Improved Method of Assembling Metal Doors and Metal Doors Assembled Thereby

Abstract

A method to fabricate and assemble metal doors and panels, or similar structures, is taught. Under the present invention, profiled edges of two or more skins forming the sides of the door or panel are moved together. The skins are only locked together when a locking bar or wedge is applied to the channels formed by the profiled edges. Under the present invention, less effort is required to assemble such metal doors and panels as the contact between the profiled edges of the skins is not tight. This allows the skins to be easily moved together or repositioned. The present invention also provides for the skins to be either reversibly or irreversibly locked, and for non-rectangular metal doors and panels to be fabricated

1 . A method for assembling two or more skins of a metal structure, the method comprising: 
 temporarily fastening a first skin with at least one profiled edge to a work surface;    overlaying a second skin with at least one profiled edge by moving the second skin with at least one profiled edge to engage the at least one profile edge with the at least one profiled edge of the first skin, thereby the engaged profiled edges forming at least one channel; and    applying at least one locking means into the at least one channel; and    finishing the metal structure.    
   
   
       2 . The method of  claim 1 , wherein the metal structure is a door.  
   
   
       3 . The method of  claim 1 , wherein the metal structure is a panel.  
   
   
       4 . The method of  claim 1 , wherein the step of moving comprises sliding the second skin over the first skin from one end of the first skin.  
   
   
       5 . The method of  claim 1 , wherein the step of moving comprises placing the second skin over the first skin.  
   
   
       6 . The method according to  claim 1 , wherein the channel distorted by the applying of the locking means.  
   
   
       7 . The method according to  claim 1 , wherein the channel not distorted by the applying of the locking means.  
   
   
       8 . The method according to  claim 1 , wherein the at least one profiled edge of the first skin and the at least one profiled edge of the second skin comprise engagement members; the engagement members of the first skin further complementary to the engagement members of the second skin.  
   
   
       9 . The method of  claim 8 , wherein the complementary engagement members are only brought into engagement by the applying of the locking means.  
   
   
       10 . The method of  claim 1 , wherein the application of the locking means is reversible.  
   
   
       11 . The method of  claim 1 , wherein the application of the locking means is not reversible.  
   
   
       12 . The method of  claim 1 , wherein in the application of the locking means causes the skins to be locked together.  
   
   
       13 . The method of  claim 1 , wherein the step of the finishing of the metal structure further comprises: 
 welding the skins;    applying fasteners;    installing ironmongery;    capping any exposed ends; and    painting the structure.    
   
   
       14 . A metal structure comprising: 
 a first skin with at least one profiled edge substantially forming one side of the structure;    at least one more skin with at least one profiled edge substantially forming the other side of the structure; and    a locking means for engaging the skins together;    wherein the at least one profiled edge of the first skin and the at least one profiled edge of the second skin form at least one channel, and a tight fit between the skins is obtained only after the locking means is applied to the at least one channel.    
   
   
       15 . A metal structure according to  claim 14 , wherein the structure is a door.  
   
   
       16 . A metal structure according to  claim 14 , wherein the structure is a panel.  
   
   
       17 . A metal structure according to  claim 14 , wherein the at least one profiled edge of the first skin and the at least one profiled edge of the at least one more skin comprise engagement members; the engagement members of the first skin further complementary to the engagement members of the at least one more skin.  
   
   
       18 . (canceled)  
   
   
       19 . A metal structure according to  claim 14 , wherein the locking means is a locking bar.  
   
   
       20 . A metal structure according to  claim 14 , wherein the locking means is a wedge.  
   
   
       21 . A metal structure according to  claim 14 , wherein the metal structure further comprises: 
 welding;    additional fasteners;    ironmongery;    end caps; and    paint.    
   
   
       22 . A metal structure according to  claim 15 , wherein the at least one profiled edge forming the one side of the first door is the shorter side (rail) of the door.  
   
   
       23 . A metal structure according to  claim 15 , wherein the at least one profiled edge forming the one side of the first door is the longer side (stile) of the door.