DOOR LEAF AND DOOR SYSTEM

Abstract

The present disclosure relates to a door leaf formed of a flexible material, wherein the flexible material is resistant to puncture and resistant to tearing; and to a door system comprising the door leaf.

Claims

1-16. (canceled)

17. A door system comprising a door leaf, an attachment member, and an attachment means, wherein the attachment means rotationally couples the door leaf to the attachment member and is configured to restrict rotation of the door leaf relative to the attachment member to less than 180 degrees; wherein the attachment means comprises a hinge pin coupled to the door leaf, and an end-cap attached to the attachment member, wherein an end of the hinge pin is received within the end-cap to thereby rotationally couple the door leaf to the attachment member.

18. The door system according to claim 17, comprising a first end-cap and a second end-cap, each end cap attached to the attachment member, wherein a first end of the hinge pin is received within the first end-cap, and a second end of the hinge pin is received within the second end-cap.

19. The door system according to claim 18, wherein the first end-cap is attached to a first end of the attachment member, and the second end-cap is attached to a second end of the attachment member.

20. The door system of claim 18, wherein at least one of the first end-cap or the second end-cap has a sloped outer surface.

21. The door system of claim 19, wherein the first end-cap and second end-cap are identical to one another.

22. The door system of claim 18, wherein the door leaf comprises a channel extending along an edge thereof, wherein the channel receives the hinge pin.

23. The door system of claim 22, wherein at least one of the first end-cap and the second end-cap abuts a respective end of the channel.

24. The door system of claim 23, wherein the attachment member comprises a recess configured to receive the channel.

25. The door system of claim 24, wherein an outer diameter of the channel is equal to an inner width of the recess.

26. The door system of claim 17, wherein one of the end-cap and the hinge pin comprises at least one detent arranged to restrict a rotation of the hinge pin relative to the attachment member.

27. The door system of claim 17, wherein a top edge of the door leaf forms an acute angle with respect to the attachment member.

28. The door system of claim 17, wherein at least one corner of the door leaf is rounded.

29. The door leaf of claim 17, wherein the door leaf is bendable, for example bendable by hand.

30. The door system of claim 17, wherein the attachment means is configured to restrict rotation of the door leaf relative to the attachment member to less than 150 degrees.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Examples of the present disclosure will now be described, by way of example only, with reference to the accompanying figures, in which:

[0033] FIG. 1 shows an exploded view of a door system;

[0034] FIG. 2 shows a magnified view of region A in FIG. 1;

[0035] FIG. 3 shows an assembled view of the door system in FIG. 1;

[0036] FIG. 4 shows a side-view of a door leaf from the door system of FIG. 1;

[0037] FIG. 5a shows a partial end-view of the door leaf in FIG. 4;

[0038] FIG. 5b illustrates the laminate structure of the door leaf in FIG. 4;

[0039] FIG. 6 shows a perspective view of an end-cap from the door system of FIG. 1;

[0040] FIG. 7 shows an end-view of the end-cap in FIG. 6;

[0041] FIG. 8 shows an end-view of a hinge pin from the door system of FIG. 1;

[0042] FIG. 9 shows an end-view of an attachment member from the door system of FIG. 1;

[0043] FIG. 10 shows an end-view of a fixing member from the door system of FIG. 1.

[0044] Like reference numerals are used for like components throughout the drawings and detailed description.

DETAILED DESCRIPTION

[0045] FIGS. 1 and 3 respectively show an exploded view and an assembled view of a door system 100 according to the present disclosure. FIG. 2 shows a magnified view of region A in FIG. 1.

[0046] The door system of FIGS. 1 to 3 comprises a door leaf 102, which is attached to an attachment member 104 by an attachment means. The attachment means comprises a steel hinge pin 106 and first and second end-caps 110A, 110B. To assemble the shower door, the hinge pin 106 is inserted into a channel 108 of the door leaf 102, such that the first and second ends 106A, 106B of the hinge pin 106 protrude from respective ends of the channel 108. The first end 106A is then inserted into first end-cap 110A which in turn is attached to the attachment member 104; and the second end 106B is inserted into the second end-cap 110B, which in turn is also attached to the attachment member 104. Therefore, when assembled, the hinge pin is received in the channel 108, the first end 106A of the hinge pin is received within first end-cap 110A; and the second end 106B of the hinge pin is received within the second end-cap 110B. End-caps 110A and 110B are attached to the attachment member 104, thereby coupling the door leaf 12 to the attachment member 104. The hinge pin 106 is a snug fit in the channel 108, which may thereby substantially prevent rotation of the hinge pin 106 relative to the door leaf 102. In some examples, the hinge pin 106 may be glued in place within the channel 108. However, the end-caps 110A, 110B support rotation of the hinge pin 106. Therefore, the attachment means (which collectively comprises the hinge pin and the end-caps) supports rotation of the door leaf 102 relative to the attachment member 104. As will be described in further detail below, the attachment means is further configured to limit the rotation of the door leaf relative to the attachment member.

[0047] Also shown in FIGS. 1-3 are a fixing member 112, and a fixing member inserts 114. The fixing member 112 is for attachment between the attachment member 104 and a wall or door frame.

[0048] FIGS. 4 and 5a respectively show a side-view and an end-view of the door leaf 102. FIG. 4 shows the sloped top edge and rounded corners of the door leaf. The door leaf comprises a flexible laminate 400. The structure of the flexible laminate 400 is shown in FIG. 5b. The flexible laminate 400 comprises a woven Kevlar® core layer 402 sandwiched between a first flexible skin layer 404A and a second flexible skin layer 404B. Each flexible skin layer comprises plasticised PVC-coated high tenacity plain weave nylon. The skin layers 404A, 404B encapsulate the core layer 402. The layers of the flexible laminate 400 are adhered to one another using epoxy resin.

[0049] Where the two skin layers 404A, 404B meet each other at the edges of the door leaf to thereby seal the core layer 402, they may be sealed, e.g. by impulse welding, to thereby ensure a safe and clean finish that is both durable and hygienic.

[0050] Further details of an exemplary material for the skin layers 404A, 404B will now be provided. The exemplary material is a PVC-coated woven nylon fabric. The woven nylon fabric is a high tenacity plain weave nylon with a linear density of 940 dtex and an area density of 170 gsm. It is coated with pigmented, plasticised PVC. The PVC is antifungal, UV stabilised, flame resistant, and non-toxic. The material of the layers 404A, 404B has a coated weight of at least 600 gsm; a tensile strength (in the warp direction) of at least 2650 N/50 mm; a tensile strength (in the weft direction) of at least 2200 N/50 mm; a tear strength (in the warp direction) of at least 400N; a tear strength (in the weft direction) of at least 300N; and a coating adhesion of at least 100 N/50 mm. It complies with regulation (EC) no. 1907/2006 (Registration, Evaluation, Authorisation and restriction of Chemicals).

[0051] As shown in FIG. 5a, the channel 108 comprises a hollow aluminium tube. The hollow aluminium tube is covered by the skin layer 404. In other words, the skin layer 404 covers the entire door leaf, including the core 402 and the aluminium tube to which the core 402 is attached. The aluminium tube is cylindrical. The interface between the core 402 and the aluminium tube is rounded, to avoid a pinch point.

[0052] FIG. 6 shows a perspective view of an end-cap 110 from the door system in FIG. 1. As shown, the end-cap has a rounded and sloped outer surface 600; fixing points 602 for attachment to the fixing member 112 and/or a wall; fixing points 604 for attachment to the attachment means 104; and a generally circular cavity 606 for receiving the hinge pin 106. The end-cap 110 is formed of aluminium. As the reader will understand, the top cap 110 of FIG. 6 could be used as the first end-cap 110A, or as the second end-cap 110B.

[0053] Also shown are detents 608 within the cavity 606. The detents are arranged to a engage protrusion 800 at a respective axial end of the hinge pin 106 (shown in FIG. 8), when the hinge pin is rotated relative to the end-cap 110. As the reader will understand, when the axial end of the hinge pin 106 is inserted into the cavity 606, it will be able to rotate within the cavity 606 due to the cylindrical shape of the hinge pin 106 and the corresponding circular shape of the cavity 606 (the diameter of the hinge pin 106 is substantially the same as the diameter of the cavity 606). However, because of the provision of the flange-shaped protrusion 800, the rotational motion of the hinge pin 106 relative to the end-cap 110 will be limited. In particular, when rotated in either direction within the end-cap 110, the protrusion 800 will eventually come into abutment with the detents 608, thereby preventing further rotation of the hinge pin 106. Accordingly, rotation of the hinge pin relative to the end-cap 110 (and thus of the door leaf 102 relative to the attachment member 104) is limited by the engagement between the detents 608 and the protrusion 800.

[0054] The positioning of the detents 608 can be selected as desired, in order to select the extend to which the door leaf 102 is rotatable relative to the attachment member 104. In the depicted example, the detents 608 limit rotation to about 130 degrees.

[0055] FIG. 9 shows an end-view of the attachment member 104. Shown in FIG. 9 are fixing points 900 for attachment to a respective end-cap 110. Also shown are opposing jaws 902, which define a recess 904 therebetween. When the door system is assembled, the channel 108 of the door leaf 102 will be received in the recess 904. Moreover, because the spacing of the jaws 902 is equal to an outer diameter of the aluminium tube which forms the channel 108, there is no cap provided therebetween. Therefore, the interface between the door leaf 102 and the attachment member 104 includes no ligature points. Moreover, because the jaws 902 have sloped outer surfaces 906, ligature points are further eliminated. The attachment member 104 is formed of aluminium.

[0056] FIG. 10 shows an end-view of the rubber fixing member 112. Similarly to the attachment member, the rubber fixing member comprises opposing jaws 1002, which define a recess 1004 therebetween. When the door system is assembled, the attachment member 104 will be received in the recess 1004. Moreover, because the spacing of the jaws 1002 is equal to an outer diameter of the attachment member 104, there is no gap provided therebetween. Therefore, the interface between the attachment member 104 and the rubber fixing member 112 includes no ligature points. Moreover, because the jaws 1002 have sloped and rounded outer surfaces 1006, ligature points are further eliminated.

[0057] The door leaf 102 typically has a total height of roughly 1.5 m. That is to say, the channel 108 typically has a height of 1.5 m. The door leaf 102 typically has a depth (as measured from the channel in a direction perpendicular to the channel) of approximately 0.78 m. The aluminium tube of the channel typically has an outer diameter of 26 mm, and an inner diameter of 20 mm. Accordingly, the hinge pin 106 typically has a diameter of 20 mm and a height of 1514 mm (so as to protrude slightly from the top and bottom ends of the channel when assembled). The jaws 902 of the attachment member 104 are typically spaced from one another by 26 mm. The flexible composite material 400 of the door leaf 102 typically has a thickness of 2.5 mm. As the reader will understand, these measurements may be changed as required.

[0058] Also disclosed herein are a number of further examples according to the following numbered clauses.

[0059] Clause 1. A door leaf formed of a flexible material having high tensile strength, such that the door leaf is flexible, resistant to puncture, and resistant to tearing.

[0060] Clause 2. The door system of any preceding Clause, wherein the flexible material has a tensile strength of at least 300 MPa.

[0061] Clause 3. The door system of Clause 1 or Clause 3, wherein the flexible material comprises aramid fibre.

[0062] Clause 4. The door system of any preceding Clause, wherein the flexible material comprises woven aramid fibre.

[0063] Clause 5. The door system of any preceding Clause, further comprising a skin covering the flexible material.

[0064] Clause 6. The door leaf of Clause 5, wherein the skin comprises a polymer.

[0065] Clause 7. The door leaf according to any preceding Clause, further comprising a channel extending along an edge thereof, for receiving a hinge pin.

[0066] Clause 8. The door leaf of Clause 7, wherein the channel comprises a rigid tube attached to the flexible material.

[0067] Clause 9. The door leaf of Clause 8 when dependent on Clause 4 or Clause 5, wherein the skin covers the flexible material and the rigid tube.

[0068] Clause 10. The door system according to any of Clause 7 to 9, wherein a top edge of the door leaf forms an acute angle with the channel.

[0069] Clause 11. A door system comprising a door leaf according to any preceding claim, an attachment member, and an attachment means, wherein the attachment means rotationally couples the door leaf to the attachment member.

[0070] Clause 12. The door system of Clause 11, wherein the attachment means is configured to restrict rotation of the door leaf relative to the attachment member to less than 180 degrees.

[0071] Clause 13. The door system of Clause 12, wherein the attachment means is configured to restrict rotation of the door leaf relative to the attachment member to less than 150 degrees.

[0072] Clause 14. The door system of Clause 13, wherein the attachment means is configured to restrict rotation of the door leaf relative to the attachment member to less than 130 degrees.

[0073] Clause 15. The door system according to any of Clauses 12 to 14, wherein the attachment means comprises a hinge pin and an end-cap, the hinge pin extending through a channel in the door leaf, and the end-cap being attached to the attachment member, and wherein an end of the hinge pin is received within the end-cap to thereby rotationally couple the door leaf to the attachment member.

[0074] Clause 16. The door system of Clause 15, wherein the attachment member comprises a recess configured to receive the channel.

[0075] Clause 17. The door system of Clause 16, wherein an outer diameter of the channel is equal to a width of the recess.

[0076] Clause 18. The door system according to any of Clauses 15 to 17, wherein one of the end-cap and the hinge pin comprises at least one detent arranged to restrict rotation of the hinge pin to thereby restrict the rotation of the door leaf relative to the attachment member.

[0077] Clause 19. The door system of Clause 18, wherein the other of the end-cap and the hinge pin comprises a corresponding protrusion, wherein the at least one detent is arranged to engage the protrusion to thereby restrict the rotation of the hinge pin.

[0078] Clause 20. The door system of Clause 19, wherein the at least one detent and the protrusion are concealed within the end-cap.

[0079] Clause 21. A door system comprising a door leaf, an attachment member, and an attachment means, wherein the attachment means rotationally couples the door leaf to the attachment member and is configured to restrict rotation of the door leaf relative to the attachment member to less than 180 degrees.

[0080] It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other implementations will be apparent to those of skill in the art upon reading and understanding the above description. Although the present disclosure has been described with reference to a specific example implementation, it will be recognized that the disclosure is not limited to the implementations described, but can be practiced with modification and alteration insofar as such modification(s) and alteration(s) remain within the scope of the appended claims. Accordingly, the specification and drawings are to be regarded in an illustrative sense rather than a restrictive sense. The scope of the disclosure should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.