Panel doors and related method

Patent metadata

Field	Value
Publication number	US-12110738-B2
Application number	US-202318197293-A
Country	US
Kind code	B2
Filing date	May 15, 2023
Priority date	Mar 29, 2018
Publication date	Oct 8, 2024
Grant date	Oct 8, 2024

Abstract

A door is provided that includes a door panel having a periphery and opposite first and second panel surfaces, stiles and rails collectively surrounding the panel, and sealant. The stiles have channeled stile surfaces extending across a thickness of the stiles and facing one another. The rails have channeled rail surfaces extending across a thickness of the rails and facing one another. The channeled stile surfaces and the channeled rail surfaces include channels with open ends that receive the periphery of the panel, first grooves positioned at first interfaces of the first panel surface and first edges of the open ends of the channels, and second grooves positioned at second interfaces of the second panel surface and second edges of the open ends of the channels. The sealant is received in the first and second grooves, preferably forming a water-proof seal.

First claim

What is claimed is:

1. A door, comprising:
a door panel having a periphery and opposite first and second panel surfaces;
stiles and rails collectively surrounding the panel, the stiles having channeled stile surfaces extending across a thickness of the stiles and facing one another, the rails having channeled rail surfaces extending across a thickness of the rails and facing one another, the channeled stile surfaces and the channeled rail surfaces comprising
channels with open ends that receive the periphery of the panel,
first sealant-receiving grooves positioned at first interfaces of the first panel surface and first edges of the open ends of the channels, the first sealant-receiving grooves having a first unobstructed, open groove area configured to receive a first continuous bead of sealant applied therethrough, and
second sealant-receiving grooves positioned at second interfaces of the second panel surface and second edges of the open ends of the channels, the second sealant-receiving grooves having a second unobstructed, open groove area configured to receive a second continuous bead of sealant applied therethrough; and

said sealant received in the first and second sealant-receiving grooves.

2. The door of claim 1 , wherein the door panel comprises an insulated glazing unit.

3. The door of claim 1 , wherein the door panel comprises laminated veneer lumber.

4. The door of claim 1 , wherein the stiles and the rails are solid members extending between opposite surfaces of the door.

5. The door of claim 1 , wherein the sealant comprises an acrylic latex polymer.

6. The door of claim 1 , wherein the channeled stile surfaces and the channeled rail surfaces slope at an oblique angle toward outer edges of the door.

7. The door of claim 1 , further comprising foam spacers positioned in the channels between the periphery of the door panel and bottoms of the channels.

8. The door of claim 1 , wherein the channels have bottom surfaces with empty recesses.

9. The door of claim 1 , further comprising a compressed elastomeric film received in the channels and positioned about the periphery of the door panel to contact the first and second panel surfaces.

10. The door of claim 1 , wherein the sealant has a joint movement capability of at least 25% of a width of the sealant to permit limited movement of the door panel relative to the stiles and the rails at the first and second interfaces.

11. The door of claim 10 , wherein the sealant provides a waterproof seal at the first and second interfaces.

12. A door, comprising:
a door panel having a periphery and opposite first and second panel surfaces, the door panel having a multi-ply construction comprising a medium density fiberboard ply and first and second solid wood plies on opposite sides of the medium density fiberboard ply;
stiles and rails collectively surrounding the panel, the stiles having channeled stile surfaces extending across a thickness of the stiles and facing one another, the rails having channeled rail surfaces extending across a thickness of the rails and facing one another, the channeled stile surfaces and the channeled rail surfaces comprising
channels with open ends that receive the periphery of the panel,
first sealant-receiving grooves positioned at first interfaces of the first panel surface and first edges of the open ends of the channels, the first sealant-receiving grooves having a first unobstructed, open groove area configured to receive a first continuous bead of sealant applied therethrough, and
second sealant-receiving grooves positioned at second interfaces of the second panel surface and second edges of the open ends of the channels, the second sealant-receiving grooves having a second unobstructed, open groove area configured to receive a second continuous bead of sealant applied therethrough; and

said sealant received in the first and second sealant-receiving grooves configured to establish water-proof seals at the first and second interfaces.

13. The door of claim 12 , wherein the stiles and the rails are solid members extending between opposite surfaces of the door.

14. The door of claim 12 , wherein the channeled stile surfaces and the channeled rail surfaces slope at an oblique angle toward outer edges of the door.

15. The door of claim 12 , further comprising foam spacers positioned in the channels between the periphery of the door panel and bottoms of the channels.

16. The door of claim 12 , wherein the channels have bottom surfaces with empty recesses.

17. The door of claim 12 , further comprising a compressed elastomeric film received in the channels and positioned about the periphery of the door panel to contact the first and second panel surfaces.

18. The door of claim 12 , wherein the sealant has a joint movement capability of at least 25% of a width of the sealant to permit limited movement of the door panel relative to the stiles and the rails at the first and second interfaces.

19. The door of claim 18 , wherein the sealant comprises an acrylic latex polymer.

20. A method of making the door of claim 1 , comprising:
providing a door panel having a periphery and opposite first and second panel surfaces;
securing stiles and rails to the panels to collectively surrounding the panel, the stiles having channeled stile surfaces extending across a thickness of the stiles and facing one another, the rails having channeled rail surfaces extending across a thickness of the rails and facing one another, the channeled stile surfaces and the channeled rail surfaces comprising channels with open ends that receive the periphery of the panel, first unobstructed, open sealant-receiving grooves positioned at first interfaces of the first panel surface and first edges of the open ends of the channels, and second unobstructed, open sealant-receiving grooves positioned at second interfaces of the second panel surface and second edges of the open ends of the channels; and
applying sealant in the first and second sealant-receiving grooves.

Assignees

• Masonite Corp

Inventors

• Ettrich Jan H
• Breton Hubert

Classifications

• E06B3/5454

  inside U-shaped section members · CPC title

• E06B3/5409

  Means for locally spacing the pane from the surrounding frame · CPC title

• E06B3/5892

  Fixing of window panes in openings in door leaves · CPC title

• E06B3/74 Primary

  with wooden panels {or frame (E06B3/721, E06B3/725 and E06B3/76 take precedence)} · CPC title

• E06B3/66304

  Discrete spacing elements, e.g. for evacuated glazing units · CPC title