower frame member  136 . 
     A sheet  126  of material is also provided, as illustrated at block  204 . In some embodiments, the sheet  126  is at least partially translucent and has an outer surface  128  and an inner surface  130 . 
     The inner surface  130  of the sheet  126  is then coupled to the exterior surface  148  of the frame members  134 ,  136 ,  138 ,  140  and  142  so that a lower edge  154  of the sheet  126  rests on the ledge  132  and so that an outer surface  128  of the sheet  126  is unobstructed by the panel frame, as illustrated at block  206 . 
     In some embodiments, the method  200  also includes placing a coupling mechanism  150 , such as an adhesive material or double-sided tape, on the exterior surface  148  of each of the frame members  134 ,  136 ,  138 ,  140  and  142  to adhere the sheet  126  to the frame members  134 ,  136 ,  138 ,  140  and  142 . 
     In other embodiments, a worker then places a lower edge  154  of the sheet  126  onto the ledge  132  of the lower frame member  136  to align the sheet  126  with the panel frame  160 ,  162  or  164 . In some embodiments, the worker then presses the sheet  126  onto the coupling mechanism  150  and, in some embodiments, clamps the sheet  126  to the panel frame  160 ,  162  or  164  until the coupling mechanism  150  has cured and hardened to a suitable strength, often referred to as the “green strength.” In some embodiments, additional sheets  126  are attached to the panel frame  160 ,  162  or  164  in like manner. 
     In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “outer” and “inner,” “upper” and “lower,” “first” and “second,” “internal” and “external,” “above” and “below” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms. 
     In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive. 
     Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment. 
     Although specific embodiments have been described in detail, those skilled in the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.