Door assembly
A door assembly is shown and described herein. The door assembly may include at least one door panel and a door frame having a plurality of frame members including a header and a mullion. The invention may also be considered a frame member. The frame member may be a mullion and include a core; and a two-piece top piece adjoining the core to form a structural member. The door assembly may further include at least one adjacent panel. The inventions disclosed are also applicable to jambs and window structures. Also disclosed are methods and assemblies for a mullion door frame members.
1. An exterior door mullion for a door assembly, said mullion comprising:
a core including a core stop end, a core rabbet end, a first core side wall and a second core side wall, each side wall forming a linear plane along an outer surface of each side wall;
a two-piece top piece adjoining said core to form a structural member with said core, the two piece top piece having a stop portion and a rabbet portion, wherein said stop portion includes a pair of extensions that project into a side wall of the core to secure the stop portion onto the core, and said rabbet portion includes a pair of extensions that project into a side wall of the core to secure the rabbet portion to the core;
a set of recess points formed in the outer surface of each side wall, wherein the recess points project medially into the core away from the linear plane, each recess point forming a recess face that is configured to mate with a face of one of the extensions; and
a stop surface formed in part by an arm of the stop portion and in part by an arm of the rabbet portion
wherein the rabbet portion includes a pair of arms having outer sides, the pair of outer sides each being parallel with the linear plane of the core, and the stop portion includes a pair of arms and at last one hollow segment enclosed within each arm.
2. The mullion for a door assembly of claim 1 , wherein the rabbet portion includes a U-shaped turn segment.
3. The mullion for a door assembly of claim 2 , wherein the stop portion includes an internal step having an internal step face that is parallel with a linear plane along the outer surface of the core stop end and a linear plane along the stop surface.
4. The mullion for a door assembly of claim 1 , wherein the core stop end is longer than the internal step face and the internal step face is longer than the stop surface.
5. The mullion for a door assembly of claim 1 , wherein the core fits into a hollow space within the stop portion and the rabbet portion.
6. The mullion for a door assembly of claim 5 , wherein each extension includes an angled side and a point.
7. The mullion for a door assembly of claim 1 , wherein the stop portion arms have faces and the rabbet portion arms have faces and the stop portion arms are parallel to the rabbet portion arms along the outer surface of each of the arms.
8. The mullion for a door assembly of claim 1 , wherein said top piece is a composite of cellulosic material and plastic material.
9. The mullion for a door assembly of claim 8 , wherein said core is at least partially formed of a non-metallic material.