Systems and methods for movable barrier panels with deep stamp-profile depth
A panel for a sectional door may include a one-piece, sheet-metal facer panel comprising a front surface, a back surface, and a drawn ledge. The drawn ledge may be disposed at a position spaced a distance apart from both the front surface and the back surface, with the drawn ledge defining a hole through the one-piece, sheet-metal facer panel. A backer panel may include an interior surface configured to cover the hole in the one-piece, sheet-metal facer panel. The interior surface may be positioned to support the drawn ledge.
1 . A panel for a sectional door, the panel comprising:
a one-piece, sheet-metal facer panel comprising a front surface, a back surface, and a drawn ledge, the drawn ledge disposed at a position spaced a distance apart from both the front surface and the back surface, the drawn ledge defining a hole through the one-piece, sheet-metal facer panel, the one-piece, sheet-metal facer panel comprising an upper lip and a lower lip, the upper lip and the lower lip each being spaced a first distance from the back surface, the drawn ledge being spaced the first distance from the back surface; and
a backer panel comprising an interior surface configured to at least partially cover the hole in the one-piece, sheet-metal facer panel, the interior surface being positioned to support the drawn ledge.
2 . The panel of claim 1 , wherein the one-piece, sheet-metal facer panel further comprises a bezel extending between the front surface and the drawn ledge.
3 . The panel of claim 2 , wherein the bezel is inclined.
4 . The panel of claim 1 , further comprising insulation disposed between the one-piece, sheet-metal facer panel and the backer panel.
5 . The panel of claim 1 , wherein the backer panel comprises a backer hole, the backer hole being at least partially aligned with the hole of the one-piece, sheet-metal facer panel.
6 . The panel of claim 5 , further comprising an outer lite frame, an inner lite frame, and a translucent panel, the outer lite frame being positioned to support the drawn ledge and the inner lite frame being positioned to support an exterior surface.
7 . A panel for a sectional door, the panel comprising:
a one-piece, sheet-metal facer panel comprising a front surface, a back surface, and a drawn ledge, the drawn ledge disposed at a position spaced a distance apart from both the front surface and the back surface, the drawn ledge defining a hole through the one-piece, sheet-metal facer panel, wherein the one-piece, sheet-metal facer panel comprises an upper lip and a lower lip, the upper lip and the lower lip being coplanar with the drawn ledge; and
a backer panel comprising an interior surface configured to cover the hole in the one-piece, sheet-metal facer panel, the interior surface being positioned to support the drawn ledge.
8 . A panel for a sectional door, the panel comprising:
a one-piece, sheet-metal facer panel comprising a front surface, a back surface, and a drawn ledge, a deep drawn stamped region extending from the front surface, through the back surface, and to the drawn ledge, the drawn ledge disposed at a position spaced a distance apart from both the front surface and the back surface, the drawn ledge defining a hole through the one-piece, sheet-metal facer panel, the one-piece, sheet-metal facer panel comprising two lips, each of the two lips being spaced a first distance from the back surface, the drawn ledge being spaced the first distance from the back surface; and
a backer panel comprising an interior surface configured to at least partially cover the hole in the one-piece, sheet-metal facer panel, the interior surface being positioned to support the drawn ledge.
9 . The panel of claim 8 , wherein the deep drawn stamped region further comprises a bezel extending between the front surface and the drawn ledge.
10 . The panel of claim 9 , wherein the bezel is inclined.
11 . The panel of claim 8 , further comprising insulation disposed between the one-piece, sheet-metal facer panel and the backer panel.
12 . The panel of claim 8 , wherein the backer panel comprises a backer hole, the backer hole being at least partially aligned with the hole of the one-piece, sheet-metal facer panel.
13 . The panel of claim 12 , further comprising an outer lite frame, an inner lite frame, and a translucent panel, the outer lite frame being positioned to support the drawn ledge and the inner lite frame being positioned to support an exterior surface.
14 . A panel for a sectional door, the panel comprising:
a one-piece, sheet-metal facer panel comprising a front surface, a back surface, and a drawn ledge, a deep drawn stamped region extending from the front surface, through the back surface, and to the drawn ledge, the drawn ledge disposed at a position spaced a distance apart from both the front surface and the back surface, the drawn ledge defining a hole through the one-piece, sheet-metal facer panel, wherein the one-piece, sheet-metal facer panel further comprises an upper lip and a lower lip, the upper lip and the lower lip being coplanar with the drawn ledge; and
a backer panel comprising an interior surface configured to cover the hole in the one-piece, sheet-metal facer panel, the interior surface being positioned to support the drawn ledge.
15 . A method of manufacturing a panel for a sectional door, the method comprising:
providing a one-piece, sheet-metal facer panel comprising a front surface, a back surface, and a lip, the lip being spaced a first distance from the back surface;
creating a hole through the one-piece, sheet-metal facer panel extending from the front surface to the back surface, the hole comprising a cross-sectional area parallel to the front surface and the back surface;
stamping an area on the front surface larger than the cross-sectional area of the hole such that a drawn ledge forms, the drawn ledge disposed at a position offset from the front surface and the back surface, the drawn ledge being spaced the first distance from the back surface; and
positioning an interior surface of a backer panel to support the drawn ledge.
16 . The method of claim 15 , wherein the method further comprises increasing the cross-sectional area of the hole by decreasing the area of the drawn ledge.
17 . The method of claim 15 , wherein the method further comprises providing an upper lip and a lower lip, the upper lip and the lower lip being coplanar with the drawn ledge.
18 . The method of claim 15 , wherein the method further comprises providing insulation disposed between the one-piece, sheet-metal facer panel and the backer panel.
19 . The method of claim 15 , wherein the method further comprises providing a backer hole in the backer panel aligned with an inner perimeter of the drawn ledge.
20 . The method of claim 15 , wherein the stamping the area on the front surface larger than the cross-sectional area of the hole such that the drawn ledge forms further comprises forming a bezel extending between the front surface and the drawn ledge.