Movable or removable closures – Panel with closure feature
Reexamination Certificate
2000-04-18
2001-10-30
Chin-Shue, Alvin (Department: 3634)
Movable or removable closures
Panel with closure feature
C052S784140, C052S784130
Reexamination Certificate
active
06308463
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to composite panel doors and, more particularly, to a hinge assembly used to mount the door within a frame, as well as a method of securing the hinge assembly to the door.
Medium density fiberboard is a composite panel product that typically comprises lignocellulosic fibers combined with a synthetic resin or other suitable bonding systems under heat and pressure. Four standard grades of medium density fiberboard are commercially available in North America and are classified under ANSI Standard A208.2 based on product density and other physical and mechanical properties.
Medium density fiberboard is widely used in the manufacture of furniture products because it provides a flat, smooth surface that can be precisely machined and easily finished. The use of medium density fiberboard for cabinet and passage doors is particularly desirable because of its smoothness, insulating properties and resistance to warping. One problem associated with doors constructed from medium density fiberboard is that the screw holding capacity of the fiberboard material may be less than desired in many applications. As a result, manufacturers recommend that specially sized pilot holes be used and that single thread parallel core screws be used in place of traditional wood screws to secure the hinges to the fiberboard material. These special requirements may present problems for installers who are unaware of the requirements or who do not have access to the recommended type of specialty screws in a finish that matches the hinge.
An alternative to the use of specialty screws to mount the hinges directly to the medium density fiberboard material is the use of wood edge banding along at least the hinge side of the door to present a wood surface which can securely retain conventional wood screws and provide the strength needed to withstand the loads experienced by the hinges. Edge banding, however, can add significantly to the cost of the door because of the need for additional equipment, material and production steps to install the edge banding. The joint between the edge banding and the fiberboard core material is aesthetically undesirable and often requires the use of a panel known as a “crossband” which extends from top to bottom and from side to side on the door to hide the edge banding joint and prevent it from “telegraphing” through the overlying veneer. The crossband further adds to the cost of the door and does not always completely hide the underlying joint.
Another approach to improving the screw holding capability of composite panel doors involves the use of a wedge-shaped strip of wood which is inserted into a groove cut from the top to bottom of the door along the hinge side of the door. Because the groove is formed only in the side of the door, no joint is formed along either face of the door and the use of a crossband is unnecessary. There is still, however, the problem of telegraphing of the joint along the side of the door when a veneer or other coating is applied to the door. The wedge-shaped wood may have different moisture absorption properties than the core material and may cause warping of the door.
A need thus exist for a method and apparatus to increase the screw holding and hinge loading capacity of a composite panel door without causing the disadvantages resulting from conventional approaches.
SUMMARY OF THE INVENTION
In one aspect, the present invention is directed to a door having at least a core made from a composite panel material such as any of the various grades of medium density fiberboard or particleboard and at least one dowel inserted into a pre-drilled opening in the core. The opening is positioned at a location corresponding to a hinge used to support the door and the dowel is secured within the opening by any of various types of adhesives. The dowel preferably comprises a hardwood, but may be formed from other materials having sufficient screw holding properties. A screw is threadably inserted into the dowel through a hole in a leaf of the hinge to secure the hinge to the door. If desired, a pilot hole may be first drilled into the dowel to facilitate insertion of the screw into the dowel. The other leaf of the hinge is then secured to the door jamb or other mounting surface in a conventional fashion.
In another aspect, the invention is directed to a method of securing a hinge to a composite panel door of the type described above. The method includes the steps of drilling one or more dowel-receiving openings into the core of the door at a location corresponding to the intended location of the door-supporting hinge. A dowel is then inserted into each opening and an adhesive is used to secure the dowel against withdrawal or turning movement. An optional screw pilot hole may be drilled into the dowel prior to or after insertion of the dowel into the opening. Once the adhesive has securely bonded the dowel in the opening, a leaf of the hinge is placed against the door and a screw is inserted through an opening in the leaf and is turned into the dowel to secure the leaf to the dowel. In many applications, a plurality of dowels are utilized for each of the two or more to hinges that support the door.
A primary advantage of the present invention is the dowels increase the screw holding capacity of the door by an unexpected amount without the need to use edge banding with its attendant problems of telegraphing of the joint between the edge banding and core material. Notably, the dowels are hidden beneath the hinges, resulting in a more desirable visual appearance for the door. Because the dowels can be formed from wood, conventional wood screws may be used to secure the hinge to the door, thereby eliminating the need to use specialty screws and special pilot holes.
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Chin-Shue Alvin
Cohen Curtis A.
Shook Hardy & Bacon L.L.P.
The Maiman Company
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