Door panel and a stile thereof

Patent metadata

Field	Value
Publication number	US-10711513-B2
Application number	US-201815863145-A
Country	US
Kind code	B2
Filing date	Jan 5, 2018
Priority date	Jan 5, 2018
Publication date	Jul 14, 2020
Grant date	Jul 14, 2020

Abstract

A door panel comprising a body having front and rear door skins sandwiching, at least partially, two stiles, which together delimit an interior for injection of filling material. At least one of the stiles comprises a hollow structure with a partitioned hollow interior that extends along substantially the entire length of the body to offer mechanical strength to the door and to provide foundation for installing door fittings.

First claim

The invention claimed is:

1. A door panel comprising:
a body comprising front and rear door skins sandwiching, at least partially, a first stile and a second stile separate from the first stile;
the first and second stiles together being configured to delimit an interior of the door panel configured to receive an injection of filing material,
wherein at least one of the first and second stiles comprises a hollow structure with a partitioned hollow interior that extends along substantially an entire length of the body and providing mechanical strength to the body and providing a foundation for installing door fittings,
wherein adjacent the hollow structure is a portion to be varnished integrally formed therewith as one piece,
wherein the front and the rear door skins engage respective outer surfaces of the stiles through an engagement between cooperating sets of male and female members,
wherein the male members are arrayed over and extend from the front and rear skins and each of the male members engages with a cooperating corresponding one of the female members,
wherein each female member is provided on outer surfaces of the stile and at the portion to be varnished, and the female member is in the form of a groove defined between two walls of one of the stiles, the groove is configured such that upon insertion of one of the male members in the groove of a corresponding one of the female members, at least one of the two walls defining the groove presses against the male member in the groove to form a fluid tight engagement; and
the at least one of the two walls extends along an axis inclined at an angle with respect to a direction of insertion of the male members such that a top portion of the at least one of the two side walls defining a respective female member closer to an outer side of the stile presses against a corresponding male member but a remaining portion of the at least one of the two side walls defining the respective female member is free of contact with the corresponding male member;
the portion to be varnished includes an internal void isolated from the hollow interior of the hollow structure so as to reduce overall thickness of the portion to be varnished.

2. The door panel as claimed in claim 1 , further comprising elongated ribs positioned to partition the hollow structure, the elongated ribs extending the entire length of the stile.

3. The door panel as claimed in claim 1 , wherein the portion to be varnished extends lengthwise along the entire length of the body and widthwise beyond the front and rear door skins.

4. The door panel as claimed in claim 1 , further comprising a top rail and a bottom rail, each of the top and bottom rails comprising a first set of protrusions, each of the first set of protrusions being dimensioned for insertion into a channel defined by ribs in the respective first and second stiles.

5. The door panel as claimed in claim 4 , wherein each of the top and bottom rails further includes a second set of protrusions for insertion into a hollow interior of the body and the second set of protrusions fitting between the first and the second stiles.

6. The door panel as claimed in claim 1 , wherein the side walls of each female groove are slanted at an angle of approximately 5°-10° with respect to an imaginary vertical line x.

Assignees

• Nanya Plastics Corp

Inventors

• Wang Kuei-Yung

Classifications

• E06B3/82 Primary

  Flush doors, i.e. with completely flat surface (E06B3/02, {E06B3/7003 and E06B3/7015} take precedence) · CPC title

• E06B3/822

  with an internal foursided frame · CPC title

• E06B3/984

  specially adapted for frame members of wood or other material worked in a similar way (E06B3/99 takes precedence) · CPC title

• E06B2003/7082

  Plastic frames · CPC title

• E06B3/725 Primary

  with separate hollow frames, e.g. foam-filled · CPC title