Patent Publication Number: US-9885211-B2

Title: Door seal

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This Application is a Section 371 National Stage Application of International Application No. PCT/GB2013/000365, filed Aug. 30, 2013 the content of which is incorporated herein by reference in its entirety, and published as WO 2014/033424 on Mar. 6, 2014, in English. 
     FIELD OF THE DISCLOSURE 
     The present invention relates to a door seal and more especially to an improved automatic door seal that acts to seal the gap between the door and its threshold on closure of the door. 
     BACKGROUND OF THE DISCLOSURE 
     An automatic drop-down door seal developed by the Applicant is disclosed in WO2012/032295. The present invention relates to improvements to the door seal disclosed therein and specifically to provide an improved mechanism to impart a continual vertical pressure on the seal housing during use to retain the seal firmly against the adjacent surface in use. 
     SUMMARY 
     A first aspect of the invention provides a sealing assembly for a hinged door which is pivotable over a door threshold when closed, the sealing assembly comprising a plurality of elements located within a channel positionable adjacent an edge of the door, the elements comprising an actuator responsive to closing of the door, the actuator comprising at least one connector rod extending along the channel and being movable longitudinally within the channel in response to the door closing, the or each rod being connected to at least one pivotable arm comprising rigid sections divided by flexible joints, the other end of the arm being connected to a sealing member, the or each arm being flexible such that as the or each connector rod moves along the channel part of the arm flexes vertically thereby imparting and maintaining vertical pressure on the sealing member during use. 
     The or each arm may comprise at least one rigid section that comprises a recessed groove shaped so as to receive and retain a curved connector rod, which rod extends beyond the arm and is connected to a second arm. 
     The connector rod may be connected to the second arm by means of a first connector block which is connected to a further connector rod which is attached to the second arm. 
     The assembly may further comprise a spring member that is connected to the sealing member at one part thereof and to a second connector block at a second part thereof, which second connector block is fixed in position within the channel, the spring member being configured to pull or push the sealing member back when the actuator is deactivated. 
     The spring member may be a leaf-type spring member, substantially planar in profile. 
     The second connector block may comprise a recessed groove through which the connector rod passes between the first and second arms. 
     The or each arm may comprise first, second and third rigid sections divided by first and second flexible joints, the first rigid section being connected to the actuator and the third rigid section being connected to the sealing member. 
     Each rigid section of the arm may be formed of polypropylene. 
     The or each flexible section of the arm may be formed of TPE. 
     The or each flexible TPE section may be selected so as to melt in the presence of heat associated with a fire so as to substantially fuse and fix the arm in its current state. 
     A second aspect of the invention provides a sealing assembly for a hinged door which is pivotable over a door threshold when closed, the sealing assembly comprising: a plurality of elements located within a channel positionable adjacent an edge of the door, the elements comprising an actuator which mechanically moves responsive to closing of the door, the actuator comprising a first connector rod extending along the channel and being movable longitudinally within the channel, the first connector rod being connected to a drop arm comprising first, second and third substantially rigid sections divided by first and second flexible joints, the first rigid section being connected to the first connector rod and the third rigid section being connected to a sealing member, the drop arm being configured to flex at one or both flexible joint(s) as the first connector rod moves along the channel in order to impart and maintain a vertical force on the sealing member in use, and wherein a spring member is provided which is connected to the sealing member at one part thereof and to a fixed connector block within the channel at another part thereof in such a way as to pull/push the sealing member backwards into the channel when the actuator is deactivated. 
     A further aspect of the invention provides a sealing assembly for a hinged door which is pivotable over a door threshold when closed, the sealing assembly comprising a plurality of elements located within a channel positionable adjacent an edge of the door, the elements comprising an actuator responsive to closing of the door, the actuator comprising at least one connector rod extending along the channel and being movable longitudinally within the channel in response to the door closing, the or each rod being connected to at least one pivotable arm comprising rigid sections divided by flexible joints, the other end of the arm being connected to a sealing member, the or each arm being flexible as the or each connector rod moves along the channel to a position whereby the part of the arm flexes vertically thereby imparting and maintaining vertical pressure on the sealing member during use. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the invention will now be described with reference to the accompanying figures in which: 
         FIG. 1  is a perspective view of a door seal in accordance with the invention; 
         FIG. 2  is a side view of the assembly of  FIG. 1 ; 
         FIG. 3  is side sectional view of a cap nut of the spring assembly of  FIG. 1 ; 
         FIG. 4  is an end view of the cap nut of  FIG. 3 ; 
         FIG. 5  is a perspective view of a drop arm of the spring assembly of  FIG. 1 ; 
         FIG. 6  is perspective view of the drop arm of  FIG. 5  with a threaded push rod attached thereto; 
         FIG. 7  is a perspective view of lead rod to connect connector rods within the assembly of  FIG. 1 ; 
         FIG. 8  is a side cross section view of the drop arm and lead rod in connection; 
         FIG. 9  is a perspective view of the spring part of the assembly of  FIG. 1 ; 
         FIG. 10  is a perspective view of a connector block for connector rods of the assembly of  FIG. 1 ; 
         FIG. 11  is a perspective view of a connector rod; 
         FIG. 12  is an end sectional view of the door seal assembly of  FIG. 1 ; 
         FIG. 13  is an end sectional view of the casing of the seal mechanism of  FIG. 12 ; 
         FIG. 14  is an end sectional view of drop bar of the seal mechanism of  FIG. 12 ; 
         FIG. 15  is an end sectional view of a seal insert of the seal mechanism of  FIG. 12 ; and 
         FIG. 16  is an exploded view of a second embodiment door seal in accordance with the invention. 
         FIG. 17  illustrates four assemblies of differing lengths provided with different numbers of drop arms used (indicated by hashed circles). 
     
    
    
     DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
     The main elements of a drop-down seal are shown and described in WO2012/032295, corresponding to U.S. Pat. No. 8,925,250, the contents of which are hereby incorporated by reference. 
     The foregoing description will only discuss the improvements to such a system. 
       FIGS. 1 and 2  show a door seal constructed in accordance with a first embodiment of the invention. 
     The seal mechanism comprises a main housing  10  (see  FIGS. 12 and 13 ) which is locatable on the edge of a door (not shown) or which may be located within a recess formed in the edge of a door. 
     It has been found, for reasons explained later, that the seal mechanism is suitable for location on the top, as well as the bottom, of a door (as is traditional) or within a recess formed in the top or bottom of the door. 
     The main housing  10  may alternatively be fixed to the back of the door bottom or top. 
     The housing  10  is formed as an inverted U-shaped section and defines a longitudinal channel  12 . 
     Referring to  FIGS. 1 and 2 , extending through the housing  10  is a spring mechanism designed to impart a vertical force to a sealing member  32  on depression of an actuation button  22  that occurs when a door carrying the seal mechanism is closed. 
     The spring mechanism comprises an assembly of spring members  14 , first and second drop arms  16 A,  16 B and connecting rods  18 . The term “drop down” has been used throughout the description for convenience and ease of understanding as it is anticipated that the most common use will be in respect of sealing at the bottom of the door. No connotation should be implied by the term “drop” as the embodiment may be used in such a way that the arm extends upward in use. 
     Referring to  FIG. 1  and  FIG. 12 , a first slide block  20  is located at one end of the housing  10 . The block  20  is connected to the actuator button  22  which activates when the door closes, to slide the block  20  along the channel  12 . 
     A longitudinal cross section of the slide block  20  can be seen in  FIG. 3 . The slide block  20  is connected to the actuator button  22  via an adjustable hexagonal cap nut  24 , shown from one end in  FIG. 4 . 
     The other end of the block  20 , remote from the actuator button, is attached via a plunger rod  26  to the first drop arm  16 A. 
     The first drop arm  16 A is shown more clearly in  FIGS. 5 and 6  ( FIG. 6  showing the plunger rod  26  connected to the arm  16 A). The arm  16 A comprises three main sections  28 A,  28 B,  28 C made from rigid polypropylene separated by sections  29  made from flexible Thermoplastic Elastomer (TPE) to provide a rigid arm with, in this case, two flexible joints  29 . 
     The first rigid section  28 A of the arm  16 A includes an end-aperture to receive one end of the plunger rod  26  (to allow movement to be imparted to the arm  16 A). The third section  28 C of the arm  16 A has an aperture  30  to receive fastening means for securing that end  28 C of the arm  16 A to a sealing member  32  of the assembly. 
     A recessed groove  34  extends through part of the first and second rigid parts  28 A,B to receive a lead rod  36 . 
     The lead rod  36  is shown in  FIG. 7 . The rod  36  comprises an elongate threaded portion  38  and a curved portion  40 , which terminates with a generally U-shaped section. As can be seen in  FIG. 8 , the curved part  40  of the rod  36  extends into the groove  34  of the arm  16 A and the tip extends between a gap  42  formed in the first section  28 A of the arm  16 A and against an abutment surface  44  to prevent the tip of the rod  36  from being accidentally extracted from the groove  34 . 
     The threaded part  38  of the rod  36  receives a complimentary threaded part of a stainless steel connector rod  18 . The connector rod  18  then extends further into the housing channel (as will be described later). 
     As movement is imparted to the arm  16 A by the actuation button (left to right shown when referencing  FIG. 2 ), the second section  28 B of the arm  16 A flexes downwardly (upwardly if the seal is used in the top of the door) due to the fact that the third section  28 C remains in a fixed position secured to the sealing member  32 . The rigidity of the main sections  28 A,  28 B,  28 C of the arm  16 A causes movement of the arm  16 A to impart a vertical force to the sealing member  32 . A tipping point is reached at which state the vertical movement occurs. 
     As can be seen in  FIG. 2 , the first connector rod  18  extends beyond the first drop arm  16 A and through a recessed groove  48  formed in a fixed connector block  50  (see  FIG. 9 ) which is fixed in position within the channel  12  of housing  10  and provides a first spring assembly through connection to a spring member  14  that extends back from the connector block  50  to the sealing member  32  to which it is secured. 
     The spring member  14  acts to pull/push the sealing member  32  back into the housing  10  once the actuator button is deactivated (i.e. un-depressed) which happens when the door is opened. When closed again, the actuator button causes the arm  16 A to flex downwardly (as described above) which acts against the spring to force the sealing member  32  down. 
     Connector rods  18  extend through the channel  12  within the housing  10  all the way to a second drop arm  16 B, as shown in  FIGS. 1 and 2 , which in the same way as the first drop arm  16 A impart vertical force on the sealing member  32  at the location of the second drop arm  16 B as well as on the first  16 A. A plurality of connecting rods  18  are interconnected through the assembly via rigid polypropylene connector blocks  54  (see  FIG. 10 ). In the case of the embodiment shown in  FIGS. 1 and 2 , a first connector rod extends from the first drop arm  16 A to the connector block  54  and a second connector rod extends from the connector block to the second drop arm  16 B. 
     To this end, as can be seen in  FIGS. 10 and 11  the ends of the connector rods  18  are curved so to be received within apertures in recessed grooves  58  formed along the connector block  54  allowing two connector rods  18  to be received into the connector block  54  at either end so to maintain longitudinal movement throughout the assembly of connector rods  18  all the way to the second drop arm  16 B. 
       FIGS. 12 to 15  show end views, in cross section, of the sealing assembly. 
       FIG. 13  shows the profile of the housing  10 .  FIG. 14  illustrates the aluminium drop bar element  60  of the assembly. 
       FIG. 15  shows the sealing member  32  in the form of an EPDM (Ethylene-propylene-diene or Ethylene-propylene) insert. It will be appreciated that any other suitable rubber or rubber like material or non-rubber like material, e.g. aluminium, may be used for the seal, and in various shapes 
     The vertical force exerted on the drop bar element  60  and hence the seal member  32  by the flexing of each drop arm  16 A,  16 B is sufficient to push and retain the sealing member  32  against the adjacent surface to provide an effective acoustic seal around that edge of the door. Unlike prior common place drop-down seals, the seal assembly of the present invention does not rely on gravity to extend downwardly across the gap between the door edge and the floor. Rather, a vertical force is exerted by movement of the arms  16 A,  16 B on closure of the door. As such, the seal assembly of the present invention would be just as applicable as, for example, use in the top edge of the door whereby flexing of the arms  16 A,  16 B imparts a vertical upward movement against the door threshold. 
       FIG. 16  is an exploded view of a second embodiment door seal in accordance with the invention, which may also be useful for understanding the arrangement of components for the first embodiment. Related components between the first and second embodiments are shown with like reference numerals. 
     In the case of both embodiments, the flexible sections  29  of the drop arms  16 A,  16 B are made from a TPE material advantageously selected so that it will melt in the event of a fire thereby fusing the rigid sections in their current position. Therefore, if the sealing member  32  is extended vertically with pressure being applied by the drop arms  16 A,  16 B, that position will be maintained by the fusing of the drop arms&#39; flexible sections  29  due to the heat of the fire thereby providing resistance to smoke and heat. 
     The drop arms  16 A,  16 B can be injection moulded as a single piece assembly. The TPE joint connections allow the arm sections to bend while being extremely robust, making them difficult to tear or rip. The drop arms  16 A,  16 B provides greater flexibility allowing the downward (or upward) pressure of the sealing member  32  to compensate for uneven floors up to 6-7 mm. If compression of one flexible section is halted, the other flexible section can still compress to allow the arm to reach its desired depth. The flexible TPE joints allow the drop arms  16 A,  16 B to compress and stretch to allow for uneven floor conditions. 
     Although the above embodiments have been described in terms of two drop arms, it will be appreciated that further drop arms may be used to apply the necessary pressure to longer seal assemblies resulting in the lowering of the seal member across the seal.  FIG. 17  shows an example whereby four assemblies of differing lengths are provided with different numbers of drop arms used (indicated by hashed circles). 
     It will be appreciated that the foregoing are merely an examples of embodiments and just some examples of their use. The skilled reader will readily understand that modifications can be made thereto without departing from the true scope of the inventions.