Metal door

• US 10,458,177 B1
• Filed: 03/09/2018
• Issued: 10/29/2019
• Est. Priority Date: 03/09/2018
• Status: Active Grant

• Current Assignee: Outdoor Spaces, Inc.
• Original Assignee: Outdoor Spaces, Inc.
• Inventors: Steele, Ryan D., Cullinane, Daniel C.
• Primary Examiner(s): Katcheves, Basil S
• Application Number:
  US15/916,803
• Time in Patent Office: 599 Days
• Field of Search: 5278415
• CPC Class Codes: E06B 1/18 composed of several parts with respect to the cross-section of the frame itself
• CPC Class Codes: E06B 1/52 Frames specially adapted for doors
• CPC Class Codes: E06B 2003/26383 with two similar parallel strips, one shifted to one side
• CPC Class Codes: E06B 2003/7023 of foam type
• CPC Class Codes: E06B 2003/7049 Specific panel characteristics
• CPC Class Codes: E06B 3/26303 with thin strips, e.g. defining a hollow space between the metal section members
• CPC Class Codes: E06B 3/267 with insulating elements formed in situ
• CPC Class Codes: E06B 3/305 Covering metal frames with plastic or metal profiled members
• CPC Class Codes: E06B 3/362 Double winged doors or windows
• CPC Class Codes: E06B 3/5892 Fixing of window panes in openings in door leaves
• CPC Class Codes: E06B 3/7001 Coverings therefor; Door leaves imitating traditional raised panel doors, e.g. engraved or embossed surfaces, with trim strips applied to the surfaces
• CPC Class Codes: E06B 3/728 of sheet metal
• CPC Class Codes: E06B 3/76 with metal panels E06B3/721 - E06B3/725 take precedence

Abstract

A metal door including a hinge stile having upper and lower ends, a lock stile having upper and lower ends, a top rail extending between the upper ends of the hinge and lock stiles, a bottom rail extending between the lower ends of the hinge and lock stiles, and an intermediate rail extending between the hinge and lock stiles above the bottom rail. The hinge stile, the lock stile, the top rail, the bottom rail and the intermediate rail having a unique construction which creates a thermal break therein. The door is mounted in a jamb which also has a unique construction which creates a thermal break therein.

Claims

1. A metal door, comprising:

a vertically disposed hinge stile having an upper end, a lower end, an inner side, an outer end, a front side and a rear side;

a vertically disposed lock stile having an upper end, a lower end, an inner end, an outer end, a front side and a rear side;

a top rail extending between said upper ends of said hinge stile and said lock stile with said top rail having a first end, a second end, an upper end, a lower end, a front side and a rear side;

a bottom rail extending between said lower ends of said hinge stile and said lock stile with said bottom rail having a first end, a second end, an upper end, a lower end, a front side and a rear side;

each of said hinge and lock stiles comprising;

(a) a vertically disposed first aluminum extrusion having;

(1) a front wall with first and second ends;

(2) a first end wall, having first and second ends, extending transversely rearwardly from said first end of said front wall;

(3) a second end wall, having first and second ends, extending transversely rearwardly from said second end of said front wall;

(4) a rear wall, having first and second ends, extending between said second end of said first end wall and said second end of said second end wall;

(5) said front wall, said first end wall, said second end wall and said rear wall defining a generally triangular-shaped second cavity;

(6) said first cavity having foam insulation therein;

(7) an elongated first channel at said second end of said first end wall;

(8) an elongated second channel adjacent said second end of said rear wall;

(b) a vertically disposed second aluminum extrusion having;

(1) a rear wall with first and second ends;

(2) a first end wall, having first and second ends, extending transversely forwardly from said first end of said rear wall thereof;

(3) a second end wall, having first and second ends, extending transversely forwardly from said second end of said rear wall;

(4) a front wall, having first and second ends, extending between said second end of said first end wall and said second end of said second end wall thereof;

(5) said rear wall, said first end wall, said second end wall and said front wall defining a generally triangular-shaped second cavity;

(6) said first cavity having foam insulation therein;

(7) an elongated first channel at said second end of said first end wall;

(8) an elongated second channel adjacent said second end of said front wall;

said second aluminum extrusion being positioned with respect to said first aluminum extrusion so as to be spaced rearwardly therefrom with said second channel of said second aluminum extrusion being aligned with said first channel of said first aluminum extrusion and so that said first channel of said second aluminum extrusion is aligned with said second channel of said first aluminum extrusion and so that said front wall of said second aluminum extrusion is spaced from said rear wall of said first aluminum extrusion and is parallel thereto;

an elongated first connector having first and second ends;

said first end of said first connector being received in said first channel of said first aluminum extrusion with said second end of said first connector being received in said second channel of said second aluminum extrusion;

an elongated second connector having first and second ends;

said first end of said second connector being received in said second channel of said first aluminum extrusion with said second end of said second connector being received in said first channel of said second aluminum extrusion;

said first and second connectors being comprised of a non-metallic and non-thermally conductive material whereby a thermal break is provided between said first and second aluminum extrusions;

an elongated first steel skin secured to said first aluminum extrusion so as to embrace said first end wall, said front wall and said second end wall thereof;

an elongated second steel skin secured to said second aluminum extrusion so as to embrace said first end wall, said rear wall and said second end wall thereof;

said first and second steel skins being spaced apart so as to create a thermal break therebetween;

said bottom rail being of identical construction to said hinge stile and said lock stile except for the length thereof which is less than the length of said hinge stile and said lock stile; and

said top rail having a thermal break created therein between said front side and said rear side thereof.

2. The metal door of claim 1 wherein said top rail comprises:

(a) a vertically disposed front rail member having a first end, a second end, an upper end, a lower end, a front side and a rear side;

(b) a vertically disposed rear rail member having a first end, a second end, an upper end, a lower end, a front side and a rear side;

(c) said front rail member and said rear rail member being secured together in a spaced-apart manner to create a thermal break therebetween; and

(d) a foam insulation between said front rail member and said rear rail member.