Abstract:
A method for forming garage door components, the method including: (a) vacuum forming a combination of a retainer combined with the formation of a decorative insert vacuum formed within the retainer, the decorative insert removed from the retainer to provide a separate retainer and a separate decorative insert, by forming them together, the interior of the vacuum formed piece is used as the decorative insert instead of being thrown away as in prior art vacuum forming processes thereby saving wasting the interior vacuum formed material. There is also a garage door panel including an interior retainer retaining a glass plate on its rear surface, and inserted into an opening in a garage door panel and a window frame inserted into the garage door panel on its opposite side to retain the glass plate by its front surface. A decorative insert is retained between the glass plate and the window frame.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to the field of garage doors and in particular to garage door frames and retainers which retain a glass panel between them and to decorative inserts affixed to the front of the retainer and in front of the glass panel to provide an aesthetic appearance to the garage door. 
     2. Description of the Prior Art 
     In the prior art, the plastic retainer is formed a by a vacuum formed process and the retainer is cut out from the final product. The interior of the retainer and the exterior circumference of the retainer are discarded, resulting in a lot of wasted material. The decorative inserts are also separately vacuum formed in a separate process and excess material is cut away, resulting in even more waste of material. 
     There is a significant need for a more cost effective way to produce the retainer and decorative insert to create a complete garage door panel. 
     SUMMARY OF THE INVENTION 
     The present invention is a method for forming garage door components, the method including: (a) vacuum forming a combination of a retainer combined with the formation of a decorative insert vacuum formed within the retainer, the decorative insert removed from the retainer to provide a separate retainer and a separate decorative insert, by forming them together, the interior of the vacuum formed piece is used as the decorative insert instead of being thrown away as in prior art vacuum forming processes thereby saving wasting the interior vacuum formed material; (b) the separate retainer is cut to include an elevated sidewall including parallel first and second lengthwise sidewalls and parallel first and second transverse walls and an interior recessed shelf with surfaces which correspond to the walls of the elevated sidewall, including a first lengthwise surface is aligned with the first lengthwise sidewall, a second lengthwise surface is aligned with the second lengthwise sidewall, a first transverse surface aligned with first transverse wall, a second transverse surface aligned with second transverse wall; (c) the interior recessed shelf is formed of sufficient thickness to pass through a garage door panel having a rear wall and interior foam of the given thickness; (d) there is further formed a multiplicity of stiffening ribs including parallel transverse ribs respectively center positioned to support first transverse surface and first transverse wall, and second transverse surface and second transverse wall, at least one stiffening rib to support first lengthwise surface and first lengthwise sidewall, and at least one stiffening rib to support second lengthwise surface and second lengthwise sidewall; (e) the interior recessed shelf is formed with four respective interior surfaces which correspond with a respective first lengthwise surface, first transverse surface, second lengthwise surface and second transverse surface; (f) adjacent the rear surfaces of interior recessed shelf is formed with an interior protruding shelf with protruding first and second lengthwise surface and first and second width-wise surfaces; and (g) a decorative insert is cut away from the interior of the retainer, the decorative insert has an exterior sidewall with parallel first and second lengthwise walls and first and second parallel transverse walls with n central interior lengthwise wall and at least one interior transverse wall which divide the decorative insert into a multiplicity of separate openings through which glass is visible. 
     Described more broadly, the present invention is a method for forming garage door components, the method including: (a) vacuum forming a combination of a retainer combined with the formation of a decorative insert vacuum formed within the retainer, the decorative insert removed from the retainer to provide a separate retainer and a separate decorative insert, by forming them together the interior of the vacuum formed piece is used as the decorative insert instead of being thrown away as in prior art vacuum forming processes thereby saving wasting the interior vacuum formed material; (b) the separate retainer is cut to include an elevated sidewall including parallel first and second lengthwise sidewalls and parallel first and second transverse walls and an interior recessed shelf with surfaces which correspond to the walls of the elevated sidewall, including a first lengthwise surface is aligned with the first lengthwise sidewall, a second lengthwise surface is aligned with the second lengthwise sidewall, a first transverse surface aligned with first transverse wall, a second transverse surface aligned with second transverse wall; (c) the interior recessed shelf is formed with four respective interior surfaces which correspond with a respective first lengthwise surface, first transverse surface, second lengthwise surface and second transverse surface; (d) adjacent the rear surfaces of interior recessed shelf is formed with an interior protruding shelf with protruding first and second lengthwise surfaces and first and second width-wise surfaces; and (e) a decorative insert is cut away from the interior of the retainer, the decorative insert has an exterior sidewall with parallel first and second lengthwise walls and first and second parallel transverse walls with a central interior lengthwise wall and at least one interior transverse walls which divide the decorative insert into a multiplicity of separate openings through which glass is visible. 
     In the first method described above, the retainer is used for garage door panels which are thicker because they have foam inside the garage door panel, which makes them stronger for a thicker recessed shelf which extends through a thick garage door interior. In the second method described above, the retainer is thinner because it does not need the stiffening ribs and is used with a garage door panel which is thinner because it has no insulation within the garage door panel. In the second method described above, to be used for a garage door panel with insulation, the method would further include (a) the interior recessed shelf of the retained is formed of sufficient thickness to pass through a garage door panel having a rear wall and interior foam of the given thickness; and (b) there is further formed in the retainer a multiplicity of stiffening ribs including parallel transverse ribs respectively center positioned to support first transverse surface and first transverse wall, and second transverse surface and second transverse wall, at least one stiffening rib to support first lengthwise surface and first lengthwise sidewall, and at least one stiffening rib to support second lengthwise surface and second lengthwise sidewall. 
     The present invention also is components for a garage door panel, including: (a) a garage door panel including a first wall, a second parallel wall, a third wall and a fourth parallel wall, the walls having a given thickness and a common front surface and a common rear surface, the walls surrounding a recessed shelf with four surfaces with two adjacent surfaces being perpendicular to each other and which are respectively aligned with a respective wall of the garage door panel, the recessed shelf and the four walls of the garage door panel surrounding an interior opening; (b) a window frame having four walls with two adjacent walls being perpendicular to each other and having a common front surface and a common rear surface, the window frame having a recessed surface having four surfaces which are respectively aligned with a respective window frame wall, the window frame inserted into the opening in the garage door panel so that the four recessed surfaces respectively fit within the opening and respectively rest adjacent recessed surfaces of the recessed shelf of the garage door panel, and the common rear surface of the frame walls respectively rest on the recessed surfaces of the shelf of the window frame and also respectively rest adjacent the garage door panel walls, the recessed surfaces respectively have recessed rear surfaces; © a glass plate has a front surface which is press fit against common rear surfaces of the recessed shelf of the window frame, the glass plate having a rear surface; (d) a separate retainer including an elevated sidewall including parallel first and second lengthwise sidewalls and parallel first and second transverse walls and an interior recessed shelf with surfaces which correspond to the walls of the elevated sidewall, including a first lengthwise surface is aligned with the first lengthwise sidewall, a second lengthwise surface is aligned with the second lengthwise sidewall, a first transverse surface aligned with first transverse wall, a second transverse surface aligned with second transverse wall; (e) the interior recessed shelf is formed with four respective interior surfaces which correspond with a respective first lengthwise surface, first transverse surface, second lengthwise surface and second transverse surface; (f) adjacent the rear surfaces of interior recessed shelf is formed with an interior protruding shelf with protruding first and second lengthwise surface and first and second width-wise surfaces; (g) a decorative insert has an exterior sidewall with parallel first and second lengthwise walls and first and second parallel transverse walls with a central interior lengthwise wall and at least one interior transverse wall which divides the decorative insert into a multiplicity of separate openings through which the glass plate is visible; (h) the retainer is inserted from the rear of the door panel so that protruding rear surfaces of protruding interior shelf are pressed against the rear surface of the glass plate and therefore, the glass plate is trapped and retained between the protruding rear surfaces of interior protruding shelf and just below a screw line of the rear surfaces of the interior recessed shelf and the common rear surfaces of the recessed shelf; and a multiplicity of fastening screws are screwed through interior recessed shelf and its surfaces and through corresponding rear surfaces and screwed into the common rear surfaces of frame walls so that the fastening members are not visible from common front surface of the frame walls; and (j) the decorative insert is inserted into a small gap between the glass plate and the recessed surfaces of the frame through edges of the decorative insert so that the glass plate is visible through decorative insert openings. 
     The above garage door panel is thin because it has no insulation. If the garage door panel has insulation, the retainer would have to be thick to accommodate the extra thickness the foam adds to the garage door panel. In that case, the components of the garage door panel would also include: (a) the interior recessed shelf is formed of sufficient thickness to pass through a garage door panel having a rear wall and interior foam of the given thickness; and (b) there is further formed a multiplicity of stiffening ribs including parallel transverse ribs respectively center positioned to support first transverse surface and first transverse wall, and second transverse surface and second transverse wall, at least one stiffening rib to support first lengthwise surface and first lengthwise sidewall, and at least one stiffening rib to support the second lengthwise surface and second lengthwise sidewall. 
     Further novel features and other objects of the present invention will become apparent from the following detailed description, discussion and the appended claims, taken in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Referring particularly to the drawings for the purpose of illustration only and not limitation, there is illustrated: 
         FIG. 1  is a front perspective view of the completed vacuum formed combination of the present invention insulated retainer and decorative insert for a long panel garage door window section; 
         FIG. 2  is a front perspective view of the cut out vacuum formed insulated retainer cut from the competed vacuum formed insulated retainer and decorative insert illustrated in  FIG. 1 ; 
         FIG. 3  is a front perspective view of the cut out vacuum formed decorative insert cut from the competed vacuum formed insulated retainer and decorative insert illustrated in  FIG. 1 ; 
         FIG. 4  is a rear perspective view of the cut out vacuum formed decorative insert cut from the competed vacuum formed insulated retainer and decorative insert illustrated in  FIG. 1 ; 
         FIG. 5  is a front perspective view of a completed short panel door size garage door panel incorporating the present invention which includes the garage door, frame, insulated retainer, plate of glass and decorative insert; 
         FIG. 6  is a rear perspective view of a completed short panel door size incorporating the present invention which includes the garage door, frame, insulated retainer, plate of glass and decorative insert; 
         FIG. 7A  is a rear exploded view of a portion of the improved cost effective garage door window assembly incorporating the present invention which includes the insulated retainer and a plate of glass; 
         FIG. 7B  is a continuation of  FIG. 7A  and is a rear exploded view of the improved cost effective garage door window assembly incorporating the present invention which includes the sample panel size garage door section, the front window frame and the decorative insert; 
         FIG. 8A  is a front exploded view of a portion of the improved cost effective garage door window assembly incorporating the present invention which includes the insulated retainer and a plate of glass; 
         FIG. 8B  is a continuation of  FIG. 8A  and is a front exploded view of the improved cost effective garage door window assembly incorporating the present invention which includes the sample panel size garage door section, the front window frame and the decorative insert; 
         FIG. 9  is a front perspective view of the alternative embodiment of a formed part before cutting and separating the non-insulated retainer and decorative insert; 
         FIG. 10  is a rear perspective view of the alternative embodiment of a formed part before cutting and separating the non-insulated retainer and decorative insert; 
         FIG. 11  is a front perspective view of a cut out vacuum formed non-insulated retainer; 
         FIG. 12  is a front perspective view of a decorative insert to be used with a non-insulated or insulated retainer; 
         FIG. 13  is a front perspective view of an alternative embodiment of a completed sample panel size garage door section incorporating the present invention door section, front window frame, non-insulated retainer, plate of glass and decorative insert; and 
         FIG. 14  is a rear perspective view of the alternative embodiment of a completed sample panel size garage door section incorporating the present invention door section, front window frame, non-insulated retainer, plate of glass and decorative insert. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Although specific embodiments of the present invention will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention. Various changes and modifications obvious to one skilled in the art to which the present invention pertains are deemed to be within the spirit, scope and contemplation of the present invention as further defined in the appended claims. 
     Referring to  FIG. 1 through 4 , a component of the present invention is the method of vacuum forming the combination  10  of a retainer  20 , whether insulated or non-insulated combined with the formation of the decorative insert  50 . The combination  10  vacuum formed retainer  20  and decorative insert  50  is illustrated in  FIG. 1 . The retainer  20  is formed by vacuum forming. In the prior art, the interior plastic vacuum formed piece  13  where the decorative insert  50  is located is a blank piece of plastic which is cut away from the retainer  20 . The exterior vacuum formed section  15  is also discarded. The retainer  20  as illustrated in  FIG. 2  remains. Also referring to  FIG. 8A , the retainer  20  has an elevated sidewall  22  including parallel lengthwise walls  24  and  26  and parallel transverse walls  28  and  30  with respective interior surfaces  24 A,  26 A,  28 A and  30 A. The retainer  20  has an interior recessed shelf  32  with surfaces which correspond to the walls of the elevated sidewall  22 . Lengthwise surface  34  is aligned with lengthwise sidewall  24 . Lengthwise surface  36  is aligned with lengthwise sidewall  26 . The interior recessed shelf  32  is of sufficient thickness to accommodate the garage door insulation. Transverse surface  38  is aligned with transverse wall  28 . Transverse surface  40  is aligned with transverse wall  30 . A multiplicity of stiffening ribs including parallel transverse ribs  21  and  23  are respectively center positioned to support transverse surface  38  and transverse wall  28 , and transverse surface  30  and transverse wall  40 . Four spaced apart stiffening ribs  25 ,  27 ,  29  and  31  support lengthwise surface  34  and lengthwise sidewall  24 . Four spaced apart stiffening ribs  33 ,  35 ,  37  and  39  support lengthwise surface  36  and lengthwise sidewall  26 . Interior recessed shelf  32  has four respective interior surfaces  34 A,  36 A,  38 A and  40 A respective corresponding surfaces  34 ,  36 ,  38  and  40 . Adjacent rear surface  34 A,  36 ,  38 A and  40 A of interior recessed shelf  32  is a small interior protruding shelf  42  with protruding rear surfaces  41 ,  43 ,  45  and  47 . 
     A key innovation of the present invention is to form the decorative insert  50  as illustrated in  FIG. 1  in place of the discarded plastic section  22 . The decorative insert  50  is cut away from the retainer  20  and is illustrated in  FIGS. 3 and 4 . As a result, there is a significant cost saving of plastic material because the plastic interior  12  which in the past was discardedis instead formed into the decorative insert  50 . The decorative inset  50  has an exterior sidewall  52  with parallel lengthwise walls  54  and  56  and parallel transverse walls  58  and  60 , with a central interior lengthwise wall  62  and three evenly spaced apart interior transverse walls  64 ,  66  and  68  which divide the decorative insert  50  into eight (8) separate openings  51 ,  53 ,  55 ,  57 ,  59 ,  61 ,  63  and  65 , through which glass is visible. 
     A shorter four (4) panel section is illustrated in  FIGS. 5 through 8B . The garage door panel  100  has a first wall  102 , a second parallel wall  104 , a third wall  106  and a fourth parallel wall  108 , the walls having a given thickness to retain insulating foam  110  (see  FIG. 7B ) and the walls surround a recessed shelf  121  with surfaces  122 ,  124 ,  126  and  128  which are respectively aligned with walls  102 ,  104 ,  106  and  108  with a common front surface  112  and common rear surface  114  and which surround an opening  120 . The walls  102 ,  104 ,  106  and  108  have the common front surface  112  and a common rear surface  114 . 
     A window frame  130  has four walls  132 ,  134 ,  136  and  138  with a common front surface  140  and a common rear surface  160 . The frame has a recessed surface  150  with surfaces  152 ,  154 ,  156  and  158  which are respectively aligned with the four walls  132 ,  134 ,  136  and  138 . The window frame  130  is inserted into opening  120  so that the four recessed surfaces  152 ,  154 ,  156  and  158  respectively fit within opening  120  and respectively rest adjacent recessed surfaces  122 ,  124 ,  126  and  128  of shelf  121  and frame walls common rear surface  160  of frame walls  132 ,  134 ,  136  and  138  respectively rest on recessed surfaces  122 ,  124 ,  126  and  128  and shelf  121 , also respectively rest adjacent garage door panel walls  102 ,  104 ,  106  and  108 . Recessed surfaces  152 ,  154 ,  156  and  158  have a given thickness to accommodate the insulation  110 . Recessed surfaces  122 ,  124 .  126  and  128  respectively have recessed rear surfaces  122 A,  124 A,  126 A and  128 A. 
     A glass plate  170  has a front surface  172  which is press fit against common rear surfaces  122 A,  124 A,  126 A, and  128 A of recessed shelf  121  and its surfaces  122 ,  124 ,  126  and  128  window frame  130 . The glass plate has a rear surface  174 . The retainer  20  is inserted from the rear of the door panel so that protruding rear surfaces  41 ,  43 ,  45  and  47  of protruding interior shelf are pressed against the rear surface  174  of the glass plate  170 . Therefore, the glass plate  170  is trapped and retained between the protruding rear surfaces  41 ,  43 ,  45  and  46  of interior protruding shelf  42  and just below the screw line of rear surfaces  34 A,  36 A,  38 A and  40 A of interior recessed shelf  32  and the common rear surfaces  122 A,  124 A,  126 A and  128 A of recessed shelf  121 . 
     A multiplicity of fastening members such as screws  180 ,  182 ,  184 ,  186 ,  188 ,  190 ,  192 ,  194 ,  196 ,  198  and  199  are screwed through interior recessed shelf  32  through corresponding rear surfaces  34 A,  36 A,  38 A and  40 A and its corresponding front surfaces  34 ,  36 ,  38  and  40  and screwed into the common rear surfaces of  160  of frame walls  132 ,  134 ,  136  and  138  so that the fastening members are not visible from common front surface  140  of frame walls  132 ,  134 ,  136  and  138 . Interior recessed shelf if of sufficient thickness to accommodate the insulation  110 . The decorative insert  50  is inserted into a small gap “G 1 ” between the glass plate  170  and recessed surfaces  152   154 ,  156  and  158  of frame  150  through the edges  54 A,  56 A,  58 A and  60 A of its sidewall  54 ,  56 ,  58  and  60  so that the glass plate  170  is visible through decorative insert openings. The completed assembly is illustrated in  FIGS. 5 and 6 . 
       FIGS. 9 through 12  illustrate the same embodiment but with a non-insulated retainer which is thinner since it does not have to accommodate any insulation thickness in a garage door. Referring to  FIG. 9 through 12 , a component of the present invention is the method of vacuum forming the combination  310  of a retainer  320 , whether insulated or non-insulated combined with the formation of the decorative insert  350 . The combination  310  vacuum formed retainer  320  and decorative insert  330  is illustrated in  FIG. 10 . The retainer  320  is formed by vacuum forming. In the prior art, the interior plastic vacuum formed piece  313  where the decorative insert  320  is located is a blank piece of plastic which is cut away from the retainer  320 . The exterior vacuum formed section  315  is also discarded. The retainer  320  as illustrated in  FIG. 11  remains. The retainer  320  has an elevated sidewall  322  including parallel lengthwise walls  324  and  326  and parallel transverse walls  328  and  330  with respective interior surfaces  324 A,  326 A,  328 A and  330 A. The retainer  320  has an interior recessed shelf  332  with surfaces which correspond to the walls of the elevated sidewall  322 . Lengthwise surface  34  is aligned with lengthwise sidewall  324 . Lengthwise surface  336  is aligned with lengthwise sidewall  326 . The interior recessed shelf  332  is thinner than recessed shelf  32  since it does not require a certain sufficient thickness because there is no garage door insulation. Transverse surface  338  is aligned with transverse wall  328 . Transverse surface  340  is aligned with transverse wall  330 . Since it is thinner, the retainer  320  does not require the multiplicity of stiffening ribs found in the thicker retainer  20  which needed to be of sufficient thickness to accommodate the insulation of a garage door. Interior recessed shelf  332  has four respective interior surfaces  334 A,  336 A,  338 A and  340 A respective corresponding surfaces  334 ,  336 ,  338  and  340 . Adjacent rear surface  334 A,  336 ,  338 A and  340 A of interior recessed shelf  332  is a small interior protruding shelf  342  with protruding rear surfaces  341 ,  343 ,  345  and  347 . 
     A key innovation of the present invention is to form the decorative insert  350  as illustrated in  FIG. 9  in place of the discarded plastic section. The decorative insert  350  is cut away from the retainer  320  and is illustrated in  FIG. 12 . As a result, there is a significant cost saving of plastic material because the plastic interior which in the past was discarded is instead formed into the decorative insert  350 . The decorative inset  350  has an exterior sidewall  352  with parallel lengthwise walls  354  and  356  and parallel transverse walls  358  and  360 , with n central interior lengthwise wall  362  and a central transverse wall  364  divides the decorative insert  350  into four (4)) separate openings  51 ,  53 ,  57 , and  59 , 
       FIGS. 13 and 14  illustrate a completed garage door assembly comparable to  FIGS. 5 and 6 , the difference being a thinner garage door panel  100  which has no insulation and the retainer  320  is thinner. Otherwise, the configuration is assembled the same way with the same components to provide a similar appearance. 
     Of course the present invention is not intended to be restricted to any particular form or arrangement, or any specific embodiment, or any specific use, disclosed herein, since the same may be modified in various particulars or relations without departing from the spirit or scope of the claimed invention hereinabove shown and described of which the apparatus or method shown is intended only for illustration and disclosure of an operative embodiment and not to show all of the various forms or modifications in which this invention might be embodied or operated.