Sectional doors made from polymer composites and a method for manufacturing same

Abstract

A sectional door includes a plurality of panels. Each panel can include two or more plies which can be made of thermally compatible material. A panel of such sectional door includes an outer ply including a thermoplastic material and a sash frame including a thermoplastic material. The outer ply forms an outer face of the door. The sash frame is secured to the outer ply. The outer ply and the sash frame include thermoplastic materials which have substantially the same rate of thermal expansion. A desired design can be formed in the outer face of the door.

1 . A panel for a sectional door, comprising:
 an outer ply, comprising an extruded thermoplastic material, forming an outer face of the door;   a sash frame comprising a thermoplastic material;   a means for securing said sash frame to said outer ply; and,   wherein said outer ply and said sash frame comprise thermoplastic materials which have substantially the same rate of thermal expansion.   
   
   
       2 . The panel of  claim 1  wherein the thermoplastic material for both said outer ply and said sash frame comprises an extruded cellular PVC material. 
   
   
       3 . The panel of  claim 1  wherein said means for securing comprises an adhesive. 
   
   
       4 . The panel of  claim 1  wherein said means for securing comprises a fastener. 
   
   
       5 . The panel of  claim 1  further comprising a reinforcing member connected to said sash frame. 
   
   
       6 . The panel of  claim 5  wherein said reinforcing member comprises a metal. 
   
   
       7 . The panel of  claim 6  further comprising a means for securing said reinforcing member to said sash frame which accommodates differential rates of thermal expansion between said reinforcing member and said sash frame. 
   
   
       8 . The panel of  claim 7  wherein said means for securing comprises an elongated aperture located in said reinforcing member and a fastener extending through said elongated aperture and into said sash frame. 
   
   
       9 . The panel of  claim 6  wherein the metallic reinforcing member includes a flange which cooperates with said outer ply. 
   
   
       10 . The panel of  claim 9  wherein said flange is accommodated in a groove of said outer ply. 
   
   
       11 . The panel of  claim 9  wherein said flange contacts an edge of said outer ply. 
   
   
       12 . The panel of  claim 6  wherein said reinforcing member includes a channel for accommodating an edge of said outer ply. 
   
   
       13 . The panel of  claim 1  further comprising a layer of insulating material positioned between said outer ply and said sash frame. 
   
   
       14 . The panel of  claim 1  further comprising an inside skin layer positioned between said outer ply and said sash frame. 
   
   
       15 . The panel of  claim 1  wherein the thermoplastic material of said outer ply is so chosen that it can be worked by routing or milling to impart a desired design thereinto. 
   
   
       16 . The panel of  claim 1  wherein said sash frame is thicker than said outer ply. 
   
   
       17 . The panel of  claim 1  further comprising a hinge mounted to said sash frame, to enable the panel to be secured to another panel of the sectional door. 
   
   
       18 . A method of manufacturing a panel for a sectional door, comprising:
 a) providing an outer ply of an extruded thermoplastic material;   b) providing a sash frame of the same thermoplastic material;   c) securing the sash frame to the outer ply; and,   d) forming a desired design in an outer surface of the outer ply.   
   
   
       19 . The method of  claim 18  further comprising securing a reinforcing member to the sash frame. 
   
   
       20 . The method of  claim 18  further comprising forming a desired edge shape on the panel. 
   
   
       21 . The method of  claim 18  wherein steps a)-d) are performed in a continuous manufacturing process. 
   
   
       22 . The method of  claim 18  wherein step d) is performed via routing of the outer ply.