Access panel assembly and method of manufacture

Abstract

A method of manufacturing a frame for an access panel, the access panel comprising a door disposed within the frame, is disclosed. The method comprises providing a frame blank including a frame opening having first and second opposing sides, cutting the frame blank to form cuts into the frame blank at opposing ends of each of the first opposing sides, the cuts forming first and second bend lines, bending the frame blank along each of the bend lines to form first and second generally upright flanges, providing first and second generally L-shaped inserts, each having an upright portion and a flange portion and securing the generally L-shaped inserts to the frame blank such that the upright portion of the L-shaped inserts extend between the first and second upright flanges of the frame blank.

Description

ACCESS PANEL ASSEMBLY AND METHOD OF MANUFACTUREBackground

[0001] Dry wall access panels, such as for flush mounting in a ceiling or wall, are known. One such access panel is the DWAL 412 Series touch latch drywall access panel with detachable door, sold by The Williams Brothers Corporation of America.

[0002] Such access panels typically may include a frame and a door, the door being pivotal relative to the frame. The access panels may include a touch latch to maintain the door in a closed position relative to the frame. While such panels have been well-received in the industry-, manufacturing the frame and the door may be difficult.

[0003] The present invention is provided to address this and other problems.Summary

[0004] It is an object of the present invention to provide a method of forming an improved access panel.

[0005] It is a further object of the present invention to provide an improved access panel manufactured according to the present invention.

[0006] This and other objectives and advantages may become apparent from the following description taken in conjunction with the accompanying Figures.Description of the Figures

[0007] Figure 1 is an illustration of one embodiment of a completed access panel according to the present invention, the access panel including a frame and a door pivotable about the frame;

[0008] Figure 2 is an illustration of a frame blank as a first step in forming the frame of the access panel of Fig. 1;

[0009] Figure 3 is a side view of the frame blank of Fig. 2;

[0010] Figure 4 is an illustration of the frame blank of Fig. 2, after a bend has been added;

[0011] Figure 5 is a side view of Fig. 4, taken along line 5-5 of Fig. of Fig 4;

[0012] Figure 6 is a side view of Fig. 4, taken along line 6-6 of Fig. of Fig 4;

[0013] Figure 7 is a perspective view of the frame blank of Figure 4;

[0014] Figure 8 is an illustration of an insert prior to bending, the insert to be a part of the frame of the access panel of Fig. 2;

[0015] Figure 9 is a perspective view of the insert of Fig.8, after bending;

[0016] Figure 10 is a perspective view of a completed frame of the access panel of Fig. 2;

[0017] Figure 11 is an illustration of a door blank as a first step in forming the door of the access panel of Fig. 1;

[0018] Figure 12 is a side view of the door blank of Fig. 11;

[0019] Figure 13 is an illustration of the door blank of Fig. 11, after bends have been added;

[0020] Figure 14 is a side view of the door blank of Fig. 13;

[0021] Figure 15 is an exploded perspective view of an assembly of the access panel of Fig. 1;

[0022] Figure 16 is an illustration of tabs for the access panel of Fig. 1; and

[0023] Figure 17 is an illustration of the completed access panel the one embodiment of an access panel system made in accordance with the present invention.Description of the Preferred Embodiment

[0024] While this invention is susceptible of embodiments in many different forms, there will be described herein in detail, a specific embodiment thereof, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiment illustrated.

[0025] An access panel, generally designated 20, is illustrated in Figure 1. The access panel 20 may be adapted for recessed mounting, such as in a ceiling or a wall. The access panel 20 may include a frame 22 and a door 24, the door 24 being pivotally coupled to the frame 22. The access panel 20 may be pivotally coupled to the frame 22 by means of conventional pins (not shown) extending from the frame 22 into conventional holes (not shown) in the frame 22. The door 24 may be secured in a closed position relative to the frame 22 by means of a conventional touch latch (not shown).

[0026] The frame 22 may be formed by starting with a frame blank 26, having a frame opening 26a. The frame blank 26 may formed from a single sheet of material, such as aluminum, painted steel or the like, cut, as by laser cutting, waterjet cutting, milling, punching, or any form of sheet cutting to a configuration as shown in Figs. 2 and 3. The sheet of aluminum may have a suitable thickness, such as in the range of 0.063" - 0.094", depending upon the rigidity necessary. The frame blank 26 may include four cuts 28, which may be formed as by laser welding, and the ends of which define two bend lines 30.

[0027] The frame blank 26 may then be bent, as by press braking, or any form of metal bending, along each of the two bend lines 30, forming two generally 90° flanges 32, as shown in Figs. 4, 5, 6 and 7. Press braking is a known method of accurately bending metal, wherein bends are formed by clamping a metal piece between an upper and a lower die.

[0028] In another step in forming the completed frame 22, an L-shaped insert 34 may be formed by first providing generally flat piece of material 33, such as aluminum, as illustrated in Figure 8, which may be laser cut from a sheet of the material. The material 33 may then be bent generally 90° along an insert bend line 36, as by press braking, to form the completed L-shaped insert 34, as illustrated in Fig. 9. The resulting L-shaped insert 34 may include an upright portion 34a and a flange portion 34b.

[0029] The L-shaped insert 34 may then be secured, as by welding or riveting, the flange portion 34b to the frame blank 26, forming the completed frame 22 illustrated in Fig. 10.

[0030] The door 24 may be formed by starting with a door blank 38, formed from a sheet of material, such as aluminum, cut, as by laser cutting, to a configuration as show n in Fig. 11. The door blank 38 may include four notches 40. which define four bend lines 30.

[0031] The door blank 38 may then be bent generally 90°, as by press braking, along the four bend lines 30, forming four upright door flanges 42, as shown in Figs. 13, 14 and 15.

[0032] Referring to Figure 15, a panel 44, such as formed of dry wall, may be received within the four door flanges 42 of the door 24. which combination (panel 44 within door flanges 42) may be received within the four flanges 32 of the frame 22. The door 24 may be bent slightly more than the thickness of the dry wall to mitigate paper peeling of the dry wall.

[0033] In one embodiment of the invention, tabs 46 (Fig. 16) may be secured, as by welding, to the door 24, to permit the door 24 to pivot relative to the frame 22. See Fig. 17. The tabs 46 may each include an offset 46a to facilitate pivoting of the door 24. The dry wall may be secured in the door 24 via gluing or, particularly in the case of larger doors, by screws.

[0034] It is contemplated that the frame 22 may alternatively be made of steel for more rigidity. Making the frame 22 out of steel could be more economical, easier to weld, and more rigid. However, it could require powder coating and could be heavier.

[0035] It is to be understood that this disclosure is not intended to limit the invention to any particular form described, but to the contrary, the invention is intended to include all may be modifications, alternatives and equivalents falling within the spirit and scope of the invention.

Claims

ClaimI claim:

1. For an access panel comprising a door disposed within a frame, a method of manufacturing the frame comprising: providing a frame blank including a frame opening having first and second opposing sides; cutting the frame blank to form cuts into the frame blank at opposing ends of each of the first opposing sides, the cuts forming first and second bend lines; bending the frame blank along each of the bend lines to form first and second generally upright flanges; providing first and second generally L-shaped inserts, each having an upright portion and a flange portion; and securing the generally L-shaped inserts to the frame blank such that the upright portion of the L-shaped inserts extend between the first and second upright flanges of the frame blank.

2. The method of claim 1, wherein the blank is formed of aluminum.

3. The method of claim 1, wherein the blank is formed of steel.

4. The method of claim 2, wherein the thickness of the blank is in the range of 0.063” -0.094”.

5. The method of claim 1. wherein the cuts are formed by laser welding.

6. The method of claim 1, wherein the first and second L-shaped inserts are formed bybending a flat piece of material along a bend line.

7. The method of claim 1, wherein the flat piece of material is bent by press braking.

8. The method of claim 1 wherein the generally L-shaped inserts are secured to the frame blank by welding.

9. The method of claim 1 wherein the generally L-shaped inserts are secured to the frame blank by riveting.

10. The method of claim 1. wherein the door is adapted to receive a dry wall panel.

11. The method of claim 1, wherein the frame is adapted for flush mounting in a ceiling.

12. The method of claim 1. wherein the frame is adapted for flush mounting in a wall.

Images