Patent Abstract:
A support frame for a sliding door comprising upper and lower support members, and a side panel attachable so as to extend between said upper and lower support members, wherein the side panel comprises two panel portions that slide relative to each other and overlap to enable the distance between the upper and lower support members to be altered during installation of the support frame.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a 35 U.S.C §371 National Phase Filing claiming the benefit of and priority to International Application No. PCT/EP2008/060059, filed on Jul. 31, 2008, which claims the benefit of and priority to British (GB) Patent Application No. 0721836.5, filed on Nov. 7, 2007, the entire contents of each of which are incorporated herein by reference. 
     The present invention relates to a support frame for mounting a sliding door. In particular, the invention relates to a support frame for mounting a sliding door in a cavity of a partition wall. 
     Sliding doors are well known for enclosing a doorway formed in a wall or the like. Such doors are generally mounted by means of a sliding guide mechanism fitted to the upper and/or lower ends of a door which is received in a respective guide rail which forms a track along which the door slides. Traditionally, such tracks have extended parallel to a portion of the wall adjacent to the doorway and across the doorway such that the door can slide from an ‘open’ position, wherein the door locates along the wall, and a ‘closed’ position, wherein the door locates to cover the doorway. An advantage of such a door is that it reduces the floor space required to open and close the door. However, a problem with such a door is that, generally, it does not form a close fit with the doorway and so allows air draughts and sound to pass through the space formed therearound. Further, the door lies along the outer surface of the respective wall when it is ‘open’ such that furniture or the like cannot be located thereagainst. 
     The interior walls of modern buildings, such as residential houses, are generally formed from partition or stud walls. Such a partition wall is formed from a framework, generally of timber construction, extending between a ceiling, a floor and opposing walls to partition the interior space into separate rooms. Plasterboard is mounted to either side of the framework to enclose the framework therebetween and form a planar surface. With such an arrangement it will be understood that a cavity is formed internally within the walls between the opposing panels of plasterboard. Additionally, doorways are formed through the partition wall, by forming a necessary sized space in the framework which is then left uncovered by plasterboard. 
     Therefore, it is known to mount a sliding door within the internal cavity formed between opposing plasterboard panels. However, with such an arrangement, it is necessary to remove part of the framework of the wall to create a substantially sized space to receive a sliding door when it is in an ‘open’ position. Therefore, there is a problem in that it is necessary to provide a support frame to support the plasterboard and form part of the framework of the wall itself, as well as to support the guide tracks along which the door is guided as well as the door itself. 
     The space between the opposing plasterboard surfaces or the like is minimised so as to maximise the floor space of the adjoining rooms and so it is advantageous to minimise the size of the support frame itself. 
     Support frames are known which are generally formed from planar sheets of material, in particular steel, which extend between lower and upper support members to support the upper and lower support members and form a surface and to which plasterboard panels or the like may be mounted. A disadvantage of such an arrangement is that the planar sheets of material are not particularly rigid and so must be of a substantial thickness to reduce deflection and form a support frame. Additionally, buildings are not generally built to exact tolerances and so it is necessary to alter the size of the frame, and hence the panel. With conventional systems it is necessary to take precise measurements so that the frame can be made to measure. Alternatively, the components can be provided oversized and then cut to the desired measurement prior to installation. However, this necessitates the use of metal cutting implements such as an angle grinder and metal saws which an installer may not have readily available. 
     The present invention seeks to provide a support frame for mounting a sliding door that overcomes or substantially alleviates the problems with conventional systems referred to above. 
     SUMMARY 
     According to the present invention, there is provided a support frame for a sliding door comprising upper and lower support members, and a side panel attachable so as to extend between said upper and lower support members, wherein the side panel comprises two panel portions that slide relative to each other and overlap to enable the distance between the upper and lower support members to be altered during installation of the support frame. 
     Preferably, the panel portions have corrugations configured such that, when the panel portions overlap, the corrugations interlock to prevent movement of the panels relative to each other, other than sliding in a direction extending along the length of the corrugations. 
     Conveniently, the corrugations form a tenon and a corresponding mortise such that the corrugations on opposing panel portions interlock to form a dovetail joint. 
     The corrugations on each panel portion may form a plurality of tenons and mortises to interlock with a plurality of tenons and mortises formed on the opposing panel portion. 
     In one embodiment the support frame for a sliding door according comprises first and second panel portions, wherein the corrugations comprise a channel formed in the first portion of the side panel and a corresponding elongate ridge formed in the second portion of the side panel which is receivable in the channel such that the elongate ridge slides in the channel. 
     Preferably, the elongate ridge comprises a pair of side walls to locate in the channel, substantially parallel to a pair of side walls of the channel. 
     Advantageously, the elongate ridge interlocks with the channel, such that the first and second portions of the side panel are slidable relative to each other along a first direction only, but cannot be drawn away from each other in a second direction perpendicular to the first direction. 
     Preferably, the side walls of the channel converge towards a mouth of the channel and the side walls of the elongate ridge are correspondingly angled. 
     In a preferred embodiment, the elongate ridge is wedge-shaped for mounting in a correspondingly wedge-shaped channel so that a portion of the wedge-shaped elongate ridge dovetails with the channel and is slidable therein. 
     The support frame may further comprise a channel formed in the second portion of the side panel and a corresponding elongate ridge formed in the first portion. 
     Preferably, one side wall of the channel forms the side wall of an adjacent elongate ridge formed in each portion of the side panel. 
     The support frame may further comprise a plurality of alternating channels and elongate ridges formed in the first and second channels, each elongate ridge corresponding with a respective channel in the opposing portion of the side panel, wherein each elongate ridge is defined by adjacent channels in a side panel. 
     Preferably, the upper and lower support members are arcuately shaped and the first and second portions of the side panel are deformable to be fixedly mountable along the upper and lower support members respectively. 
     Conveniently, the support frame further comprises a plurality of corresponding first and second support portions fixedly mountable to the upper and lower support members respectively. 
     Preferably, a pair of side panels are attachable on opposing sides of said upper and lower support members so as to extend between said upper and lower support members. 
    
    
     
       DETAILED DESCRIPTION OF THE DRAWINGS 
       Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: 
         FIG. 1  is a side view of a support frame for a sliding door in accordance with the present invention; 
         FIG. 2  is a side view of a support frame for a sliding door as shown in  FIG. 1 , showing a sliding door supported thereon in a ‘closed’ position; 
         FIG. 3  is an exploded perspective view of the support frame for a sliding door as shown in  FIG. 1 ; 
         FIG. 4  is a cross-sectional view of a side panel of the support frame for a sliding door as shown in  FIG. 1  in accordance with an exemplary embodiment of the present invention; 
         FIG. 5  is a perspective view of the side panel as shown in  FIG. 4 ; 
         FIG. 6  is a perspective view of a pair of interlocking side panels as shown in  FIG. 5 ; 
         FIG. 7  is a side view of a support frame for a sliding door in accordance with another exemplary embodiment of the present invention, and 
         FIG. 8  is a perspective view of a support frame for a sliding door in accordance with yet another exemplary embodiment of the present invention, showing a sliding door supported thereon. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Referring now to the drawings, there is shown in  FIGS. 1 and 2  a sliding door assembly  1  comprising a support frame  2  and a sliding door  3 . The support frame  2  includes an upper support arrangement  4 , a sole plate  5 , an end support  6 , an end panel  7  and a pair of side panels  8 . The sliding door  2  is slidably mounted to the upper support arrangement  4  in this exemplary embodiment, although it will be understood that the invention is not limited thereto and may be mounted to the sole plate  5 . 
     Referring to  FIG. 3 , an exploded view of the support frame  2  is shown. The upper support arrangement  4  comprises an upper support member  10 , a guide track  11 , a door mounting  12  and an end stop  13 . The upper support member  10  is a beam which is shown in the drawings to be solid, but may have a box-shaped cross section, and extends substantially horizontally. The guide track  11  has a substantially C-shaped cross section comprising a base portion  14  with side portions  15 , 16  extending perpendicularly from the base portion  14  along a longitudinal plane of the base portion  14 , parallel to each other to form a longitudinally extending cavity  17 . Opposing return tabs (not shown) extend from the ends of the side portions  15 , 16 , distal to the base portion  14 , to define a longitudinally extending opening  19  to the cavity  17 , for reasons that will become apparent hereinafter. 
     The base portion  14  of the guide track  11  is fixedly mounted to a lower surface  20  of the upper support member  10  by known means such that the longitudinally extending opening  19  to the cavity  17  extends along the longitudinal axis of the upper support member  10 . The door mounting  12  comprises a sliding trolley mechanism (not shown) and a door hanging mounting  22 . The sliding trolley mechanism (not shown) is conventional and so no further discussion of it will be given in this specification. 
     The end panel  7  is a beam, wherein a longitudinally extending recess  25  is formed therein to extend along one side. The end panel  7  is fixedly mounted relative to one end of the upper support member  10  and extends vertically downwards therefrom. 
     The sole plate  5  has a substantially C-shaped cross-section and comprises a plate base  26  and flange portions  27 , 28  extending perpendicularly therefrom, parallel to each other. The sole plate  5  is disposed parallel to the upper support arrangement  4 . First and second side panels  8   a ,  8   b  are shown in  FIG. 3  and each side panel  8   a , 8   b  extends from the sole plate  5  to the upper support arrangement  4 . The first and second side panels  8   a ,  8   b  oppose each other and extend parallel to each other. Each side panel  8   a ,  8   b  is fixedly attached to a corresponding inner surface  29 , 30  of the respective flange portions  27 ,  28  of the sole plate  5 , and fixedly attached to a corresponding outer surface  31 , 32  of the upper support member  10  such that a space is defined between the first and second side panels  8   a , 8   b  for the sliding door  3  to be disposed therein. 
     Although in this embodiment a pair of first and second side panels  8   a , 8   b  are shown opposing each other, it will be understood that only a single side panel  8   a  may be used. 
     An end support  6  extends along one edge of each first and second end panel  8   a , 8   b  between the upper support member  10  and the sole plate  5  and is fixedly mounted thereto by known means. In this embodiment the first and second side panels  8   a , 8   b  extend substantially along the length of the sole plate  5 . The upper support member  10  and guide track  11  extend further than the sole plate  5  from the edge of the side panels  8   a , 8   b  to which the end support  6  is mounted and the end panel  7  extends from the corresponding end of the upper support member  10 . The upper support arrangement  4 , pair of end supports  6  and the end panel  7  therefore define a doorway. Further, the pair of end supports  7  define an opening to the space between the side panels  8   a , 8   b.    
     Although in this embodiment the sole plate  5  does not extend between the end panel  7  and the side panels  8   a , 8   b , in another embodiment it may do so. 
     The end stop  13  is formed from a resilient material and is mounted to the upper support member  10  proximate to the end panel  7  at the end of the guide track  11  such that the door hanging mounting  22  impacts thereupon. 
     Referring to  FIG. 6 , the side panels  8   a , 8   b  each comprise first and second panel portions  35 , 36 . Each panel portion  35 , 36  is formed from a rigid corrugated sheet, such as sheet steel, and extends along a plane to define a panel. The cross sectional shape of each panel portion  35 , 36  is shown in  FIGS. 4 and 5 . The cross-sectional shape of each panel portion  35 , 36  forms a number of alternating elongate channels  37  and elongate ridges  38  on each face  40 , 41  of the panel portion  35 , 36 , which extend parallel to each other along the panel portion  35 , 36 . 
     Each channel  37  formed in a face  40 , 41  of each panel portion  35 , 36  includes a base  42 , a mouth  43 , and opposing side walls  44 , 45  that taper from the base  42  towards the mouth  43  so that the width of the mouth  43  extending between the side walls  44 , 45  is less than the width of the base  42  extending between the side walls  44 , 45 , for reasons that will become apparent hereinafter. Each ridge  38  is formed between adjacent channels  37  and is formed by an outer surface  46  extending between ends  47  of opposing side walls  44 , 45  of each channel  37  such that each ridge  38  is defined by the outer surface  46  and opposing side walls  44 , 45  which taper from the base  42  of the channel  37  to the mouth  43  such that the width of the base  42  of each channel  37  is substantially the same as the width of the outer surface  46  of each ridge  38 . 
     The alternating ridges  38  and channels  37  formed in a first face  40  of each panel portion  35 , 36  form corresponding alternating elongate channels  37  and ridges  38  respectively on the opposing second face  41  of the panel portion  35 , 36 , wherein a ridge  38  formed on the first face  40  of the panel portion  35 , 36  defines a channel  37  on the opposing second face  41  of the panel portion  35 , 36 , and a channel  37  formed on the first face  40  of the panel portion  35 , 36  defines a ridge  38  on the opposing second face  41  of the panel portion  35 , 36  With such a panel portion  35 , 36  with the above described cross sectional shape, each elongate ridge  38  defines a tenon which corresponds to a dovetail of the channel  37 . Such a panel as described above is inherently very strong and has a low deflection along its length. 
     The elongate ridges  38  of the first panel portion  35  are slidable in the elongate channels  37  of the second panel portion  36 , as shown in  FIG. 6 , such that the base  42  of each channel  37  is locatable relative to the outer surface  46  of each respective elongate ridge  38  of the opposing panel portion  35 , 36  and the side walls  44 , 45  of the first panel portion  35  are relative to the side walls  44 , 45  of the second panel portion  36  and subtend thereagainst such that the first and second panel portions  35 , 36  are located against each other and cannot be drawn away from each other in a direction perpendicular to the longitudinal axis of the elongate channels  37  and ridges  38 . 
     One advantage of the support frame  2  described above is that the first and second panel portions  35 , 36  cannot deflect relative to each other because if a force is applied to a side of the panel portions  35 , 36  then the opposing side walls  44 , 45  of the channel  37  and ridge  38  act against each other and therefore are held rigidly thereagainst. The panel portions  35 , 36  therefore interlock with each other. This reduces the number of locking bolts (not shown), for example, that are required to prevent movement of the panel portions relative to each other as will become apparent below. 
     Corresponding holes (not shown) are formed through each of the first and second panel portions  35 , 36  at regular intervals therealong such that they can be aligned with each other dependent on the desired height of the side panel  8   a , 8   b . Alternatively, the panel portions  35 , 36  are set to the desired position and a drill may be used to drill through the panel portions  35 , 36  to form aligned holes. Locking bolts (not shown) are disposed through the aligned holes to mount respective panel portions  35 , 36  to each other. In this embodiment the locking bolts comprise a flat headed portion with a threaded shank extending therefrom. The threaded shank is disposed through respectively aligned holes formed in both the first and second plate portions and a locking nut is threadingly engaged thereon. In this embodiment a pair of locking bolts are used, although the invention is not limited thereto. One advantage of utilising locking bolts is that they can be removed if the support frame  2  is to be disassembled, or the height of the door  3  adjusted. 
     Although the use of locking bolts and corresponding holes is described above, it will be understood that the invention is not limited thereto. In an alternative embodiment, it will be understood that the first and second plate portions may be fixedly mounted together by means of any suitable fixing means, for example, welding, rivets or a clamp. 
     Although in the above illustrated embodiment the side panels  8  have a particular cross sectional shape, it will be understood that the invention is not limited thereto and that the panel may form an alternative corrugated shape, for example, an arcuate wave-form shaped cross-section. 
     Assembly of the support frame  2  for the sliding door  3  will now be discussed with reference to  FIGS. 1 ,  3  and  6 . 
     The upper support arrangement  4  is mounted to a required upper surface, such as a beam, and the sole plate  5  is mounted to a respective lower surface by known means. The upper support arrangement  4  and sole plate  5  are disposed parallel to each other. The elongate ridges  38  are slid into the channels  27  of the first and second panel portions  35 , 36  such that the first and second panel portions  35 , 36  are interlocked with each other to form a panel  8   a . The first and second panel portions  35 , 36  are slid with respect to each other to set the height of the panel and are then fixedly mounted to each other as described above. The corresponding second panel  8   b  is then formed to the same height by adjusting corresponding first and second panel portions  35 , 36  thereof. 
     Each panel  8   a , 8   b  is then mounted at one end to the respective inner surface  29 , 30  of the flange of the sole plate  5 , and to the outer surface  31  of the upper support arrangement  4  such that they are securely mounted thereto. 
     The sliding trolley mechanism (not shown) is received through the opening  19  of the guide track  11  such that it is supported by the opposing return tabs (not shown) of the guide track  11  and is slidable therealong, to abut against the end stop  13 . The end panel  7  is mounted to a distal end of the upper support member and is disposed to define one side of a doorway. Similarly, the pair of end supports  6  are fixedly mounted to opposing edges of the side panels  8   a , 8   b , to define an opposing side of the doorway, and to define an opening to the cavity defined by the side panels  8   a , 8   b , the upper support member  10  and the sole plate  5 . 
     A door  3  is mounted at an upper end to the door hanging mounting  22  by known means, such that it is slidable with the door mounting when the sliding trolley mechanism (not shown) slides in the guide track  11 . Herein, the door  3  is slidable through the opening defined by the pair of end supports  8  between an open position and a closed position. The door  3  is guided by the end supports  6  and is received in the recess  25  formed in the end panel  7  when the door  3  is closed. 
     A further exemplary embodiment of the invention will now be described with reference to  FIG. 7 . The main features of this embodiment are generally the same as those described in the embodiment discussed above, and so no further description of them will be given here. However, in this embodiment the support frame  2  comprises a plurality of side panels  50   a , 50   b , 50   c  mounted on each side of the sole plate  5  and upper support member  10 . Each side panel  50   a , 50   b , 50   c  is formed from first  51   a , 51   b , 51   c  and second  52   a , 52   b , 52   c  panel portions. This embodiment has an advantage in that the width of the support frame  2  may be altered by varying the distance between adjacent side panels  50   a , 50   b , 50   c.    
     A further exemplary embodiment of the invention will now be described with reference to  FIG. 8 . The main features of this embodiment are generally the same as those described in the embodiment discussed above, and so no further description of them will be given here. 
     One advantage of the side panels  8   a , 8   b  discussed above is that, although they are substantially rigid and have a low deflection along their length defined by the elongate channel, they are relatively flexible in a perpendicular direction thereto. The present embodiment comprises an arcuate upper support arrangement  53  and an arcuate sole plate  54 . Side panels are deformed about an axis parallel to the elongate channels  55  and ridges  56  such that a first panel portion  57  of the side panel  8   a , 8   b  is fixedly mounted to the arcuate upper support member  53  along one edge and a second panel portion  58  is fixedly mounted to the arcuate sole plate  54  along one edge. Such a support frame means that an arcuate sliding door may be utilised. 
     Although the exemplary embodiments discussed above describe doors formed in vertical walls, it will be understood that the invention is not limited thereto and may be utilised in horizontal surfaces, such as floors or ceilings. 
     Although embodiments of the invention have been shown and described, it will be appreciated by those skilled in the art that these are preferred embodiments only and that changes may be made to these embodiments, or alternative embodiments are included, within the scope of the invention which is defined in the claims hereafter.

Technology Classification (CPC): 4