Metal door

• US 9,175,508 B1
• Filed: 10/03/2014
• Issued: 11/03/2015
• Est. Priority Date: 06/10/2014
• Status: Active Grant

• Current Assignee: Ryan D. Steele
• Original Assignee: Ryan D. Steele
• Inventors: Steele, Ryan D.
• Primary Examiner(s): KATCHEVES, BASIL S
• Application Number:
  US14/505,919
• Time in Patent Office: 396 Days
• Field of Search: 527/841.5, 528/001.3, 527/921, 527/841.3, 522/11
• US Class Current: 1/1
• CPC Class Codes: E06B 2003/7076 insulated
• 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 3/72 consisting of frame and panels , e.g. of raised panel type E06B3/7001 - E06B3/7015 and E06B3/82 take precedence

Abstract

A metal door comprising first and second side frames or stiles and upper and lower frames or rails which are joined together. Each of the frames includes front and rear panels which are spaced apart and which are secured together by means of insulating panel connectors. The space between the panel connectors in each of the frames is filled with an insulating foam material. The panel connectors are also comprised of an insulating material such as wood, fiberglass, plastic or other insulative material.

Claims

1. A door comprising:

a vertically disposed and vertically extending first side frame or stile having an upper end, a lower end, a front side, a rear side, an inner end and an outer end;

said first side frame including a vertically disposed metal front or exterior panel having an upper end, a lower end, an inner end, an outer end, a first flange extending transversely rearwardly from said outer end of said front panel, a second flange extending inwardly from the rearward end of said first flange, a third flange extending transversely rearwardly from said inner end of said front panel, a fourth flange extending outwardly from the rearward end of said third flange;

said first side frame also including a vertically disposed metal rear panel which is spaced rearwardly of said front panel and which has an upper end, a lower end, an inner end and an outer end, a first flange extending transversely forwardly from said outer end of said rear panel, a second flange extending inwardly from the forward end of said first flange, a third flange extending transversely forwardly from said inner end of said rear panel and a fourth flange extending outwardly from the forward end of said third flange;

said first side frame further including an elongated, vertically disposed first panel connector having an upper end, a lower end, an outer side and an inner side;

said first panel connector of said first side frame having a vertically disposed slot formed in said outer side thereof;

said first panel connector of said first side frame being positioned between said front and rear panels of said first side frame inwardly of said outer ends thereof with said vertically disposed slot in said first panel connector of said first side frame receiving said second flange of said front panel of said first side frame and said second flange of said rear panel of said first side frame therein;

said first panel connector of said first side frame being secured to said front and rear panels of said first side frame so that said second flange of said front panel of said first side frame is spaced forwardly of said second flange of said rear panel of said first side frame;

a caulking material in said slot in said first panel connector;

an elongated, vertically disposed second panel connector having an upper end, a lower end, an outer side, and an inner side;

said second panel connector of said first side frame having a vertically disposed slot formed in said inner side thereof;

said second panel connector of said first side frame being positioned between said front and rear panels of said first side frame with said vertically disposed slot in said second panel connector of said first side frame receiving said fourth flange of said front panel of said first side frame and said fourth flange of said rear panel of said first side frame therein;

said second panel connector of said first side frame being secured to said front and rear panels of said first side frame so that said fourth flange of said front panel of said first side frame is spaced forwardly of said fourth flange of said rear panel of said first side frame;

a caulking material in said slot in said second panel connector;

a foam insulation material in said lower frame between said first and second panel connectors thereof;

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

said second side frame including a vertically disposed metal front panel having an upper end, a lower end, an inner end, and an outer end, a first flange extending transversely rearwardly from said outer end of said front panel, a second flange extending inwardly from the rearward end of said first flange, a third flange extending transversely from said inner end of said front panel, a fourth flange extending outwardly from the rearward end of said third flange;

said second side frame also including a vertically disposed metal rear panel which is spaced rearwardly of said front panel thereof and which has an upper end, a lower end, an inner end and an outer end, a first flange extending transversely forwardly from said outer end of said rear panel, a second flange extending inwardly from the forward end of said first flange, a third flange extending transversely forwardly from said inner end of said rear panel and a fourth flange extending outwardly from the forward end of said third flange;

said second side frame further including an elongated, vertically disposed first panel connector having an upper end, a lower end, an outer side and an inner side;

said first panel connector of said second side frame having a vertically disposed slot formed in said inner side thereof;

said first panel connector of said second side frame being positioned between said front and rear panels of said second side frame inwardly of said inner ends thereof with said vertically disposed slot in said first panel connector of said second side frame receiving said second flange of said front panel of said second side frame and said second flange of said rear panel of said second side frame therein;

said first panel connector of said second side frame being secured to said front and rear panels of said second side frame so that said second flange of said front panel of said second side frame is spaced forwardly of said second flange of said rear panel of said second side frame;

an elongated, vertically disposed second panel connector having an upper end, a lower end, an outer side, and an inner side;

said second panel connector of said second side frame having a vertically disposed slot formed in said outer side thereof;

said second panel connector of said second side frame being positioned between said front and rear panels of said second side frame with said vertically disposed slot in said second panel connector of said second side frame receiving said second flange of said front panel of said second side frame and said second flange of said rear panel of said second side frame therein;

said second panel connector of said second side frame being secured to said front and rear panels of said second side frame so that said fourth flange of said front panel of said second side frame is spaced forwardly of said fourth flange of said rear panel of said second side frame;

a caulking material in said slot in said second panel connector of said second side frame;

a horizontally disposed and horizontally extending upper frame having a first end, a second end, a front side and a back side;

said first end of said upper frame being secured to said upper end of said first side frame;

said second end of said upper frame being secured to said upper end of said second side frame;

said upper frame including a vertically disposed metal front panel having an upper end, a lower end, a first end and a second end,

a first flange extending transversely rearwardly from said upper end of said front panel of said upper frame;

a second flange extending downwardly from the rearward end of said first flange of said upper frame;

a third flange extending rearwardly from said lower end of said front panel of said upper frame;

a fourth flange extending upwardly from the rearward end of said front panel of said upper frame;

said upper frame also including a vertically disposed metal rear panel having an upper end, a lower end, a first end and a second end;

said rear panel of said upper frame being positioned rearwardly of said front panel of said upper frame;

a first flange extending forwardly from said upper end of said rear panel of said upper frame;

a second flange extending downwardly from the forward end of said first flange of said rear panel of said upper frame;

a third flange extending forwardly from said lower end of said rear panel of said upper frame;

a fourth flange extending upwardly from the forward end of said third flange of said rear panel of said upper frame;

said upper frame including a horizontally disposed and horizontally extending first panel connector having a first end, a second end, an upper side, a lower side, a front side and a rear side;

said first panel connector of said upper frame having a horizontally disposed slot formed in said upper side thereof;

said first panel connector of said upper frame being positioned between said front and rear panels of said upper frame whereby said second flange of said front panel of said upper frame and said second flange of said rear panel are received in said slot formed in said first panel connector of said upper frame;

said first panel connector of said upper frame being secured to said front and rear panels of said upper frame;

a caulking material in said slot in said first panel connector of said upper frame;

said upper frame also including a horizontally disposed and horizontally extending second panel connector having a first end, a second end, an upper side, a lower side, a front side and a rear side;

said second panel connector of said upper frame having a horizontally disposed slot formed in said lower side thereof;

said second panel connector of said upper frame being positioned between said front and rear panels of said upper frame whereby said fourth flange of said front panel of said upper frame and said fourth flange of said rear panel are received in said slot formed in said second panel connector of said upper frame;

a caulking material in said slot in said second panel connector of said upper frame;

a horizontally disposed and horizontally extending lower frame having a first end, a second end, a front side and a back side;

said first end of said lower frame being secured to said lower end of said first side frame;

said second end of said lower frame being secured to said lower end of said second side frame;

said lower frame including a vertically disposed metal front panel having an upper end, a lower end, a first end and a second end,

a first flange extending transversely rearwardly from said upper end of said front panel of said lower frame;

a second flange extending downwardly from the rearward end of said first flange of said lower frame;

a third flange extending rearwardly from said lower end of said front panel of said lower frame;

a fourth flange extending upwardly from the rearward end of said third flange of said upper frame;

said lower frame also including a vertically disposed metal rear panel having an upper end, a lower end, a first end and a second end;

said rear panel of said lower frame being positioned rearwardly of said front panel of said lower frame;

a first flange extending forwardly from said upper end of said rear panel of said lower frame;

a second flange extending downwardly from the forward end of said first flange of said rear panel of said upper frame of said lower frame;

a third flange extending forwardly from said lower end of said rear panel of said lower frame;

a fourth flange extending upwardly from the forward end of said third flange of said rear panel of said upper frame of said lower frame;

said lower frame including a horizontally disposed and horizontally extending first panel connector having a first end, a second end, an upper side, a lower side, a front side and a rear side;

said first panel connector of said lower frame having a horizontally disposed slot formed in said upper side thereof;

said first panel connector of said lower frame being positioned between said front and rear panels of said lower frame whereby said second flange of said front panel of said lower frame and said second flange of said rear panel of said lower frame are received in said slot formed in said first panel connector of said lower frame;

said first panel connector of said lower frame being secured to said front and rear panels of said lower frame;

a caulking material in said slot in said first panel connector of said lower frame;

said lower frame including a horizontally disposed and horizontally extending second panel connector having a first end, a second end, an upper side, a lower side, a front side and a rear side;

said second panel connector of said lower frame having a horizontally disposed slot formed in said lower side thereof;

said second panel connector of said lower frame being positioned between said front and rear panels of said lower frame whereby said fourth flange of said front panel of said lower frame and said fourth flange of said rear panel of said lower frame are received in said slot formed in said second panel connector of said lower frame;

said second panel connector of said lower frame being secured to said front and rear panels of said lower frame;

a caulking material in said slot in said second panel connector of said lower frame.

2. The door of claim 1 wherein said panel connectors are comprised of an insulating material.

3. The door of claim 1 wherein said panel connectors are comprised of wood.

4. The door of claim 1 wherein said panel connectors are comprised of plastic.

5. The door of claim 1 wherein said panel connectors are comprised of fiberglass.

6. The door of claim 1 wherein an intermediate frame is secured to and extends between said first and second side frames above said lower ends thereof.

7. The door of claim 1 wherein an insulated glass member is positioned between said front and second side frames.

8. The door of claim 1 wherein said panel connectors are secured to said front and rear panels by bolts.

9. The door of claim 1 wherein the door is mounted in a door frame including first and second vertically disposed jambs which include insulative material.

10. The door of claim 9 wherein one of said first and second side frames is hingedly secured to one of said jambs.

11. The door of claim 9 wherein said jambs extend forwardly from said outer ends of said first and second side frames.

12. The door of claim 9 wherein said jambs include insulation means for preventing the passage of cold temperature therethrough.

13. A metal door, comprising:

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

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

a horizontally disposed upper frame having a first end, a second end, an upper end, a lower end, a front side and a rear side;

said first end of said upper frame being joined to said upper end of said first side frame;

said second end of said upper frame being joined to said upper end of said second frame;

a horizontally disposed lower frame having a first end, a second end, an upper end, a lower end, a front side and a back side;

said first end of said lower frame being joined to said lower end of said first side frame;

said second end of said lower frame being joined to said lower end of said second side frame;

said first side frame including spaced-apart front and rear panels which are comprised of a metal material;

a pair of spaced-apart insulated connectors positioned between said front and rear panels of said first side frame which are connected to said front and rear panels to maintain said front and rear panels of said first side frame in a spaced-apart position and to provide a thermal break between said front and rear panels of said first side frame;

said second side frame including spaced-apart front and rear panels being comprised of a metal material;

a pair of spaced-apart insulated connectors positioned between said front and rear panels of said second side frame which are connected to said front and rear panels of said second side frame to maintain said front and rear panels of said second side frame in a spaced-apart position and to provide a thermal break between said front and rear panels of said second side frame;

said upper frame including spaced-apart front and rear panels which are comprised of a metal material;

a pair of spaced-apart insulated connectors positioned between said front and rear panels of said upper frame which are connected to said front and rear panels of said upper frame to maintain said front and rear panels of said upper frame in a spaced-apart position and to provide a thermal break between said front and rear panels of said upper frame;

said lower frame including spaced-apart front and rear panels which are comprised of a metal material;

a pair of spaced-apart insulated connectors positioned between said front and rear panels of said lower frame which are connected to said front and rear panels of said lower frame to maintain said front and rear panels of said lower frame in a spaced-apart position and to provide a thermal break between said front and rear panels of said lower frame;

and an insulation means positioned between said connectors of said first side frame, said connectors of said second side frame, said connectors of said upper frame and said connectors of said lower frame.

14. The metal door of claim 13 wherein each of said front and rear panels of each of said first side frame, said second side frame, said upper frame and said lower frame have flanges extending therefrom which are received by the respective connectors.