AU2012203251B2

AU2012203251B2 - Door and door panel

Info

Publication number: AU2012203251B2
Application number: AU2012203251A
Authority: AU
Inventors: Willy Lim
Original assignee: OREICA Pty Ltd
Current assignee: OREICA Pty Ltd
Priority date: 2011-06-01
Filing date: 2012-06-01
Publication date: 2015-06-18
Anticipated expiration: 2032-06-01
Also published as: AU2012203251A1

Abstract

A door 10 has a surrounding framework incorporating a top rail 12, a bottom rail 14, and two opposed side portions 16,18, (e.g. lock stile and hinge 5 stile) connecting the top and bottom rails together. The top rail includes an aperture 20 in the form of a slot through the top rail. The slot connects channels 22,24 that extend along the inside edges 26,28 in the respective side portions (stiles). These channels terminate a required distance into the bottom rail. The bottom rail also includes a channel 36 in its inner edge 30. The slotted top rail 10 and channels in the side portions and bottom rail receive a panel 32. The slot can then be covered with a covering piece 34 which can be retained by screw fasteners 36,38 going into the material of the door framework to hold it in place. 3'6 -L6. + + -F + +F + + + + + ++ +- + - +

Description

1 DOOR AND DOOR PANEL TECHNICAL FIELD The present invention relates to a door and a door panel for a door. A door panel fills a central portion of a door and is bounded by the 5 surrounding framework of the door. BACKGROUND Internal and external doors are typically either of solid or core construction. The central panel is either fixed in place as part of the construction, or includes 10 one or more glass or timber panels held in place by beading nailed around the periphery of the panel(s). Either a solid door or a panelled door of these types does not allow ready removal and replacement of the door panel(s) simply to change appearance or security of the door. For example, a solid door must be entirely replaced to provide a glass panelled door, and a glass panelled door 15 must have beading removed from around the glass panel(s) and then putty/sealant cut out from around the glass, before the panel(s) can be removed. Then the panel(s) must be resealed with a silicon/acrylic sealant or putty before re-beading. Nailing or pinning the beading back in place risks damage to the glass. 20 Alternative forms of door have double or triple glazed units set into a plastic (uPVC) or aluminium frame. These panels are placed into the external or internal face of the door and then held in place by clip strip beading. However, the need to have external or internal beading weakens the structure of the door and, in the case of external beading, can be removed by someone breaking into a 25 property or room. It is a desired object of the present invention to provide an improved door that allows changing of the door panel(s) for aesthetic or security purposes whilst maintaining security and integrity of the door surround around the panel(s). 30 SUMMARY OF THE PROPOSED INVENTION A door having a first end portion and a second end portion and two opposed side portions connecting the first and second end portions, and the two side portions each including a channel, the channels arranged to receive and 2 guide a door panel into the door to fill a section of the door between the first end portion, second end portion and the opposed side portions, the channels acting as guides and retainers to maintain the panel in the door. Beneficially, having channels within the side portions of the door allows a 5 door panel to be inserted or replaced at will, thereby allowing the aesthetics of the door to be varied. For example, when decor in rooms adjacent the door is changed, the door panel(s) can be varied to suit. Alternatively, if security for a room or building is changed, a door panel with inbuilt security protection (e.g. metal mesh, solid panel, screen or bars) may be added or replaced as required. 10 Where security or safety glass needs inserting into the door to meet requirements, the glass panel(s) can be upgraded by sliding out the current panel(s) and replacing with higher specification panels. Also, if a solid door panel needs replacing with a transparent, frosted or patterned panel to let in more light, the panel(s) can be slid out and glass/plastic ones inserted. 15 The present invention allows the door to be adapted to a required use and decor, without the need to remove beading and sealant/putty from around the panel, replacing the panel and re-fitting the beading. Because beading is nailed or pinned in place, removal of beading often results in the beading becoming damaged. Likewise, installing the beading can result in the glass panel cracking 20 or shattering when pinning or nailing the beading back in place. The door panel may be a decorative, clear or frosted glass or plastic panel, or a solid wood, plastic, board or opaque glass, plastic or fibreglass panel, or combinations of two or more thereof. The door panel may be, may include or may cover within the door, a protective barrier, such as a metal security mesh, metal bars or solid 25 metal panel. The door panel may be a decorative, clear or frosted glass or plastic panel, or a solid wood, plastic, board or opaque glass, plastic or fibreglass panel, or combinations of two or more thereof. The door panel may be, may include or may cover within the door, a protective barrier, such as a metal security mesh, 30 metal bars or solid metal panel. Preferably the door panel may include laminated glass, which preferably includes a natural or synthetic fabric laminated between glass sheets. The fabric may be set within a bonding agent between the glass sheets. Preferably the 3 fabric is a decorative natural silk fabric, providing aesthetic qualities as well as a fine thread thickness and material strength. The first of second end portion may be preferably be permanently attached to the respective opposed side channels, or may be removable to provide access 5 to the channels where a slotted Preferably the first or second end portion may include an aperture, such as a slot, therethrough. The first or second end portion aperture may act to guide the door panel into the channels. The first or second end portion may be removable from the rest of the door to provide access to the channels, and then reattached once the door panel has been installed or 10 removed. The channels in the side portions may be formed by machining the side portions, such as by routing. Alternatively the side portions may be formed by outer surfaces and a core of material. The outer most edge of at least one of the side portions may have at least one strengthener for mounting one or more 15 hinges to the door, such as when hanging the door to a door frame. The side portions may be formed of or include timber, medium density fibreboard (MDF) or high density fibreboard (HDF). The aperture (e.g. slot) in the first or second end portion provides access for at least one door panel to be received into the door. The aperture may 20 provide an initial guide for opposed side edges of the at least one door panel to be received by the respective channels along the opposed sides of the door. At least one cover member may be provided to cover the aperture in the first or second end when the at least one panel has been installed in the door. The at least one cover member may be a single piece component or may include 25 multiple sub components, such as one or more slot fillers or packers and an external cover piece. The at least one cover member may include multiple cover pieces that install side by side to cover the aperture. Preferably the at least one cover member is releasably fastened to the door using releasable fasteners, such as screws, tabs or catches. Preferably the 30 fasteners fasten through the at least one cover member into respective ends of the side portions. At least one filler may be provided between an end of the door panel and the at least one cover member. Said at least one filler may include resilient 4 material, such as rubber, silicon rubber, foam, plastic or a solidified gel. Preferably the at least one filler is an anti rattle device to restrict movement of the door panel within the door. Preferably the at least one filler provides a gasket to provide cushioning to prevent or reduce likelihood of damage to the door panel 5 form contact with the door or from sudden shock to the at least one door panel, such as slamming of the door in a door frame or impact to the at least one door or door panel. The at least one door panel may include multiple door panels, which may be inserted one after the other into the channels of the door via the aperture. 10 The door may include at least one intermediate rail between the first and second ends and extending between and connecting the opposed side portions. The at least one rail may have a rail aperture therethrough to allow a door panel to pass through to fill a section of the middle of the door. Alternatively, the door may include an aperture in both the first and second 15 ends, such that a door panel may be inserted into the channels of the opposed side portions from each end of the door. In such instances, at least one said intermediate rail may be provided, with the door panels inserted into each end of the door and retained by the channels and butting up to or being received into a respective channel in top and bottom faces of the intermediate rail. 20 The first and second ends may be the top and bottom rails of the door. Another form of the present invention provides a panel for a door, the panel including at least two laminated transparent or semi-transparent sheets with a bonding agent between the laminations, and a decorative material incorporated in the bonding agent to provide aesthetic appeal and/or privacy. 25 Preferably the material includes a natural or synthetic fabric, preferably silk. Preferably the sheets are of glass or plastic, such as polycarbonate. A further aspect of the present invention provides a door panel including a sandwich construction of sheets (i.e. veneer or fiberglass etc.) and at least one 30 metal sheet therebetween.

5 BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 shows front, side, top and bottom views of a door with door panel installed, according to an embodiment of the present invention. Figures 2a-2c show a broken longitudinal section through a door, with 5 close up portions of the top and bottom of the door, according to an embodiment of the present invention. Figure 3 shows front, side, top and bottom views of an alternative door with an intermediate rail and a door panel installed, according to a further embodiment of the present invention. 10 Figures 4a-4d show a broken longitudinal section through a door with an intermediate rail, with close up portions of the top and bottom of the door and intermediate rail section, according to a further embodiment of the present invention. Figures 5a to 5d show various views of portions of a door with cover 15 member and channelling, according to an embodiment of the present invention. Figures 6a-6c show alternative forms of gasket members according to embodiments of the present invention. Figure 7 shows various views of a cover member according to an embodiment of the present invention. 20 Figure 8 shows an alternative form of door panel of sandwich construction according to an embodiment of the present invention. Figure 9 shows a vertical cross section through a door and door panel, with close up partial top and bottom section cross sections, according to an embodiment of the present invention. 25 Figures 10a to 10d show alternative gaskets or extrusions for holding the door panel in place in a door, according to an embodiment of the present invention. Figure 11 shows a door panel within a door, the panel having a metal mesh or screen providing additional security, according to an embodiment of the 30 present invention. Figure 12 shows a vertical sectional view through the door and panel of the embodiment of figure 11.

6 DESCRIPTION OF PREFERRED EMBODIMENTS Figure 1 shows various views of a door 10. The door has a surrounding framework incorporating a top rail 12, a bottom rail 14, and two opposed side portions 16,18, (e.g. lock stile and hinge stile) connecting the top and bottom rails 5 together. The top rail includes an aperture 20 in the form of a slot through the top rail. This slot connects channels 22,24 that extend along the inside edges 26,28 in the respective side portions (stiles). These channels terminate a required distance into the bottom rail. The bottom rail also includes a channel 36 in its inner edge 30. The slotted top rail and channels in the side portions and bottom 10 rail allow a door panel 32 to be inserted into the door via the slot and channels. The slot can then be covered with a covering piece 34. Preferably the covering piece has screw fasteners 36,38 going into the material of the door framework to hold it in place. It will be appreciated that the door can readily be removed from a door frame, the covering piece unscrewed and set to one side, and the door 15 panel(s) can be removed and replaced with door panel(s) of different designs, styles, transparency/opacity, security and materials. For example, if renovating a room, the door panel(s) may be changed to suit the new decor or furniture. Alternatively, instead of applying cheaper frosted stick on sheeting to a clear glass panel, real frosted glass could be inserted in place of the clear glass. The 20 present invention avoids the need to change the entire door or risk damaging the door, panel and/or beading in order to provide enhanced aesthetic, security or privacy appeal. A solid panel may be replaced with a glass panel etc. A glass panel may be of laminated glass with a bonding agent between the laminations. A fabric, 25 such as silk, may be incorporated in the bonding agent to provide aesthetic appeal and/or privacy. Alternatively, the panel may include a sandwich construction including solid outer sheets with a layer, preferably a metal layer, therebetween. Figure 2a shows a vertical side sectional view through the door 10. As 30 shown in Figure 2c, being a close up part sectional view of the door bottom of Figure 2a, the lower end of the door panel 32 sits in the channel 36 of the bottom rail 14. This end of the door panel actually sits in a gasket 38 formed as a U shaped member, preferably of a resilient material, such as rubber, silicon or 7 plastic. Figure 2b shows a close up part section of the top end of the door and panel of Figure 2a. Similarly, the top of the door panel includes a gasket 40 between the panel and a packing piece 43, preferably of a resilient material, such as foam, rubber, silicon etc to prevent movement of the panel and cushion the 5 covering piece 34 when fastened down to retain the panel in situ. One or more gaskets 42 may be provided down each side of the panel in the respective side channels 26,28. Figure 3 shows a door 50 similar to the door 10 of Figure 1 with similar features of the channels and covering piece etc.; however, the door 50 includes a 10 centre or intermediate rail 52. The door panel(s) 54 can be a single panel that extends down through slot 55 through the intermediate rail i.e. the panel is a one piece panel. Alternatively, the panel(s) may be multiple panels 56,58 that have a join covered by the intermediate rail. Figures 5a and 5b show a cover 60 for insertion into the upper part of the 15 aperture 62 in the top of the door 64. The cover includes side projections 66,68 arranged to receive respective fasteners 70,72 for attaching the cover within the top rail of the door. Figures 5c and 5d show the bottom section of the door with the panel 74 in the two side channels and the bottom channel 36 in the bottom rail 14. 20 Figures 6a to 6c show alternative embodiments of a gasket for use as a bottom gasket 80, a top gasket 82 and a side gasket 84 for use in the respective bottom, top and side channels. These help to protect the door panel from contact with the material of the respective rail/stile and cushion the panel against impact shocks, such as from the door slamming closed in its frame or direct impact to the 25 panel. Each gasket is of a generally U shaped cross section 86,88,90, with a thickened, preferably convex, base portion 92,94,96. Figure 7 shows the cover/covering piece 60 with side projections 66,68and apertures 98,100 for receiving therethrough fasteners 70,72 (figure5a). The cover may be of a plastics material, or of wood or metal, or combinations thereof. 30 The cover finishes the top edge of the door, prevents ingress of dirt/dust into the top aperture and in conjunction with the gaskets and optional packing piece, prevents the panel(s) from rattling.

8 In use, the door can be removed from its hinges, the cover removed, the door panel slide out and a replacement panel inserted. The cover is then replaced and fastened in position. The door can then be re-hung, giving a fresh aesthetic and/or privacy and/or security benefit. 5 As shown in figure 8, the door 110 includes a door panel 112 of sandwich construction. The panel includes opposed outer sheets 114,116 with a central core of one or more other sheets 118, preferably a metal sheet or mesh. Figure 9 shows a vertical cross sectional view through a door 120 with a sandwich form door panel 122 having the sandwich construction held in place by 10 fasteners 124,126 adjacent the respective top 128 and bottom 130 sections of the door. The extrusion views 140,142,144,146 shown in figures 10a to 10d show various profile/sectional features of the extrusion for retaining a panel within the door framework. The extrusion may be a metal extrusion, such as aluminium, or 15 may be a rubber/plastic type extrusion, such as a gasket. Figure 11 shows a door panel 150 within a door 152. The panel includes a metal mesh or screen 154 providing additional security. Figure 12 shows a vertical sectional view through the door and panel of figure 11. The panel includes a central metal mesh or screen 154 sandwiched between outer sheets 20 156,158 of glass, fibreglass, wood, plastic or metal.

Claims

1. A door having a top end portion and a bottom end portion and two opposed side portions connecting the top or bottom end portions, and the two side portions each including a channel, the channels arranged to receive and guide at least one door panel into the door through an aperture in the top or bottom end portion to fill a section of the door between the top end portion, bottom end portion and the opposed side portions such that the received at least one door panel can only be removed from the door after the door has been uninstalled from the door frame; the channels acting as guides and retainers to maintain the at least one panel in the door; and further wherein the top and the bottom end portions are permanently attached to the two opposed side portions; and including at least one cover member to cover said aperture in the top or bottom end portion when the at least one door panel has been installed in or removed from the door wherein dimension of said at least one cover member allows said cover member to be fully inserted into said aperture in the top or bottom end portion and said cover member is fastened in place using one or more fasteners.

2. A door according to claim 1, the top or bottom end portion being removable from the rest of the door to provide access to the channels, and re-attachable to the rest of the door once the door panel has been installed or removed.

3. A door according to any one of the preceding claims, wherein the channels in the side portions are formed by machining the side portions.

4. A door according to any one of the preceding claims, the aperture in the top or bottom end portion providing access for at least one door panel to be received into the door.

5. A door according to claim 1, the at least one cover member including a single piece component or multiple sub components.

6. A door according to claim 5, wherein the at least one cover member includes one or more fillers or packers and at least one external cover piece. 10

7. A door according to any one of claims 5 to 6, the at least one cover member being releasably fastenable to the door by releasable fastening means.

8. A door according to any one of claims 5 to 7, including at least one filler provided between an end of the door panel and the at least one cover member.

9. A door according to claim 8, said at least one filler including resilient material.

10. A door according to any one of the preceding claims, including at least one intermediate rail between the top or bottom ends and extending between and connecting the opposed side portions.

11. A door according to claim 10, the at least one intermediate rail having a rail aperture therethrough to allow a door panel to pass through to fill a section of the middle of the door.

12. A door according to any one of the preceding claims, including a said aperture through both the top or bottom ends, such that a door panel can be inserted into the channels of the opposed side portions from each end of the door.

13. A door according to any one of the preceding claims, wherein the at least one door panel includes a decorative, clear or frosted glass or plastic panel, or a solid wood, plastic, board or opaque glass, plastic or fibreglass panel, or combinations of two or more thereof. 11

14. A door according to claim 13, the at least one door panel including or covering within the door, a protective barrier.

15. A door according to claim 14, the protective barrier including a metal security mesh, metal bars or solid metal panel.

16. A door according to any one of the preceding claims, the door panel including lamininated glass, which preferably includes a natural or synthetic fabric laminated between glass sheets.

17. A door according to claim 16, wherein the fabric is set within a bonding agent between the glass sheets.

18. A door according to claim 1, wherein the door panel including at least two laminated transparent or semi-transparent sheets with a bonding agent between the laminations, and a decorative material incorporated in the bonding agent to provide aesthetic appeal and/or privacy.

19. A door according to claim 18, the decorative material including a natural or synthetic fabric, preferably silk.

20. A door according to claim 18 or 19, the laminated sheets being of glass or plastic.

21. A door according to claim 1, wherein the door panel including a sandwich construction of sheets and at least one metal sheet therebetween.