Patent Publication Number: US-2009223131-A1

Title: Steel frame wood panel garage door

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     (Not Applicable) 
     STATEMENT RE FEDERALLY SPONSORED RESEARCH/DEVELOPMENT 
     (Not Applicable) 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to garage doors and more particularly, to a garage door having a plurality of front panel members and a plurality of frame assemblies, each frame assembly connected to a respective one of a plurality of front panel members. 
     2. Description of the Related Art 
     Garages are commonly used to provide storage space for both residential and commercial buildings. Although garages may be used for storage of a wide range of items (e.g., tools, seasonal equipment, etc.), many garages are primarily used for storage of a vehicle. It is common for garages to include a garage door which may be opened to provide access into the garage from the outside environment. Garage doors are typically large to allow for the ingress and egress of vehicles into and out of the garage. Garage doors may also be employed to protect the inside of the garage, and items contained therein, from the natural elements such as rain, snow, and flying debris. When closed, the garage door may also provide security by restricting access into the inside of the garage. Garage doors may be configured to easily move between open and closed positions to allow easy access into and out of the garage. A typical garage door is opened by moving it upwardly into its open position. Most doors are maintained in the open position until they are acted upon to close. Some garage doors are manually opened, while other garage doors employ the assistance of a garage door opener. A garage door may be comprised of a single large panel, while others include a series of interconnected, smaller panels which collectively comprise the garage door. 
     Many garage doors are constructed from a metal material. Metal tends to be a very durable material that is capable of withstanding the environmental elements as well as the repeated uses thereof. However, given that garage doors tend to be very large, and commonly face the front of the residential structure, it may be desirable for the garage door to have aesthetically pleasing attributes. As such, many doors incorporate designs to improve the aesthetic quality thereof. With regard to metal garage doors, various designs may be stamped into the exterior surface of the door to improve the appearance of the same. In addition, windows and other features may also incorporated into the garage door to enhance its aesthetic appeal. 
     Although metal may be a preferable material because of its cost and ease of manufacture, other materials may prove to be more aesthetically pleasing. For instance, wood is a material that is commonly used in the construction industry because of its durability as well as its desirable appearance. Consequently, it may be desirable to incorporate wood into the design of the garage door in order to improve the aesthetic quality of the door. However, the structural integrity of the door may decrease, while the ease and cost of manufacture may increase in order to include wood within the garage door. Furthermore if the door is comprised of multiple panels, interruption of the natural design of the wood grain may decrease the overall aesthetics of the door. In addition, it may be difficult to incorporate windows and other design features into a wood door. 
     As is apparent from the foregoing, there exists a need in the art for a garage door including a strong, durable frame to which an aesthetically pleasing panel such as wood may be attached to. The present invention addresses this particular need, as will be described in more detail below. 
     BRIEF SUMMARY OF THE INVENTION 
     There is provided a garage door comprising a front panel including a plurality of front panel members. Each front panel member defines a panel member front surface and a panel member rear surface. The garage door further includes a plurality of frame assemblies connected to the front panel. Each frame assembly is connected to the panel member rear surface of a respective one of the plurality of front panel members. Each frame assembly includes a pair of rails and a plurality of stiles. Each rail includes a rail inner surface, wherein the rail inner surfaces of the pair of rails are disposed in opposed relation to each other. Each stile includes a pair of opposing stile end surfaces and a pair of opposing stile inner surfaces. Each one of the pair of opposing stile end surfaces is attached to a respective one of the pair of rails to form a plurality of frame opening peripheries. Each frame opening periphery is defined by the opposing rail inner surfaces and the opposing stile inner surfaces of adjacent stiles. The garage door additionally includes a plurality of fasteners. Each fastener connects a respective one of the plurality of frame assemblies to a respective one of the plurality of front panel members. The garage door further includes a plurality of pivot members. Each pivot member is connected to adjacent ones of the plurality of frame assemblies to enable pivotal movement between the same. 
     The garage door of the present invention may provide a structurally sound and aesthetically pleasing garage door. The front panel may be comprised of a wood material to enhance the aesthetic quality of the door. Furthermore, various aesthetic designs may be incorporated into the front panel to enhance the appearance thereof. The frame assemblies included in the garage door provide a rigid framework to which the front panel may be securely attached to. It is contemplated that the frame assemblies may be constructed of a strong, rigid material such as steel. 
     The front panel members of the garage door may include a panel member top surface and a panel member bottom surface. At least one of the panel member top surfaces and the panel member bottom surfaces may be non-orthogonal to the panel member front surface. At least one of the plurality of front panel members may include a panel member top surface and a panel member bottom surface that is non-orthogonal to the panel member front surface. The non-orthogonal orientation of the panel member top and/or bottom surfaces may allow adjacent front panel members to intersect along a non-orthogonal angle to the panel member front surface, which tends to mitigate outside elements such as water from passing through the garage door. 
     Furthermore, the frame assembly may include powder/coated rails and stiles to mitigate the formation of rust thereon. Furthermore, the opposing stile end surfaces may be attached to a respective one of the pair of rails by a butt joint. The butt joint may enhance the structural integrity of the frame assembly. 
     Each frame assembly may also include a plurality of affixing members. Each affixing member may be connected to a respective one of the plurality of frame opening peripheries. Each fastener may connect a respective one of the plurality of affixing members to the respective one of the plurality of front panel members. Each frame assembly may include a frame assembly front surface, and each affixing member may include an affixing member front surface. The affixing member front surface may be offset from the frame assembly front surface by 1/16 of an inch. 
     An aspect of the present invention additionally includes a method of forming a garage door. The method includes the steps of providing a front panel having a front panel rear surface, a plurality of rails and a plurality of stiles. The method also includes the step of constructing a plurality of frame assemblies by attaching multiple ones of the plurality of stiles between a pair of the plurality of rails. The opposing stile end surfaces are attached to a respective one of the rail inner surfaces to form a plurality of frame opening peripheries. The plurality of frame assemblies are then disposed adjacent the front panel rear surface. Adjacent ones of the plurality of frame assemblies are spaced apart to define a cutting channel. The plurality of frame assemblies are then fastened to the front panel. The front panel is then cut along each cutting channel. Adjacent ones of the plurality of frame assemblies are then connected with at least one pivot member to enable pivotal movement between the respective frame assemblies. 
     The present invention is best understood by reference to the following detailed description when read in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings in which like numbers refer to like parts throughout and in which: 
         FIG. 1  is a front, top perspective view of a garage door constructed in accordance with an aspect of the present invention; 
         FIG. 2  is a rear top perspective view of the garage door illustrated in  FIG. 1 ; 
         FIG. 3  is a side elevation view of the garage door illustrated in  FIG. 1 ; 
         FIG. 4  is an exploded view of a frame assembly; 
         FIG. 5  is a top perspective view of the frame assembly; 
         FIG. 6  is a top perspective view of the frame assembly illustrated in  FIG. 5 , further including a plurality of affixing members; 
         FIG. 7  is a side sectional view of the frame assembly illustrated in  FIG. 6 ; 
         FIG. 8  is a front, sectional elevation view of the frame assembly illustrated in  FIG. 6 ; 
         FIG. 9  is an exploded view of a plurality of frame assemblies and a front panel; 
         FIG. 10  is a rear elevation view of the plurality of frame assemblies connected to the front panel; 
         FIG. 11  is a side elevation view of the plurality of frame assemblies and front panel as shown in  FIG. 10 , the front panel being cut along a plurality of cutting axes, each cutting axis forming an angle φ with a front panel rear surface; 
         FIG. 12  is a top perspective view illustrating a plurality of filler members disposed within a frame assembly; 
         FIG. 13  is a top cutaway perspective view of a frame assembly having a window box disposed within a frame periphery, the front panel defining a window opening between the plurality of affixing members; 
         FIG. 14  is a top cutaway perspective view of a frame assembly having a plurality of window backstops disposed within the frame periphery adjacent the window opening; 
         FIG. 15  is a top cutaway perspective view of a frame assembly having a window box disposed within a frame periphery, the front panel including a front panel window cutout defining a cutout window opening; and 
         FIG. 16  is a top cutaway perspective view showing a prefabricated window disposed within a window opening formed within the front panel. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings wherein the showings are for purposes of illustrating a preferred embodiment of the present invention only, and not for purposes of limiting the same, there is shown a garage door  10  constructed in accordance with an aspect of the present invention. Referring specifically to  FIG. 1-3 , the garage door  10  includes a front panel  12  connected to a plurality of frame assemblies  32 . The front panel  12  defines a front panel forward surface  14  and a front panel rear surface  16 . The front panel  12  may be formed of a plurality of panel elements  20 . The panel elements  20  may be constructed out of a variety of materials, including wood, plywood, tongue and groove (e.g., cedar, knotty pine), or other materials known by those skilled in the art. As depicted in  FIG. 1 , the front panel  12  is constructed out of a plurality of tongue and groove members that engage with each other to collectively define the front panel  12 . In one embodiment, each panel element  20  is ⅝ inch in width. 
     The front panel  12  may be cut into several front panel members  18 . The process of cutting the front panel  12  into the front panel members  18  is described in more detail below. Each front panel member  18  defines a panel member front surface  22 , a panel member rear surface  24 , a panel member top surface  26 , and a panel member bottom surface  28 . 
     Referring now to  FIGS. 4-5 , the garage door  10  additionally includes a plurality of frame assemblies  32 . Each frame assembly  32  is connected to the panel member rear surface  24  of a respective one of the plurality of front panel members  18 . Each frame assembly  32  includes a pair of rails  36  disposed in spaced parallel relation to each other. Each rail  36  includes a rail inner surface  38 . The rail inner surfaces  38  are disposed in opposed relation to each other. 
     Each frame assembly  32  also includes a plurality of stiles  46 . Each stile  46  includes a pair of opposing stile end surfaces  48 , a pair of opposing stile inner surfaces  50 , a stile forward surface  52  and a stile rear surface  54 . Each one of the pair of opposing stile end surfaces  48  is attached to a respective one of the pair of rails  36  to form a plurality of frame opening peripheries  56 . As shown, the stile end surfaces  48  are connected to the rail inner surface  38  of a respective rail  36 . Each frame opening periphery  56  is defined by the opposing rail inner surfaces  38  and the opposing stile inner surfaces  50  of adjacent stiles  46 . Each frame opening periphery  56  defines a frame opening  58 . Windows  30  and other aesthetic elements may be disposed within the frame opening  58 , as described in more detail below. 
     According to one embodiment, the rails  36  and stiles  46  may be constructed out of a steel material. For instance, the rails  36  and stiles  46  depicted in the figures are comprised of hollow, square and rectangular, steel tubing. However, it is understood that other materials and configurations known by those skilled in the art may be used without departing from the spirit and scope of the present invention. 
     The rails  36  and stiles  46  may be joined by welded joints. In one embodiment, the stiles  46  may be joined to the rails  36  by a butt joint. However, other joining techniques known by those skilled in the art, such as a bevel joint, may also be used. The rails  36  and stiles  46  are completely welded and sealed to mitigate the formation of rust. Once the rails  36  are joined to the stiles  46 , all seams may be ground smooth to provide a smooth surface. 
     In order to enhance the structural integrity of each frame assembly  32  and to lengthen the life span thereof, additional measures may be taken to protect against rust forming on the frame assembly  32 . In order to protect against rust formation, the rails  36  and/or the stiles  46  may be powder coated. Various colors of powder coating may be applied to the rails  36  and stiles  46  in order to match the color of the frame assembly  32  with the remaining portions of the garage door  10 . 
     Each frame assembly  32  is connected to a respective one of the plurality of front panel members  18 . In order to facilitate this connection, each frame assembly  32  may include a plurality of affixing members  62  as best shown in  FIG. 6 . Each affixing member  62  may be connected to a respective one of the plurality of frame opening peripheries  56 . In one embodiment, four affixing members  62  are connected to each frame opening periphery  56 ; one on each opposing stile inner surface  50  and one on each opposing rail inner surface  38 . In one embodiment, the affixing members  62  are comprised of flashing, as best shown in  FIGS. 6-8 . The flashing may be constructed out of twenty six gauge aluminum steel. The flashing may be welded to the frame opening periphery  56 . The flashing may be welded every eight inches to securely fasten it to the frame opening periphery  56 . However, other securing techniques known in the art may also be used. Furthermore, each affixing member  62  may be powder-coated to mitigate rust formation thereon, as described above in relation to the frame assembly  32 . 
     According to one embodiment, the frame assembly  32  defines a frame assembly front surface  34 . Likewise, the affixing member  62  defines an affixing member front surface  64 . One aspect of the present invention includes offsetting the affixing member front surface  64  from the frame assembly front surface  34  by a distance “d.” In one embodiment, the distance d is equal to 1/16 of an inch. The offset allows the affixing member  62  to be pulled toward the panel member rear surface  24  when the affixing member  62  is attached to the front panel member  18 . 
     The garage door  10  further includes a plurality of fasteners  66  to connect a respective one of the plurality of frame assemblies  32  to a respective one of the plurality of front panel members  18 . The fasteners  66  may connect the affixing members  62  to a respective front panel member  18 . In one implementation of the present invention, the fasteners  66  include Number  8 , ⅝ inch hex head self tapping screws. It may be desirable to use a screw every two inches to securely fasten the frame assembly  32  to the front panel member  18 . 
     Each frame assembly  32  may be connected to the front panel  12  in such a manner so as to define a space between adjacent frame assemblies  32  as depicted in  FIG. 3 . This space defines a cutting channel  60  to allow the front panel  12  to be cut into separate front panel members  18 , as described in more detail below. 
     The garage door  10  may include a plurality of filler members  70  disposed within respective frame openings  58 . Each filler material  70  may be constructed out of Styrofoam or other insulating material. The filler member  70  may provide thermal insulation as well as sound insulation. In one implementation of the invention, each filler member  70  is comprised of 1¾ inch Styrofoam® and is inserted into each frame opening  58 . The filler member  70  defines a filler member periphery that is smaller than the frame opening periphery  56 . It may be desirable to have a ½ inch gap between the filler member periphery and the frame opening periphery  56  to allow for easy insertion of the filler member  70  into the frame opening periphery  56 . In other embodiments, the filler members  70  are sized and configured to be press-fit into the frame opening periphery  56  and maintained in place via frictional contact between the filler member  70  and the frame opening periphery  56 . 
     The filler members  70  may be maintained within the frame opening  58  by a rear panel member  72  that is connected to the frame assembly  32 . The rear panel member  72  may include a ¼ inch Luan panel covering each filler member  70  within a respective frame assembly  32 . The rear panel member  72  may be connected to the frame assembly  32  by a plurality of ½ inch self tapping truss screws. It may be desirable to use one screw every four inches to securely fasten the rear panel member  72  to the frame assembly  32 . 
     As previously mentioned, the garage door  10  may include a various aesthetic features to enhance the appearance thereof. Windows  30  are commonly incorporated into the design of a garage door  10  to enhance its aesthetic quality. It is contemplated that the window  30  may fit within the frame opening  58  of the frame assembly  32 . Referring now to  FIG. 13 , there is shown a garage door  10  having a window  30  that fits between the affixing members  62 . A window opening  76  is cut out of the front panel  12  between the affixing members  62 . A window box  78  is constructed and inserted within the respective frame opening  58 . According to one aspect of the invention, the window box  78  defines a window box periphery  79  that is ⅛ of an inch larger than the window opening  76 . The window  30  may be placed within the window box  78  and the ⅛ inch edge may act as a stop to prevent the window  30  from passing through the window opening  76 . 
     It is contemplated that the window box  78  is assembled from a plurality of window box elements  80 . The window box elements  80  may include  1  ½ inch by ⅝ inch lumber having slots which matingly engage with one another to form the window box  78  as shown in  FIG. 13 . One or more window back stops  82  may be inserted behind the window  30  to maintain the window  30  in place. 
     It is also contemplated that the garage door  10  may include a window  30  that may not fit between the affixing members  62 . In such an embodiment, the affixing members  62  are removed from the respective frame opening periphery  56 , or never attached thereto. A front panel window cutout  84  is removed from the front panel  12 , as shown in  FIG. 15 . The front panel window cutout  84  includes a cutout window opening  86 . A window box  78  is placed within the frame opening  58 . As described above, the window box periphery  79  is slightly larger than the cutout window opening  86  to provide a small edge which acts as a glass stop. It is contemplated that the front panel window cutout  84  may be connected to the frame assembly front surface  34  to maintain the front panel window cutout  84  in its proper position. For instance, connections members, such as screws, nails, rivets, etc., may be used to connect the front panel window cutout  84  to the frame assembly  32 . In another embodiment, the front panel window cutout  84  may be connected to adjacent portions of the front panel  12  to maintain the front panel window cutout  84  in its desired position. 
     It is contemplated that for larger windows  30  a window box  78  may not be needed. In the embodiment shown in  FIG. 14 , the window  30  is large enough to fit within the frame opening  58  without a window box  78 . As shown, a front panel window cutout  84  includes a cutout window opening  86  which is slightly smaller than the frame opening periphery  56 . In one embodiment, such a cutout window opening  86  is ⅞ of an inch smaller than the frame opening periphery  56 . Therefore, windows  30  that are larger than the cutout window opening  86 , but smaller than the frame opening periphery  56  may be placed within the frame opening periphery  56 . A plurality of window backstops  82  may be placed behind the window  30  to maintain the window  30  in place. Each window backstop  82  may be secured to the frame assembly  32 . 
     Referring now to  FIG. 16 , there is shown a garage door  10  configured to receive a prefabricated window frame  88 . A front panel window cutout  84  may be removed from the front panel  12  to create a cutout window opening  86  into which a prefabricated window frame  88  may be inserted into. In this manner, the affixing members  62  connected to the respective frame opening periphery  56  may be removed to allow the front panel window cutout  84  to be detached from the front panel  12 . The front panel window cutout  84  may be secured to the frame assembly front surface  34 . The cutout window opening  86  may be slightly larger than the prefabricated window frame  88  to allow the prefabricated window frame  88  to be inserted therein. The prefabricated window frame  88  may include frame flanges  90  to enable easy attachment of the prefabricated window frame  88  to the front panel window cutout  84 . 
     The garage door  10  may further include a plurality of pivot members  68  to enable pivotal movement between adjacent front panel members  18 . Each pivot member  68  is connected to adjacent ones of the plurality of frame assemblies  32  to enable pivotal movement between the same. 
     In addition to the foregoing, it is expressly contemplated that various aspects of the present invention additionally include a method of forming a garage door  10 . The method includes the steps of providing a front panel  12  having a front panel rear surface  16 . A plurality of rails  36  and stiles  46 , as described in more detail above, are also provided. The plurality of frame assemblies  32  are constructed from the rails  36  and stiles  46 . Each frame assembly  32  is constructed by attaching multiple ones of the plurality of stiles  46  between a pair of the plurality of rails  36 . The opposing stile end surfaces  48  are attached to a respective one of the rail inner surfaces  38  to form a plurality of frame opening peripheries  56 . The frame assemblies  32  may include affixing members  62  as described in more detail above. The affixing member front surface  64  may be offset from the frame assembly front surface  34  by a distance of 1/16 of an inch. 
     The frame assemblies  32  are then disposed adjacent the front panel rear surface  16 , as best shown in  FIG. 9 . Adjacent frame assemblies  32  are spaced apart to define a cutting channel  60 . One or more shims  74  may be disposed between adjacent frame assemblies  32  to create the cutting channel  60  between the adjacent frame assemblies  32 . The frame assemblies  32  may be fastened to the front panel  12 . In this manner, a respective fastener  66  may connect an affixing member  62  to the front panel rear surface  16 . The offset between the affixing member front surface  64  and the frame assembly front surface  34  allows the affixing member front surface  64  to be drawn toward the front panel rear surface  16  as the fastener  66  connects the affixing member  62  to the front panel  12 . 
     The method may also include the step of disposing filler members  70  within the frame openings  58  of the frame assemblies  32 . A rear panel member  72  may be connected to the frame assembly  32  to maintain the filler members  70  within the respective frame opening  58 . 
     After the frame assemblies  32  have been connected to the front panel  12 , the front panel  12  is cut along each cutting channel  60  to separate the front panel  12  into separate front panel members  18 . It may be desirable to cut the front panel  12  at a non-orthogonal angle φ to the front panel rear surface  16 , as shown in  FIG. 11 . In this manner, the panel member top surface  26  and/or the panel member bottom surface  28  is non-orthogonal to the panel member rear surface  24 . The front panel  12  may be cut along the cutting channel  60  along a cutting axis  92 . The cutting axis  92  may be non-orthogonal to the front panel rear surface  16 . In one embodiment, the cutting axis  92  is disposed approximately 70 degrees relative to the front panel rear surface  16 . The non-orthogonal orientation of the panel member top surface  26  and/or the panel member bottom surface  28  may mitigate natural elements from entering the garage. For instance, this unique angular engagement of the panel member bottom surface  28  of one front panel member  18  with the panel member top surface  26  of an adjacent front panel member  18  may further insulate the garage. 
     The method may also include connecting adjacent ones of the plurality of frame assemblies  32  with at least one pivot member  68  to enable pivotal movement between the respective frame assemblies  32 . Windows  30  may also be incorporated into the garage door  10 , as described in more detail above. 
     The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments.