Sliding barn door hardware

Patent metadata

Field	Value
Publication number	US-10538947-B2
Application number	US-201715452586-A
Country	US
Kind code	B2
Filing date	Mar 7, 2017
Priority date	Mar 7, 2016
Publication date	Jan 21, 2020
Grant date	Jan 21, 2020

Abstract

The present disclosure provides for a sliding (barn-style) door and methods and hardware for mounting. The sliding barn door includes a door slab and mounting hardware including a top extension and a bottom extension. The top and bottom extensions each have a rectangular face having substantially the same dimensions and configured to lengthen the height of the door slab.

First claim

The invention claimed is:

1. A sliding door, comprising:
a door slab having a front face, a rear face opposite the front face, and spaced-apart top and bottom sides extending between the front and rear faces along respective top and bottom portions of the door slab, the door slab having a slab height between the top and bottom sides and a width;
a top extension member attached to the door slab adjacent the top side thereof, the top extension member having a first flange aligned with the front face of the door slab, the first flange extending along the width of the door slab and having a rectangular shape and a width that approximately equals the width of the door slab, and an attachment member connected to the first flange and extending transversely therefrom, the attachment member being secured to the top portion of the door slab; and
a bottom extension member attached to the door slab adjacent the bottom side thereof, the bottom extension member aligned with the front face of the door slab and extending along the width of the door slab,
the top and bottom extension members protruding beyond the respective top and bottom sides of the door slab to result in a door height of the door that is greater than the slab height; and
a plurality of hangers, each hanger secured to the door slab behind the first flange and extending upwardly away from the top side of the door slab toward a distal end of the hanger which carries a wheel, the hangers and wheels configured and positioned to suspend the door slab from a rail such that the door slab hangs from the rail in a vertical orientation and to guide the door slab for movement along the rail between an open position and a closed position.

2. The sliding door of claim 1 wherein the top extension member has a first opposing flange spaced apart from and substantially aligned with the first flange and wherein the attachment member extends between and connects the first flange to the first opposing flange to form a substantially H-shaped profile.

3. The sliding door of claim 2 wherein the attachment member comprises a web that overlays the top side of the door slab.

4. The sliding door of claim 1 wherein the bottom extension member further comprises a second flange aligned with the front face of the door slab and extending along the width of the door slab.

5. The sliding door of claim 4 wherein the first flange and the second flange each have a height greater than one inch.

6. The sliding door of claim 4 wherein the first flange and the second flange each have a height greater than 2 inches.

7. The sliding door of claim 4 wherein the bottom extension member has a second opposing flange spaced apart from and substantially aligned with the second flange and wherein a bottom attachment member extends between and connects the second flange to the second opposing flange to form a substantially H-shaped profile.

8. The sliding door of claim 1 wherein the first and second flanges are made of metal.

9. The sliding door of claim 1 , wherein the first and second flanges are rectangular, have substantially the same dimensions, and contrast visually with the front face of the door slab, so as to present a letterbox appearance.

10. The sliding door of claim 1 wherein the top extension member comprises a set of holes pre-formed in the top extension member to locate at least one fastening point for securing the top extension member to the door slab.

11. The sliding door of claim 1 further comprising fasteners securing the attachment member to the top side of the door slab.

12. The sliding door of claim 1 wherein at least one of the first and second flanges overlaps the front face of the door slab.

13. The sliding door of claim 1 wherein the attachment member connects to the first flange below a midpoint of the first flange.

14. The sliding door of claim 1 the top side of the door slab extends between first and second lateral sides of the door slab, the first and second lateral sides lying in respective first and second planes that are substantially perpendicular to the front face of the door slab, and wherein no portion of the first flange extends beyond the first lateral plane or the second lateral plane.

15. The sliding door of claim 1 wherein each hanger of the plurality of hangers is secured to the door slab by a fastener that engages the top portion of the door slab.

16. A method for installing a sliding door, comprising:
providing a door slab having a front face, a rear face opposite the front face, a top side extending between the front and rear faces at a top of the door slab, a bottom side spaced apart from the top side and extending between the front and rear faces at a bottom of the door slab, the door slab having a slab height between the top and bottom sides and a width;
providing a top extension member including a first flange, the first flange having a rectangular shape and a width that extends along the width of the door slab and is approximately equal to the width of the door slab, and a top attachment member connected to the first flange and extending transversely therefrom;
providing a bottom extension member including a second flange having a width approximately equal to the width of the door slab and a bottom attachment member connected to the second flange and extending transversely therefrom;
positioning the top extension member at the top of the door slab so that the first flange is aligned with the front face of the door slab to result in a door height of the door that is greater than the slab height;
securing the top attachment member to the door slab;
positioning the bottom extension member at the bottom of the door slab so that the second flange is aligned with the first flange and is adjacent to the front face of the door slab to further increase the door height of the door;
securing the bottom extension member to the door slab;
providing a plurality of hangers each carrying a wheel at a distal end of the hanger;
securing the hangers to the door slab behind the first flange so that the hangers extend with their distal ends upwardly away from the top side of the door slab; and
suspending the door slab from a rail such that the door slab hangs from the wheels with the rail in a vertical orientation and the wheels guide the door slab for movement along the rail between an open position and a closed position.

17. The method of claim 16 wherein the top extension member further includes a first opposing flange spaced apart from the first flange, and the top attachment member extends between and connects the first flange to the first opposing flange to form a substantially H-shaped profile, the top attachment member comprising a web that overlays the top side of the door slab.

18. The method of claim 16 wherein at least one of the first flange and the second flange overlaps the front face of the door slab.

19. The method of claim 16 wherein the first flange and the second flange each have a height greater than 1 inch.

20. The method of claim 16 wherein the first flange and the second flange each have a height greater than 2 inches.

21. The method of claim 16 wherein the first and second flanges are rectangular and contrast visually with the front face of the door slab, so as to present a letterbox appearance.

22. The method of claim 16 wherein positioning the top extension member at the top of the door slab further comprises using a set of holes pre-formed in the top extension member to locate at least one fast

Assignees

• Jeld Wen Inc

Inventors

• Boring Tommy
• Sisson Stephen
• Cooper James
• Miranda Joe
• Powell Brian

Classifications

• E05D15/063 Primary

  on wheels with fixed axis · CPC title

• E05D15/0656

  Bottom guides · CPC title

• E05D15/0652

  Tracks (E05D15/063 - E05D15/0647 and E05D15/0656 take precedence) · CPC title

• E05Y2900/132

  Doors · CPC title

• E05D15/0626

  for wings suspended at the top · CPC title