Patent Publication Number: US-7210274-B2

Title: Door stile structure

Description:
BACKGROUND OF THE INVENTION 
   The present invention relates to a novel and useful door stile structure. 
   Modern doors are typically formed with a frame including vertical stiles spanned by horizontal rails. Muntins and panels may also lie within the frame formed by the stiles and rails. Skins are normally employed to enclose the stiles and rails leaving the panel surfaces visible for the sake of esthetics. 
   At least one of the stiles is employed to receive mounting hardware, such as hinges to rotatably hold the door to a jamb of a door opening. Fasteners such as screws are typically used to hold the hinges to the door stile, in this regard. Needless to say, the stile employed for mounting hinges must be constructed so as not to be displaced by the torque or moment generated by the weight of the door. 
   In the past, many types of door stiles have been proposed to form door structures. For example, U.S. Pat. Nos. 2,699,578, 4,265,067, 4,364,987, 5,448,869, and 5,737,890 describe door and window frame assemblies in which a stile of rectangular configuration is used as a base for supporting hardware. 
   U.S. Pat. No. 6,308,463 shows a hinge assembly which employs dowels that are imbedded in the core of the door to hold metallic fasteners used to mount hinges. 
   U.S. Pat. Nos. 3,798,863, 5,934,040, and 6,311,454 illustrate door constructions in which stile frame members are formed as interlocking pieces to enhance strength. 
   U.S. patent application Ser. No. 2002/0124497 shows a fire resistant door edge in which an intumescent strip seal is placed adjacent the stile holding the hinge hardware. 
   U.S. Pat. Nos. 435,313, 635,341, 3,254,592, and Publication WO 0231306 describe door stiles in which interlocking tongues in the form of mortis and tenon structures are used between the stile and the interior portions of the door to increase the sturdiness of the door unit. 
   U.S. Pat. Nos. 2,399,666, 3,950,894, 5,074,087 and 5,720,142 teach stile structure having notches or grooves for aiding in the interlocking of the stile to the skins of the door. 
   A door structure which includes a stile that resists separation from the door unit as a whole would be a notable advance in the building and construction field. 
   BRIEF SUMMARY OF THE INVENTION 
   In accordance with the present invention a novel and useful door stile structure is herein provided. 
   The door stile structure of the present invention utilizes an elongated member which extends between at least a portion of first and second skins in a sandwich configuration. The elongated member includes an outer surface having a first ridge, a second ridge, and recessed portion between the first and second ridges. The outer surface of the elongated member faces the first or second skin. A second surface similarly constructed may also be found on the elongated member to face the remaining skin. 
   Fixing means may be utilized to hold the elongated member between the first and second skins to form a door unit. Such fixing means may take the form of fasteners, glue layers, and the like. The certain instances the elongated member includes an extending intermediate surface located between the first and second ridges and forms the recessed portion. Such intermediate surface may meet the ridges at an angle which may be orthogonal or non-orthogonal. In addition, cavities may be formed on the intermediate surface of the recessed portion to accommodate or accept a portion of a glue layer which may be located between the elongated member and the first and/or second skins. 
   Another embodiment of the present invention employs a door stile formed from an elongated member positioned between the first and second skins and constructed with a narrow portion and a thick portion. The narrow and thick portions would be spanned or connected by a planar surface to form a wedge-like cross-sectional configuration. Where the fixing means takes the form of fasteners, gluing, and the like, the first and second skins would overlie the elongated member and form an edge. The first narrow portion of the elongated member would lie at the edge of the door unit and the think portion would lie within the door unit. 
   Yet another embodiment of the present invention takes the form of one elongated member which extends at least between a portion of the first and second skins which form an edge of a door unit. The one elongated member would lie inwardly from and substantially parallel to the edge of the door formed by the first and second skins in an embedded format. In certain instances, another elongated member may lie inwardly and substantially parallel to the edge of the door unit and be positioned further inwardly from the edge of the door unit than the one elongated member. In this manner, fasteners may engage the one and another elongated members, locked within the door unit to support of the mounting hardware of the door unit. 
   It may be apparent that a novel and useful door stile structure has been hereinabove described. 
   It is therefore an object of the present invention to provide a door stile structure which is extremely strong and resists forces tending to separate the door unit exerted by the door hardware. 
   Another object of the present invention is to provide a door stile structure in which a door stile takes a form which interacts with the skins forming the door unit to serve as a interlocking member. 
   A further object of the present invention is to provide a door stile structure in which a door stile interacts with the skins of the door and is susceptible to fixation by a glue layer. 
   Another object of the present invention is to provide a door stile structure in which cavities are formed on the door stile to strengthen a glue layer between the door stile and the skins forming the door unit. 
   A further object of the present invention is to provide a door stile structure which is adaptable for to usage in panel doors of various configurations without alternation of the form of the door stile itself. 
   The invention possesses other objects and advantages especially as concerns particular characteristics thereof which should become apparent as the specification continues. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
       FIG. 1  is a front elevational view of a door unit formed with the embodiment of the door stiles of the present invention depicted schematically, in phantom. 
       FIG. 2  is a sectional view taken along line  2 — 2  of  FIG. 1  showing a first embodiment of the present invention. 
       FIG. 3  is a sectional view similar to the one depicted in  FIG. 2  showing second embodiment of the door stile which may be employed with the door depicted in  FIG. 1 . 
       FIG. 4  is a sectional view similar to that depicted in  FIG. 2  in which third embodiment of the door stile is employed with to door depicted in  FIG. 1 . 
       FIG. 5  is a sectional view similar to that depicted in  FIG. 2  in which a fourth embodiment of a door stile is shown and may be used with the door depicted in  FIG. 1 . 
       FIG. 6  is a sectional view similar to that depicted in  FIG. 2  and illustrating a fifth embodiment of a door stile which may be employed with the door shown in  FIG. 1 . 
   

   For a better understanding of the invention reference is made to the following detailed description of the preferred embodiments thereof which should be referenced to the prior described drawings. 
   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION 
   Various aspects of the present invention will evolve from the following detailed description of the preferred embodiments thereof which should be taken in combination with the drawings heretofore described. 
   Preferred embodiments of the invention are depicted in the drawings by reference character  10  followed by an uppercase letter to denote variations thereof.  FIG. 1  depicts a door  12  including embodiments of the stiles door units  10 A– 10 E of the present invention depicted schematically in phantom,  FIGS. 2–6 . With respect to door unit  10 A, a panel door  12  includes skins  14  and  16  which are sandwiched to a stile  18 ,  FIGS. 1 and 2 . A single panel  20  is depicted in door  12  although it should be understood doors having multiple panels of opaque, and translucent materials may also be employed with the present invention. Hinges  22  and  24  have been fastened to panel door  12  and are capable of also fastening to a jamb of a doorway (not shown) to mount panel door  12  in place. 
   With further reference to  FIG. 2 , it may be observed that stile  18  and panel  20  are held in sandwiched configuration by skins  14  and  16  to form a door unit  10 A. Glue layers such as exemplar glue layer  26  represents means  28  for fixing or holding elongated member  18  between first and second skins  14  and  16 . Stile  18  is formed with a first narrow portion  30  and a second thick portion  32 . Planar surfaces  34  and  36  span narrow portion  30  and thick portion  32  of stile  18  in cross-sectional configuration. In other words, stile  18  appears to be a wedge shaped member in cross-sectional configuration which aids in the locking of the same to door unit  10  to resist the separation forces exerted between door unit  10 A and hinge  24 . It should be realized that hinge  24  may be employed in the hereinafter described door units  10 B– 10 E. 
   Turning to  FIG. 3 , another embodiment  10 B of the present invention is depicted. Door unit  10 B includes an elongated member or stile  38  which lies between portions of skins  40  and  42 . As shown in  FIG. 3 , stile  38  has been positioned into place but skin  42  is slightly separated from the remainder of door-oriented  10 B for the purpose of demonstrating assembly of unit  10 B. Directional arrow  44  indicates the movement of skin  42  in order to assemble unit  10 B. Again, glue layers may serve as means  28  for fixing or holding elongated member  38  to skins  40  and  42 . Exemplar glue layers  46  and  48  are depicted in  FIG. 3  in this regard. Elongated member or stile  38  possesses a “bowtie” cross-sectional configuration formed by a first ridge  50 , and second ridge  52  and a recess portion therebetween on one side of stile  38 . A similar structure exists on the other side of stile  38 . Recess portion  54  includes an extending surface  56  which meets ridges  50  and  52  at an angular configuration. In the embodiment  10 B depicted in  FIG. 3  such angular orientation of surface  56  relative to ridges  50  and  52  is a non-orthogonal one. A plurality of cavities  58  along surface  56  and opposite surface  60  serves to accommodate or accept glue from exemplar glue layers  46  and  48 . Cavities  58  add to the strength of door unit  10 B in its finished format. Edge portion  62  of stile  38  may be trimmed, directional arrow  63 , to lie flush with the edges  62  and  64  of skins  40  and  42 . 
   Referring now to  FIG. 4 , another embodiment  10 C of the structure is depicted. Skins  66  and  68  sandwich elongated stile member  70  therewithin. Again, ridges  72 ,  74 , and  76  are shown on one side of stile  70 . A similar arrangement appears on the other side  78  of stile  70 . Recesses  80  and  82  lie between ridges  72  and  70  and ridges  74  and  76 , respectively. A similar arrangement appears on side  78  of stile  70 . The surfaces forming recesses  80  and  82  meet ridges  72 ,  74 , and  76  at a right angle or orthogonally. Again exemplar glue layers  84  and  86  represent means  28  for holding skins  66 , and  68  to stile  70 . 
   With reference to  FIG. 5 , the embodiment  10 D is shown. Skins  88  and  90  surround elongated members  92  and  94  which serve as a stile for embodiment  10 D. That is to say, elongated members  92  and  94  lie inwardly from the edges  96  and  98  formed by skins  88  and  90 , respectively. Again glue layers such as glue exemplar layers  100 ,  102 , and  104  hold elongated members  92  and  94  in place. 
     FIG. 6  represents embodiment  10 E of the present invention which may be considered to be an alternate embodiment of  10 D of  FIG. 5 . Structure  10 E includes skins  106  and  108  which hold embedded elongated member or stile  110  in place. Again, stile  110  lies inwardly from edges  112  and  114  of skins  106  and  108 , respectively. Glue layers  116  and  118  serve as means  128  for fixing elongated member stile  110 , skin  106  and skin  108  together as a unit forming structure  10 E. 
   In operation, door structure  10 A– 10 E is formed by using a stile of a particular cross-sectional configuration illustrated in  FIGS. 2–6  between skins formed to snuggly hold the same in place. For example with respect to the embodiment depicted in  FIG. 2 , means  28  for holding skins  14  and  16  to stile  18  include glue layers  26 . Following assembly of door structures  10 A– 10 E, hinges  22  and  24  are attached as exemplified by hinge  24  in  FIG. 2 . Door units  10 A– 10 E are then ready for positioning to a jamb within a doorway for use. Doorknob  120  allows the user to open and close any one of the door units  10 A– 10 E. 
   While in the foregoing, embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such detail without departing from the spirit and principles of the invention.