Seamless multi-panel door

Abstract

A panel of a sectional door includes a panel frame and a sheet of material that is coupled to the panel frame. The panel frame includes a top frame member, a bottom frame member, a first side frame member and a second side frame member. The frame members include a rear surface and a front surface, and the front surface includes a ledge. The sheet of material is coupled to the front surface such that a bottom edge of the sheet rests on the ledge and a front surface of the sheet is unobstructed by the panel frame.

Claims

1. An upward acting, multi-panel door, the door comprising: a first panel frame of a plurality of panel frames rotatably coupled together and movable, the first panel frame comprising a ledge and defining an opening, the ledge extending continuously along a majority of a longitudinal length of the first panel frame, wherein the ledge is cantilevered outward from a proximal end of the ledge and free of a vertical extension at a distal end of the ledge, the opening extending across a majority of an area defined by an outer perimeter of the first panel frame, wherein a bottom surface of the ledge extends perpendicularly outward from the first panel frame, wherein the bottom surface of the ledge is spaced apart from a bottom edge of the first panel frame in a direction opposite a direction in which the bottom surface faces, and wherein a top surface of the ledge is disposed on an opposing side of the ledge from the bottom surface, wherein the first panel frame comprises a bottom frame member, wherein the bottom frame member is formed as an aluminum extrusion; a sheet of material having a rear surface and an opposed front surface, the rear surface coupled to a front surface of the first panel frame such that a bottom edge of the sheet rests on the ledge, wherein no portion of the first panel frame contacts the front surface of the sheet such that the front surface of the sheet is unobstructed; a second panel frame of the plurality of panel frames, the second panel frame comprising a top frame member having a front surface, wherein the sheet of material coupled to the first panel frame is substantially entirely disposed outward of the top frame member of the second panel frame in a direction the front surface of the top frame member of the second panel frame faces; and a hinge rotatably coupling the first panel frame of the plurality of panel frames to the second panel frame.

2. The door of claim 1, further comprising: a coupling mechanism having an adhesive positioned between the first panel frame and the sheet.

3. The door of claim 2, wherein the coupling mechanism consists of an adhesive layer bonded to the first panel frame and to the sheet of material, and wherein the coupling mechanism and the ledge comprise the only coupling of the sheet of material to the first panel frame.

4. The door of claim 2, wherein the sheet is at least partially translucent.

5. The door of claim 2, wherein the sheet is at least partially opaque.

6. The door of claim 2, wherein the sheet is tempered glass.

7. The door of claim 6, wherein the tempered glass includes flame-polished edges.

8. The door of claim 2, wherein the sheet is polycarbonate.

9. The door of claim 1, wherein at least a portion of the bottom edge of the first panel frame is disposed below and parallel to the bottom surface of the ledge.

10. The door of claim 1, wherein a portion of the bottom edge of the first panel frame adjacent to an outward facing surface of the first panel frame is perpendicular to the outward facing surface of the first panel frame.

11. The door of claim 1, wherein the bottom edge of the first panel frame comprises a sealing member receptacle and a top edge of the second panel frame comprises a sealing member receptacle, wherein a sealing member is disposed in both the sealing member receptacle of the bottom edge and the sealing member receptacle of the top edge when the door is in a closed configuration.

12. An upward acting, multi-panel door, the door comprising: a first panel frame, including an inward facing surface, an outward facing surface, and a ledge cantilevered outward from the outward facing surface at a proximal end of the ledge and being free of a vertical extension at a distal end thereof, the ledge having a top surface and a bottom surface, the bottom surface being spaced apart from a bottom edge of the first panel frame defined by a bottom frame member comprising aluminum, the ledge extending continuously along a majority of a longitudinal length of the first panel frame; a panel having a front surface and a rear surface, wherein the rear surface of the panel is coupled to the outward facing surface of the first panel frame and covers an opening defined by the first panel frame, the opening extending across a majority of an area defined by an outer perimeter of the outward facing surface of the first panel frame, wherein a lower edge of the panel rests on the top surface of the ledge; a second panel frame including a top frame member defining a top edge, the top edge configured to contact the bottom edge of the bottom frame member of the first panel frame along a reference plane substantially parallel to the top surface of the ledge when the door is in a closed configuration, wherein a contact interface between the top edge of the top frame member of the second panel frame and the bottom edge of the bottom frame member of the first panel frame is formed of at least two discontiguous regions on the reference plane separated by a portion of the top frame member of the second panel frame extending above the reference plane, wherein at least a portion of the bottom edge of the first panel frame is disposed below and parallel to the bottom surface of the ledge; and a hinged connection configured to hingedly couple the first panel frame to the second panel frame, wherein the ledge is configured to be spaced apart from and not contact the second panel frame.

13. The door of claim 12, wherein the ledge extends from the outward facing surface of the first panel frame at a right angle.

14. The door of claim 12, wherein an outward facing surface of the panel is unobstructed.

15. The door of claim 12, wherein a color of the ledge matches a color of the panel.

16. The door of claim 12, further comprising an adhesive positioned between the panel and the first panel frame.

17. The door of claim 12, further comprising a double-sided tape positioned between the panel and the first panel frame.

18. The door of claim 12, wherein a portion of the bottom edge of the first panel frame adjacent to the outward facing surface of the first panel frame is perpendicular to the outward facing surface of the first panel frame.

19. The door of claim 12, wherein the bottom edge of the first panel frame comprises a sealing member receptacle.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of an embodiment of a multi-panel door having three panels in accordance with this disclosure.

(2) FIG. 2 is a partial exploded view of the multi-panel door of FIG. 1.

(3) FIG. 3 is a rear view of the multi-panel door of FIG. 1.

(4) FIG. 4 is a cross section view of the top panel of the multi-panel door of FIG. 1.

(5) FIG. 5 is a cross section view of the intermediate panel of the multi-panel door of FIG. 1.

(6) FIG. 6 is a cross section view of a hinged connection between the top panel and the intermediate panel of FIG. 1.

(7) FIG. 7 is a flow diagram illustrating a method of manufacturing the multi-panel door of FIG. 1.

DETAILED DESCRIPTION

(8) In the description which follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawings may not be to scale and certain features may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness.

(9) FIG. 1 is a perspective view of an embodiment of a multi-panel, upward-acting, sectional door 100 having a seamless exterior appearance. The multi-panel door 100 includes a plurality of panels 102 that form a front face 104 of the door 100 and enclose an opening 106 in a building 108 or other structure. In the embodiment illustrated in FIG. 1, for example, the door 100 includes three panels 102, namely, a top panel 110, an intermediate panel 112 and a bottom panel 114, that enclose an opening 106 defined by two jambs 116 and 118, a header 120 and a driveway 122. In some embodiments, the panels 102 are hingedly connected and mounted on conventional track and rollers (not shown) within the building to enable movement of the door 100 between the vertical position shown in FIG. 1, and a horizontal (i.e., overhead) position. In other embodiments, the door 100 may include any number of panels 102 and may be located in any suitable opening 106.

(10) In FIGS. 1-3, each panel 102 of the door 100 includes a frame 160, 162 or 164 (see FIGS. 2 and 3) and at least one sheet 126 of material coupled to the frame 160, 162 or 164. The sheets 126 of material are coupled to the panel frame 160, 162 or 164 such that an outer surface 128 of each sheet 126 is unobstructed by the panel frames 160, 162 or 164. In some embodiments, the unobstructed sheets 126 give the multi-panel door 100 a seamless exterior appearance when the door 100 is in the closed position, as will be described in more detail below.

(11) The sheets 126 of material may be made of any suitable material and may be opaque, translucent, semi-translucent, transparent, semi-transparent or a combination of any of the foregoing. For example, in some embodiments the sheets 126 are made of semi-translucent black, white, bronze or mirror silver glass. In other embodiments, the sheets 126 are made of an opaque metal material. In yet other embodiments, the sheets 126 are made of tempered glass that has flame-polished edges to prevent chipping or cracking. In some embodiments, the sheets 126 are partially translucent, partially opaque or a combination of partially translucent and partially opaque.

(12) The sheets 126 may also have any suitable thickness. In some embodiments, for example, the sheets 126 are ⅛ inch thick. In other embodiments, the sheets 126 are thicker or thinner than ⅛ inch. For example, in some embodiments the sheets 126 are a glass material that is ¼ inch thick. In some embodiments, the sheets 126 have a height and width that are substantially equal to the height and width of the corresponding panel frame 160, 162 or 164. In other embodiments, multiple sheets 126 couple to each of the panel frames 160, 162 or 164 and the sheets 126 have a combined height and width that is substantially equal to the height and width of the corresponding panel frame 160, 162 or 164.

(13) The sheets 126 may also have any suitable color. For example, in some embodiments the sheets 126 have an anodized bronze or anodized brown color. In yet other embodiments, the sheets 126 have a semi-transparent black, white or mirror silver color.

(14) As discussed above, in some embodiments the sheets 126 are coupled to the frames 160, 162 or 164 such that the frames 160, 162 and 164 do not obstruct an outer surface 128 of the sheets 126. As will be described in more detail below, in some embodiments, a ledge 132 (see FIGS. 3-7) of each panel frame 160, 162 and 164 is positioned below the sheets 126 and is partially exposed on the front face 104 of the door 100. As such, in some embodiments the ledge 132 of each panel frame 160, 162 and 164 is painted, coated, or otherwise configured to have a color that is similar to the coloring of the sheets 126. Thus, in some embodiments the entire front face 104 of the multi-panel door 100 has a substantially uniform color to give the door 100 a seamless appearance.

(15) Referring now to FIG. 2, in some embodiments each panel frame 160, 162 and 164 includes an upper frame member 134, a lower frame member 136, a first side member 138 and a second side member 140. In some embodiments, the upper frame member 134, the lower frame member 136, the first side member 138 and the second side member 140 are metal extrusions that are coupled to form a rectangular panel frame 160, 162 and 164, as illustrated in the embodiment of FIG. 2. In some embodiments, the panel frame 160, 162 or 164 also includes one or more intermediate frame members 142. For example, in the embodiment illustrated in FIG. 2 each frame 160, 162 and 164 includes an intermediate frame member 142 that couples the upper frame member 134 to the lower frame member 136 and divides the frames 160, 162 and 164 into two equal sections. While the panel frames 160, 162 and 164 illustrated in FIG. 2 are rectangular in shape, the panel frames 160, 162 and 164 may be any suitable shape in other embodiments.

(16) Each member 134, 136, 138, 140 and 142 of the panel frames 160, 162 and 164 includes an inner surface 144 (see FIGS. 4-6) that faces an interior portion of the space enclosed by the door 100, such as the interior portion of a garage, and an exterior surface 148 that faces away from the space enclosed by the door 100. The lower frame member 136 of each frame 160, 162 and 164 includes the ledge 132 (FIGS. 3-7) that extends from the exterior surface 148 of the lower frame member 136. In some embodiments, the exterior surfaces 148 of the frame members 134, 136, 138, 140 and 142 of each panel frame 160, 162 and 164 are substantially co-planar when the door 100 is in the vertical position, as illustrated in FIG. 1, with the exception of the ledges 132 that protrude from the exterior surfaces 148, as best illustrated in FIGS. 4, 5 and 6. In some embodiments, the sheets 126 are substantially planar pieces of material that are also substantially coplanar when adhered to the frame members 134, 136, 138, 140 and 142 of each panel frame 160, 162 and 164.

(17) Referring again to FIG. 2, a coupling mechanism 150 is positioned on the exterior surfaces 148 of the frame members 134, 136, 138, 140 and 142 to adhere the sheets 126 to the exterior surfaces 148 of the frame members 134, 136, 138, 140 and 142. In some embodiments, the coupling mechanism 150 is a layer of adhesive, a layer of double-sided tape or some other coupling object. In some embodiments, the coupling mechanism 150 is a double-sided tape, such as 4991 VHB tape made by 3M Company of Maplewood, Minn. In other embodiments, the coupling mechanism 150 is an adhesive, such as Adseal 4549 silicone based adhesive made by AdChem Corporation of Riverhead, N.Y. The coupling mechanism 150 may be any suitable adhesive, double-sided tape or other coupling mechanism in other embodiments.

(18) In some embodiments, the coupling mechanism 150 is positioned on the outer surfaces 128 of the frame members 134, 136, 138, 140 and 142 and on a top surface 152 (FIGS. 4-7) of the ledges 132. In yet other embodiments, the coupling mechanism 150 is not positioned on the ledges 132 but is only positioned on the outer surfaces 128 of the frame members 134, 136, 138, 140 and 142.

(19) In the embodiment illustrated in FIG. 2, two sheets 126 of material are coupled to each panel frame 160, 162 and 164 by way of the coupling mechanism 150. In other embodiments, any number of sheets 126 can be coupled to each panel frame 160, 162 and 164 by way of the coupling mechanism 150.

(20) FIG. 3 is a rear view of the door of FIG. 1. In the embodiment illustrated in FIG. 3, the positioning of the panel frames 160, 162 and 164 behind the sheets 126 of material is illustrated. In some embodiments, a majority of the inner surface 130 of the sheets 126 is unobstructed by the panel frames 160, 162 and 164 so that the door 100 has a principally transparent or translucent appearance when the sheets 126 are made of a transparent or translucent material. In some embodiments, for example, more than seventy percent of the inner surface 130 of the sheets 126 is unobstructed by the panel frames 160, 162 or 164. In other embodiments, more than sixty percent of the inner surface 130 of the sheets 126 is unobstructed by the panel frames 160, 162 or 164. In yet other embodiments, more than fifty percent of the inner surface 130 of the sheets 126 is unobstructed by the panel frames 160, 162 or 164.

(21) FIGS. 4 and 5 illustrate cross-section views of the top and intermediate panels 110 and 112, respectively, of the door 100 of FIG. 1. The bottom panel 114 is a mirror image of the top panel 110 and thus is not individually illustrated herein in the interest of conciseness. Referring specifically to FIG. 4, in some embodiments the top panel frame 160 includes a large, or “heavy-duty,” upper frame member 134 and a small, or “light duty,” lower frame member 136. In some embodiments, the upper frame member 134 is substantially rectangular in shape and generally has a cross-section profile configured to provide structural strength to a top portion 178 of the top panel frame 160.

(22) The upper frame member 134 includes an exterior surface 148 that is substantially planar and provides a surface to which the coupling mechanism 150 can be adhered. In some embodiments, the coupling mechanism 150 covers only a portion of the exterior surface 148 of the upper frame member 134, as illustrated in FIG. 4. In other embodiments, the coupling mechanism 150 covers all or substantially all of the exterior surface 148 of the upper frame member 134.

(23) In some embodiments, the upper frame member 134 also includes one or more openings 180 to receive an end cap (not shown) or other device to protect the upper frame member 134.

(24) The lower frame member 136 also includes a planar exterior surface 148 to which a coupling mechanism 150 can be adhered. The planar, exterior surface 148 faces an exterior of the door and is substantially parallel to the exterior surface 148 of the upper frame member 134. The lower frame member 136 also includes a sealing member receptacle 166 and a groove 168 that helps to seal the upper panel 110 to the intermediate panel 112, as discussed in more detail below in connection with FIG. 6.

(25) As described above, the lower frame member 136 of each of the panel frames 160, 162 and 164 includes a ledge 132 to support at least part of the weight of the sheet(s) 126. The ledge 132 extends from the exterior surface 148 of the lower frame member 136 and includes a top surface 152 that supports the sheet 126. In some embodiments, the top surface 152 directly contacts a lower edge 154 of the sheet 126. In other embodiments, the top surface 152 contacts another element, such as an adhesive or double-sided tape (not shown), that is placed between the sheet 126 and the ledge 132.

(26) In some embodiments, the ledge 132 extends perpendicularly from the exterior surface 148 of the lower frame member 136 a distance that corresponds to the combined thickness of the sheet 126 and the coupling mechanism 150. As such, in some embodiments the ledge 132 and the outer surface 128 of the sheet 126 are substantially aligned when the sheet 126 is coupled to the respective panel frame 160, 162 or 164. As discussed above, in some embodiments the ledge 132 of each panel frame 160, 162 and 164 is visible at the front face 104 of the door 100 when the door 100 is in the fully closed position, as illustrated in FIG. 1.

(27) Referring now to FIG. 5, in some embodiments the intermediate frame member 142 includes a small, or “light duty,” upper frame member 134 and a small, or “light duty,” lower frame member 136. As discussed above, each of the upper and lower frame members 134 and 136 include a planar exterior surface 148 that provides a surface to which the coupling member 150 is adhered. The upper and lower frame members 134 and 136 each include a sealing member receptacle 166 used to seal adjacent panels 110, 112 and 114. In addition, the upper frame member 134 includes a tongue protrusion 170 while the lower frame member 136 includes a groove 168 that are each used to further seal adjacent panels 110, 112 and 114, as described in more detail below.

(28) The lower frame member 136 also includes a ledge 132 that protrudes from the exterior surface 148 to support the sheet 126. In some embodiments, the ledge 132 protrudes perpendicularly from the exterior surface 148 and supports the lower edge 154 of the sheet 126 on the top surface 152 of the ledge 132.

(29) FIG. 6 illustrates a hinged connection 172 between the top panel 110 and the intermediate panel 112 of FIG. 1. A hinged connection between the intermediate panel 112 and the bottom panel 114 may be substantially similar to the hinged connection 172. In addition, a hinged connection between adjacent intermediate panels 112 (in an embodiment in which the door 100 includes multiple intermediate panels 112) may also be substantially similar to the hinged connection 172.

(30) In some embodiments, the top panel frame 160 is hingedly coupled to the intermediate panel frame 162 by one or more hinge members 174. In some embodiments, the frame members 134 and 136 include sealing features to prevent water, air, insects or another elements from passing between the top and intermediate panels 110 and 112 when the door 100 is in the closed position. In some embodiments, for example, the lower frame member 136 of the top panel 110 includes a groove 168 and the upper frame member 134 of the intermediate panel frame 162 includes a corresponding tongue protrusion 170 configured to reside within the groove 168 when the door 100 is in the closed position. In some embodiments, the interaction between the groove 168 and the tongue protrusion 170 when the door 100 is in the closed position substantially prevents entry of water and light between the top and intermediate panels 110 and 112.

(31) In addition, in some embodiments one or more of the lower frame member 136 of the top panel 110 and the upper frame member 134 of the intermediate panel 112 includes a resilient sealing member 176 located in the respective sealing member receptacle 166. In some embodiments, the resilient sealing member 176 is compressed when the door 100 is in the closed position to further seal the top and intermediate panels 110 and 112 to each other.

(32) FIG. 7 illustrates an embodiment of a method 200 for manufacturing a panel 110, 112 or 114 for use on a seamless, multi-panel door 100. In some embodiments, the method 200 begins and a panel frame 160, 162 or 164 that includes an upper frame member 134, a lower frame member 136, a first side frame member 138, a second side frame member 140, and one or more intermediate frame members 142 is provided, as illustrated at block 202. The frame members 134, 136, 138, 140 and 142 include an exterior surface 148 and the lower frame member 136 includes a ledge 132 that protrudes from the exterior surface 148 of the lower frame member 136.

(33) A sheet 126 of material is also provided, as illustrated at block 204. In some embodiments, the sheet 126 is at least partially translucent and has an outer surface 128 and an inner surface 130.

(34) The inner surface 130 of the sheet 126 is then coupled to the exterior surface 148 of the frame members 134, 136, 138, 140 and 142 so that a lower edge 154 of the sheet 126 rests on the ledge 132 and so that an outer surface 128 of the sheet 126 is unobstructed by the panel frame, as illustrated at block 206.

(35) In some embodiments, the method 200 also includes placing a coupling mechanism 150, such as an adhesive material or double-sided tape, on the exterior surface 148 of each of the frame members 134, 136, 138, 140 and 142 to adhere the sheet 126 to the frame members 134, 136, 138, 140 and 142.

(36) In other embodiments, a worker then places a lower edge 154 of the sheet 126 onto the ledge 132 of the lower frame member 136 to align the sheet 126 with the panel frame 160, 162 or 164. In some embodiments, the worker then presses the sheet 126 onto the coupling mechanism 150 and, in some embodiments, clamps the sheet 126 to the panel frame 160, 162 or 164 until the coupling mechanism 150 has cured and hardened to a suitable strength, often referred to as the “green strength.” In some embodiments, additional sheets 126 are attached to the panel frame 160, 162 or 164 in like manner.

(37) In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “outer” and “inner,” “upper” and “lower,” “first” and “second,” “internal” and “external,” “above” and “below” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

(38) In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.

(39) Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.

(40) Although specific embodiments have been described in detail, those skilled in the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.