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(11) | EP 0 612 909 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | Metal door |
| (57) A metal door (10) is made from a pair of identical facing sheets (11) and a pair
of identical edge strips (14) which have interengaging formations (12). The facing
sheets having edge formations (13) of channel-section facing towards the inner face
of the sheet. The edge strips have channel-shaped edges provided on the outer side
of the sheet so as to form a rebate at the edge of the door when the formations (13,15)
are interengaged by sliding translational movement. Size and shape variations can
be accommodated by using different facing sheets (11) or edge strips (14). |
[0002] It has been the practice to manufacture metal doors used as fire doors or security doors by welding facing sheets of metal to an edge frame. The door may be filled with an insulating material or a security reinforcement.
[0003] Such use of welding requires the provision of welding equipment and skilled operators. Further, welding may not be possible or desirable in all instances.
[0004] For example, where a special surface finish is provided on the facing sheets, it may not be possible to achieve a weld without damaging the surface finish. Some metals are incompatible or are difficult to weld together. Thermal effects during the course of a fire severely distort structures and may therefore be expected to damage a rigidly welded structure.
[0005] It is an object of the present invention to provide a metal door and a pair of doors and a method of making such a door or pair of doors which overcome or reduce some or all of these disadvantages.
[0006] According to the invention there is provided a metal door comprising a pair of metal facing sheets, each of said sheets including at least one edge formation disposed substantially at right angles to the plane of said sheet and comprising a channel having an open mouth facing towards the sheet; and at least one metal edge strip having a pair of channel shaped cooperating edge formations slidably engaged with the edge formations of the respective facing sheets.
[0007] The cooperating edge formations of the metal edge strip may both lie at the same face of the edge strip and preferably lie at the face which is the outer face in use.
[0008] Thus, when the door is assembled, the edge strip is effectively recessed at the edge of the door.
[0009] The recess may accommodate a draught or smoke seal or an intumescent fire strip or a decorative strip.
[0011] The door may comprise one of a pair of rebated doors having the edge formations of the facing sheets spaced apart at one edge of the door as considered in the general plane of the door; the metal edge strip being of generally Z-shaped cross section and having a pair of cooperating edge formations, at least one of which is of channel shape, slidably engaged with the edge formations of the respective facing sheets to form a rebated edge at said one edge of the door.
[0012] Viewed from a further aspect, the invention provides a pair of rebated doors, each door comprising a pair of metal facing sheets, each of said sheets including at least one edge formation disposed substantially at right-angles to the plane of said sheet and comprising a channel having an open mouth facing towards the sheet, the sheets having their edge formations spaced apart at one edge of the door as considered in the general plane of the door; and at least one metal edge strip having a generally Z-shaped cross-section, the metal edge strip having a pair of cooperating edge formations slidably engaged with the edge formations of the respective facing sheets so as to form a rebated edge to said door.
[0015] According to a further aspect of the invention there is provided a method of making a metal door comprising the steps of taking a pair of metal facing sheets, each of said sheets including at least one edge formation disposed substantially at right angles to the plane of said sheet and comprising a channel having an open mouth facing towards the sheet; taking at least one metal edge strip having a pair of channel shaped cooperating edge formations; and slidably engaging the strip with the facing sheets so that said cooperating edge formations interengage the edge formations of the respective facing sheets.
[0016] The method may further include the step of filling the space between the facing sheets with one or more of the following:- thermal insulation material, intumescent material, security reinforcement, sound reducing material, structural stiffening material.
[0017] The method may include spacing apart said edge formations of the metal facing sheets as considered in the general plane of the door; taking a metal edge strip of generally Z-shaped cross-section and having at least one channel shaped cooperating edge formation; and slidably engaging the strip with the facing sheets so that said cooperating edge formations interengage the edge formations of the respective facing sheets to provide a rebated edge at said one edge of the door.
[0018] Viewed from a still further aspect the invention provides a method of making a pair of metal doors, the method of making each door comprising the steps of taking a pair of metal facing sheets, each of said sheets including one edge formation disposed substantially at right-angles to the plane of said sheet and comprising a channel having an open mouth facing towards the sheet; spacing apart said edge formations as considered in the general plane of the door; taking at least one metal edge strip of generally Z-shaped cross-section and having a pair of cooperating edge formations; and slidably engaging the strip with the facing sheets so that said cooperating edge formations interengage the edge formations of the respective facing sheets to provide a rebated edge to each of said metal doors.
[0019] Embodiments of the invention will now be described in more detail by way of example only with reference to the accompanying drawings in which:-
FIGURE 1 is a diagrammatic partial isometric view of a door,
FIGURE 2 illustrates a modified edge formation.
FIGURE 3 is a diagrammatic partial isometric view of a pair of rebated fire doors.
[0020] Referring firstly to Figure 1, a door generally indicated at 10 comprises a pair of facing sheets 11 of metal such as steel, which may be provided with a chosen finish, for decorative or protective purposes. At each upright edge of the sheets there is provided an edge formation 12, disposed generally at right angles to the plane of the sheet 11 and comprising a channel 13 with a mouth facing towards the plane of the sheet.
[0021] An edge strip 14 of metal, which may be the same as, or different from the metal of the facing sheets as regards material and thickness has a pair of cooperating edge formations 15 of channel shape, which are slidably interengaged with the channels 13 of the edge formations 12 on the respective facing sheets to form an edge of the door. A similar edge strip 14 is provided at the opposite edge of the door.
[0022] A filling (not shown) of insulating material, an uninsulated honeycomb or intumescent material may be provided inside the door in the space 16. Alternatively, structural or security reinforcement may be provided, during or after assembly of the door.
[0023] Top and bottom caps may be added, if the filling does not complete the door. (A foamed insulation may be foamed in situ as part of the structure of the door for example)
[0024] One of the edge strips 14 is shown as carrying a lock or latch. The other edge strip may carry a hinge. The edge strips may be suitably reinforced.
[0025] Figure 2 shows an alternative edge formation providing an overlap for use on one of a pair of fire doors.
[0026] Where it is desired to provide a pair of fire doors, it is usual to provide a rebate so that the doors do not allow penetration of flame or substantial quantities of smoke through their meeting edges.
[0027] Referring to Figure 3, a first fire door is generally indicated at 20 and a second fire door at 21. The doors have meeting rebates at the junction 22.
[0028] Each door comprises a longer facing sheet 23 and a shorter facing sheet 24. These have edge formations 25 comprising generally channel section folds in the metal, the mouth of the channels facing towards the sheets and the edge formations 25 extending at right-angles to the sheets.
[0029] The edge formations are linked by a generally planar metal strip 26 which is slid into place at the outer or hinge edge of the door. However at the inner edge adjacent the joint 22, the respective edge formations 27 of the shorter facing sheet and 28 of the longer facing sheet are staggered or spaced apart, considered in the general plane of the door. An edge strip 29 is provided which is of general Z-shaped cross-section as seen in the drawing. At one end of the Z-shape, a channel-section edge formation 30 extends externally of the Z-shape to cooperate with the edge formation 27 of the shorter facing sheet 24 so that there is a limb 31 of the Z spaced inwardly from the plane of the facing sheet 24.
[0030] At the other end of the Z cross-section, the edge formation 28 comprises a flange which is at right-angles to the adjacent limb portion 32 and which faces inwardly of the Z. The adjacent limb portion 32 of the Z-shaped cross-section abuts the inner face of the longer facing sheet 23 so as to provide a double skin terminating in the edge formation 28 at the extreme free edge of the door.
[0031] A generally Z-shaped hollow 34 remains between the two doors 20 and 21, which can house intumescent material, resilient sealing strips and/or locking gear (not shown). Additional sealing can be provided on the outwardly presented face of the limb 31 of each of the Z sections, to receive the edge formation 28 of the meeting door.
[0032] It will be appreciated that the Z-shaped edge strip 29 is slid into place in the edge formations 27 and 28 of the door, in the same way as the generally planar edge strip 26, giving the advantages of the method and construction of the first-described embodiment.
[0033] It will be appreciated that many advantages accrue from the method of construction outlined. Firstly, the two faces of the door are unmarred by welding when so joined. Secondly, the use of a variety of different materials in the same door may be achieved, even where these would be incompatible and incapable of being welded.
[0034] The production of thick and thin doors can be achieved simply by using alternative edge strips of the appropriate size, whereas this is more difficult by welding methods, since differently sized jigs and tools are required especially when door edges are created by folding over door sides.
[0035] Edge strips and facing sheets can be stocked and transported separately, with reduction in space.
[0036] A rebate occurs at each upright edge of the door, within which strips of intumescent material for fire-resistant purposes or smoke protection can be provided or alternatively draught- or smoke-seals or decorative strips can be provided.
1. A metal door comprising a pair of metal facing sheets, each of said sheets including
at least one edge formation disposed substantially at right-angles to the plane of
said sheet and comprising a channel having an open mouth facing towards the sheet;
and at least one metal edge strip having a pair of channel-shaped cooperating edge
formations slidably engaged with the edge formations of the respective facing sheets.
2. A metal door according to claim 1 wherein the cooperating edge formations of the metal
edge strip both lie at the same face of the edge strip.
3. A metal door according to claim 2 wherein both cooperating edge formations lie at
the face which is the outer face in use of the door, to define a recess.
4. A metal door according to claim 3 wherein the recess accommodates a draught seal,
smoke seal, intumescent fire strip or decorative strip.
5. A metal door according to any one of claims 1-4 wherein a lock or latch is mounted
on the edge strip.
6. A metal door according to claim 1 wherein the door comprises one of a pair of rebated
doors having the edge formations of the facing sheets spaced apart as considered in
the general plane of the door at one edge of the door; the metal edge strip being
of generally Z-shaped cross-section and having a pair of cooperating edge formations
at least one of which is of channel shape, slidably engaged with the edge formations
of the respective facing sheets to form a rebated edge at said one edge of the door.
7. A pair of rebated fire doors, each door comprising a pair of metal facing sheets,
each of said sheets including at least one edge formation disposed substantially at
right-angles to the plane of said sheet and comprising a channel having an open mouth
facing towards the sheet, the sheets having their edge formations spaced apart at
one edge of the door as considered in the general plane of the door; and at least
one metal edge strip having a generally Z-shaped cross-section, the metal edge strip
having a pair of cooperating edge formations slidably engaged with the edge formations
of the respective facing sheets so as to form a rebated edge to the door.
8. A door according to claim 7 wherein at least one of the cooperating edge formations
is channel-shaped.
9. A door according to claim 8 wherein the other of said cooperating edge formations
comprises a flange at right-angles to the adjacent portion of the edge strip.
10. A method of making a metal door comprising the steps of taking a pair of metal facing
sheets, each of said sheets including at least one edge formation disposed substantially
at right-angles to the plane of said sheet and comprising a channel having an open
mouth facing towards the sheet; taking at least one metal edge strip having a pair
of channel-shaped cooperating edge formations; and slidably engaging the strip with
the facing sheets so that said cooperating edge formations interengage the edge formations
of the respective facing sheets.
11. A method according to claim 10 further including the step of filling the space between
the facing sheets with one or more of the following:-
thermal insulation material, intumescent material, security reinforcement, sound reducing material, structural stiffening material.
thermal insulation material, intumescent material, security reinforcement, sound reducing material, structural stiffening material.
12. A method according to claim 10 or claim 11 wherein the door is one of a pair of rebated
metal doors, the method including spacing apart the edge formations of the metal facing
sheets as considered in the general plane of the door; taking a metal edge strip of
generally Z-shaped cross-section and having at least one channel-shaped cooperating
edge formation; and slidably engaging the strip with the facing sheets so that said
cooperating edge formations interengage the edge formations of the facing sheets to
provide a rebated edge at said edge of the door.
13. A method of making a rebated door forming one of a pair of doors, comprising the steps
of taking a pair of metal facing sheets, each of said sheets including one edge formation
disposed substantially at right-angles to the plane of said sheet and comprising a
channel having an open mouth facing towards the sheet; spacing apart said edge formations
as considered in the general plane of the door; taking at least one metal edge strip
of generally Z-shaped cross-section and having a pair of cooperating edge formations;
and slidably engaging the strip with the facing sheets so that said cooperating edge
formations interengage the edge formations of the respective facing sheets to provide
a rebated edge to said metal door.
14. A door substantially as hereinbefore described with reference to and as illustrated
in Figure 1 of the accompanying drawings.
15. A door substantially as hereinbefore described with reference to and as illustrated
in Figure 2 of the accompanying drawings.
16. A door substantially as hereinbefore described with reference to and as illustrated
in Figure 3 of the accompanying drawings.
17. A method of making a metal door according to claim 10 or claim 13 and substantially
as hereinbefore described.