Title:
DOOR FRAME ASSEMBLY AND DOOR FRAME SECTION THEREOF
United States Patent 3808759
Abstract:
A prefabricatd door jamb assembly adapted for installation in a rough door opening, said assembly including a top or head frame arrangement and two side frame arrangements which are connected at corresponding ends to opposite ends of the top frame arrangement by fastenerless miter joints, the latter comprising cooperating groove and spline means. Each of the frame arrangements includes a pair of elongated sections which have L-shaped cross-sections and which have cooperating longitudinal edges adapted to engage against one another so that together the pair of elongated sections displays a U-shaped cross-section. The two sections of each frame arrangement are connected together for movement between a first position such that the aforestated longitudinal edges engage one another and a second position such that the longitudinal edges are spaced-apart and parallel. Novel shims or frame anchors are provided to act as a stabilizer between the door opening and the frame arrangements.
US Patent References:
Door
Bilton - April 1932 - 1855470
Prefabricated door and door frame unit
Chenoweth - March 1960 - 2927352
Packaged door assembly
Parker - March 1966 - 3239978
/1098405.html
Reinecke - June 1914 - 1098405
Metal frame for doors
Baum - June 1929 - 1717084
Door
Bilton - April 1932 - 1855470
Prefabricated door and door frame unit
Chenoweth - March 1960 - 2927352
Packaged door assembly
Parker - March 1966 - 3239978
/1098405.html
Reinecke - June 1914 - 1098405
Metal frame for doors
Baum - June 1929 - 1717084
Application Number:
05/280487
Publication Date:
05/07/1974
Filing Date:
08/14/1972
View Patent Images:
Export Citation:
Assignee:
Doorcraft Inc. (Burlingame, CA)
Primary Class:
Other Classes:
49/505, 52/656.400
International Classes:
E06B1/10; E06B1/60; E06B1/04; E06B1/56; E06B1/04
Field of Search:
52/211,212,656 49/504,505
US Patent References:
Primary Examiner:
Perham, Alfred C.
Attorney, Agent or Firm:
Burton, Crandell & Polumbus
Claims:
I claim
1. A door frame assembly adapted for installation in a rough door opening, said assembly comprising:
2. A door frame assembly according to claim 1 wherein one end portion of each of said side frame members is reverse mitered and the opposite ends of said top frame member are mitered at an angle substantially perpendicular to the reverse mitered end portions of said side frame members, each of said mitered ends of said top frame member including a groove and spline adapted to fit tightly within said groove so as to align the longitudinal axes of said side frame members in a direction substantially perpendicular to the longitudinal axis of said top frame member.
3. A door frame assembly according to claim 2 including a plurality of shim members adapted for positioning between said top frame member and the rough door opening, whereby said shim members act as stabilizers between said frame members and said opening.
4. A door frame assembly according to claim 1 wherein each of said interlocking members of said cooperating pair is L-shaped in configuration and has a pair of legs, each interlocking member has a first leg thereof connected to a respective one of said elongated sections so as to extend substantially perpendicular to the longitudinal axis thereof and a second leg extending toward the first leg of the other interlocking member, said second leg having a side edge disposed substantially parallel with the longitudinal axis of said elongated section and the side edge of said other interlocking member whereby said parallel side edges engage each other when said elongated sections are in said spaced apart second position.
5. A door frame assembly adapted for installation in a rough door opening comprising:
6. A door frame assembly according to claim 5 wherein said door frame assembly also includes door stop means on one side of said assembly overlying the engageable longitudinal edges of said elongated sections.
7. A door frame assembly according to claim 5 wherein one end of each of said side frame members is mitered and the opposite ends of said top frame member are reverse mitered so as to be adapted for positioning in engagement with respective opposite mitered ends of said side frame member so that said top and side frame members fit contiguously about the sides and top of the rough door opening, and wherein said door frame assembly also includes means for connecting said side frame members to the opposite ends of said top frame member so as to align the longitudinal axes of said side frame members in a direction substantially perpendicular to the longitudinal axis of said top frame member.
8. A door frame assembly according to claim 7 wherein said last-mentioned means includes cooperating grooves in the mitered ends of said top frame members and splines adapted to fit tightly within said cooperating grooves and against said reversed mitered end portions.
9. A door frame assembly adapted for installation in a rough door opening, said assembly comprising:
10. A door frame assembly according to claim 9 wherein said connecting means includes cooperating grooves in said mitered ends and spline means adapted to fit tightly within said grooves and against said reverse mitered end portions.
11. A door frame assembly according to claim 10 wherein said cooperating grooves and spline means extend at approximately a forty-five degree angle with respect to the longitudinal axes of said frame arrangements.
12. For use in a door frame assembly adapted for installation in a rough door opening, a door frame arrangement comprising:
13. A door frame arrangement according to claim 12 wherein said connecting means includes a plurality of spring elements each of which has one end connected to said first elongated section and the other end is connected to said second elongated section, and at least one pair of interlocking members respectively fastened to said first and second sections and movable along with said sections between said first and second positions, whereby said members are engageable at least one in one of said positions.
14. A door frame arrangement according to claim 13 wherein each of said interlocking members includes locking means whereby said interlocking members interlock together when in said second position for preventing further spaced-apart movement of said longitudinal edges.
15. A door frame arrangement according to claim 14 wherein each of said interlocking members of said cooperating pair is L-shaped in configuration and has a pair of legs, each interlocking member has a first leg thereof connected to a respective one of said elongated sections so as to extend substantially perpendicular to the longitudinal axis thereof and a second leg extending toward the first leg of the other interlocking member, said second leg having a side edge disposed substantially parallel with the longitudinal axis of said elongated section and the side edge of said other interlocking member whereby said parallel side edges engage each other when said elongated sections are in said second position.
16. A door frame arrangement according to claim 12 wherein said connecting means includes at least one pair of interlocking members, said interlocking members including a first L-shaped member fastened to said first elongated section and having one leg extending substantially perpendicular to said longitudinal edges, said one leg including a raised portion at its free end so as to define a pocket, said interlocking member further including a second L-shaped member fastened to said second elongated section and having one leg extending substantially perpendicular with said longitudinal edges and aligned with said pocket whereby said leg of said second L-shaped member is disposed within said pocket when said longitudinal edges move to said first position and is at least partially withdrawn from said pocket when said longitudinal edges move to said second position.
17. A door frame assembly for installation in a rough door opening in a wall wherein the wall thickness may fall within a given range of thicknesses, comprising a top frame assembly and a pair of side frame assemblies, each of said assemblies comprising a pair of elongate frame members of a generally L-shaped transverse cross-section disposed in opposed relationship to each other to cooperatively present an assembly of a generally U-shaped transverse cross-section, a door stop strip on the exterior side of said assembly overlying the adjacent longitudinal edges of said L-shaped members to conceal said edges, said strip being fixedly secured to one of said members and slidably engageable with the other of said members to accommodate transverse shifting of said members relative to one another while maintaining said strip in overlying concealing relationship with both of said edges, cooperating paired interlocking plates fixedly mounted on the interior side of each of said members and overlying said adjacent longitudinal edges, said plates being positioned to limit both longitudinal and transverse shifting movement of said L-shaped members relative to each other and to prevent pivotal movement of said L-shaped members relative to each other about axes parallel to said longitudinal edges.
18. The door frame assembly of claim 17 wherein each paired plate member comprises a pair of flat L-shaped plates each having a first leg fixedly secured to one of said members and projecting across said longitudinal edges in perpendicular relationship thereto, and a second leg on each of said plates extending at right angles to and integral with said first leg and slidably engageable with the other of said L-shaped members, said second legs of each pair of said plates extending in opposite directions and being aligned with each other transversely of said L-shaped members.
1. A door frame assembly adapted for installation in a rough door opening, said assembly comprising:
2. A door frame assembly according to claim 1 wherein one end portion of each of said side frame members is reverse mitered and the opposite ends of said top frame member are mitered at an angle substantially perpendicular to the reverse mitered end portions of said side frame members, each of said mitered ends of said top frame member including a groove and spline adapted to fit tightly within said groove so as to align the longitudinal axes of said side frame members in a direction substantially perpendicular to the longitudinal axis of said top frame member.
3. A door frame assembly according to claim 2 including a plurality of shim members adapted for positioning between said top frame member and the rough door opening, whereby said shim members act as stabilizers between said frame members and said opening.
4. A door frame assembly according to claim 1 wherein each of said interlocking members of said cooperating pair is L-shaped in configuration and has a pair of legs, each interlocking member has a first leg thereof connected to a respective one of said elongated sections so as to extend substantially perpendicular to the longitudinal axis thereof and a second leg extending toward the first leg of the other interlocking member, said second leg having a side edge disposed substantially parallel with the longitudinal axis of said elongated section and the side edge of said other interlocking member whereby said parallel side edges engage each other when said elongated sections are in said spaced apart second position.
5. A door frame assembly adapted for installation in a rough door opening comprising:
6. A door frame assembly according to claim 5 wherein said door frame assembly also includes door stop means on one side of said assembly overlying the engageable longitudinal edges of said elongated sections.
7. A door frame assembly according to claim 5 wherein one end of each of said side frame members is mitered and the opposite ends of said top frame member are reverse mitered so as to be adapted for positioning in engagement with respective opposite mitered ends of said side frame member so that said top and side frame members fit contiguously about the sides and top of the rough door opening, and wherein said door frame assembly also includes means for connecting said side frame members to the opposite ends of said top frame member so as to align the longitudinal axes of said side frame members in a direction substantially perpendicular to the longitudinal axis of said top frame member.
8. A door frame assembly according to claim 7 wherein said last-mentioned means includes cooperating grooves in the mitered ends of said top frame members and splines adapted to fit tightly within said cooperating grooves and against said reversed mitered end portions.
9. A door frame assembly adapted for installation in a rough door opening, said assembly comprising:
10. A door frame assembly according to claim 9 wherein said connecting means includes cooperating grooves in said mitered ends and spline means adapted to fit tightly within said grooves and against said reverse mitered end portions.
11. A door frame assembly according to claim 10 wherein said cooperating grooves and spline means extend at approximately a forty-five degree angle with respect to the longitudinal axes of said frame arrangements.
12. For use in a door frame assembly adapted for installation in a rough door opening, a door frame arrangement comprising:
13. A door frame arrangement according to claim 12 wherein said connecting means includes a plurality of spring elements each of which has one end connected to said first elongated section and the other end is connected to said second elongated section, and at least one pair of interlocking members respectively fastened to said first and second sections and movable along with said sections between said first and second positions, whereby said members are engageable at least one in one of said positions.
14. A door frame arrangement according to claim 13 wherein each of said interlocking members includes locking means whereby said interlocking members interlock together when in said second position for preventing further spaced-apart movement of said longitudinal edges.
15. A door frame arrangement according to claim 14 wherein each of said interlocking members of said cooperating pair is L-shaped in configuration and has a pair of legs, each interlocking member has a first leg thereof connected to a respective one of said elongated sections so as to extend substantially perpendicular to the longitudinal axis thereof and a second leg extending toward the first leg of the other interlocking member, said second leg having a side edge disposed substantially parallel with the longitudinal axis of said elongated section and the side edge of said other interlocking member whereby said parallel side edges engage each other when said elongated sections are in said second position.
16. A door frame arrangement according to claim 12 wherein said connecting means includes at least one pair of interlocking members, said interlocking members including a first L-shaped member fastened to said first elongated section and having one leg extending substantially perpendicular to said longitudinal edges, said one leg including a raised portion at its free end so as to define a pocket, said interlocking member further including a second L-shaped member fastened to said second elongated section and having one leg extending substantially perpendicular with said longitudinal edges and aligned with said pocket whereby said leg of said second L-shaped member is disposed within said pocket when said longitudinal edges move to said first position and is at least partially withdrawn from said pocket when said longitudinal edges move to said second position.
17. A door frame assembly for installation in a rough door opening in a wall wherein the wall thickness may fall within a given range of thicknesses, comprising a top frame assembly and a pair of side frame assemblies, each of said assemblies comprising a pair of elongate frame members of a generally L-shaped transverse cross-section disposed in opposed relationship to each other to cooperatively present an assembly of a generally U-shaped transverse cross-section, a door stop strip on the exterior side of said assembly overlying the adjacent longitudinal edges of said L-shaped members to conceal said edges, said strip being fixedly secured to one of said members and slidably engageable with the other of said members to accommodate transverse shifting of said members relative to one another while maintaining said strip in overlying concealing relationship with both of said edges, cooperating paired interlocking plates fixedly mounted on the interior side of each of said members and overlying said adjacent longitudinal edges, said plates being positioned to limit both longitudinal and transverse shifting movement of said L-shaped members relative to each other and to prevent pivotal movement of said L-shaped members relative to each other about axes parallel to said longitudinal edges.
18. The door frame assembly of claim 17 wherein each paired plate member comprises a pair of flat L-shaped plates each having a first leg fixedly secured to one of said members and projecting across said longitudinal edges in perpendicular relationship thereto, and a second leg on each of said plates extending at right angles to and integral with said first leg and slidably engageable with the other of said L-shaped members, said second legs of each pair of said plates extending in opposite directions and being aligned with each other transversely of said L-shaped members.
Description:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to door frame assemblies and more particularly to a prefabricated door frame assembly and door frame section or arrangement therefor.
2. Discussion of the Prior Art
Heretofore, doors have been hung by shimming the door frame or jamb around a rough opening with, for example, wooden shingles so that it is plumb and square and held tightly in place, after which the door is cut to the plumbed door jamb. This method has long since been found to be less than completely satisfactory. For example, in addition to being time consuming, complicated and expensive, the wood shingles are no longer suitable for the new advanced door frame assemblies of today. One reason for this is that there is no access to the space between the jamb member and the studs which define the rough opening when the door frame is positioned for installation about the studs.
Many of the previous door frames were constructed with a single piece jamb member which limited the use of that product to the exact thickness of the wall for which is was designed. Since wall thickness is quite variable in both commercial and residential construction, the single piece jamb members had to be stocked in a variety of sizes which, of course, is expensive and can easily lead to providing the wrong size jamb member in the field.
Various attempts have been made to rectify the foregoing problems. For example, prefabricated door units comprising a unitary door and door frame assembly have been used for years. The size and bulk of these units have caused much difficulty, especially during on-site installation. On the other hand, the heretofore used split door jamb arrangements, i.e., those arrangements including separate sections positionable on opposite sides of a stud, have been found to be difficult to assemble in the field.
SUMMARY OF THE INVENTION
In accordance with the foregoing difficiencies of the prior art as well as other difficiencies thereof, an object of the present invention is to provide a new and novel door frame assembly and door frame section therefor.
Another object of the present invention is to provide a new and improved door frame assembly which is uncomplicated in design and economical to manufacture.
Still another object of the present invention is to provide a new and improved door frame assembly which is uncomplicated to assemble about a rough door opening.
Another object of the present invention is to provide a new and improved door frame assembly which provides for faster on-site installation, improved quality and lower shipping costs.
Still another object of the present invention is to provide a new and improved door frame assembly which adjustably fits to varying wall thickness.
Another object of the present invention is to provide a new and improved door frame assembly which, in the main, requires only three fully assembled frame sections, i.e., two side frame sections and a head frame section.
Another object of the present invention is to provide a frame assembly of the last-mentioned type wherein each of the frame sections are adjustable so as to fit about studs of varying wall thicknesses.
Another object of the present invention is to provide a door frame assembly of the last-mentioned type wherein each of said frame sections provides new and improved means for imparting adjustability thereto.
Another object of the present invention is to provide a door frame assembly of the last-mentioned type including a novel means for connecting the side frame sections to the head frame section.
Another object of the present invention is to provide a door frame assembly of the last-mentioned type wherein the connecting means include fastenerless miter joints.
Another object of the present invention is to provide a door frame assembly of the last-mentioned type wherein the miter joints aid in aligning the side frame sections perpendicular to the head jamb section and maintaining such alignment.
Another object of the present invention is to provide a novel shim means between the aforedescribed door frame assembly and a rough door opening thereby to act as stabilizers therebetween.
These and other objects and features of the present invention will become apparent from the following descriptions.
DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 is an exploded perspective view of a door frame assembly constructed in accordance with the present invention and illustrating a door connectable thereto;
FIG. 2 is an enlarged partially broken away perspective view of one of the frame sections utilized with the assembly of FIG. 1;
FIG. 3 is a view similar to that of FIG. 2 with the frame sections being illustrated in an extended position;
FIG. 4 is a top view taken generally along line 4--4 in FIG. 3;
FIG. 5 is a frontal view of two frame sections connected together by a fastenerless miter joint constructed in accordance with the present invention;
FIG. 6 is a sectional view taken along line 6--6 in FIG. 5;
FIG. 7 is a sectional view taken along line 7--7 in FIG. 5;
FIG. 8 is a perspective view of a preferred interlocking frame anchor utilized with the door frame assembly of FIG. 1 and constructed in accordance with the present invention; and
FIG. 9 is a sectional view taken generally along line 9--9 in FIG. 8.
DETAILED DESCRIPTION
The present invention is directed to a new and novel door frame assembly which, in the main, includes three frame sections, i.e., two side sections and a head or top section. Each frame section is a preassembled unit for easy installation in the field.
In accordance with one aspect of the present invention, each of the frame sections is comprised of two elongated members which alone display L-shaped cross-sections and which together display a U-shaped cross-section. The two elongated members are connected together and allowed to move towards and away from one another in a direction perpendicular to their respective longitudinal axes by a predetermined amount without becoming disconnected from one another. In this manner, the two members of each frame section may be spread apart, if necessary, to fit about a stud member which defines a section of a rough door opening. Hence, the frame section does not have to be custom designed in accordance with the dimensions of a particular stud member. In addition, because the two elongated members making up to form each frame section remain engaged to one another during this adjustment procedure, mounting of the frame section to the stud member is greatly facilitated.
Another aspect of the present invention resides in the manner in which the two side frame sections are connected to the head section. Specifically, the top end of each side section is mitered, actually reversed mitered, so as to define a plane substantially perpendicular with a respective mitered end of the head section so that when these mitered and reverse mitered ends are assembled to one another, the side sections extend in the same direction from opposite ends of the head section and perpendicular thereto.
As will be seen hereinafter, a groove and spline arrangement is provided in each of the cooperating mitered and reverse mitered ends so as to provide a rigid joint or connection without the necessity of fastener means. In addition, the groove and spline arrangments aid in aligning accurately the side frame section in a direction perpendicular to the head section which is, of course, important for properly fitting the door frame assembly about a rough door opening. The reverse mitered ends of the side sections simplify installation of the joints.
The foregoing aspects of the present invention as well as other aspects thereof will become apparent from the following description of the drawings, wherein like components are designated by like reference numerals throughout the various figures. Turning specifically to FIG. 1, a door frame assembly constructed in accordance with the present invention is illustrated and generally designated by the reference numeral 10. The assembly 10 includes a first side or hinge frame section 12, a second side or strike frame section 14 and a top or head jamb section 16, which together form a frame assembly for a door 18.
As illustrated, hinge frame 12 displays a U-shaped cross-section so as to fit about a stud member (not shown) and has its top end mitered at 20 and reverse mitered at 21, the top of the jamb portion of the hinge frame. The hinge frame 12 includes a longitudinally extending door stop 22 which extends the entire length of the frame and which has its upper edge mitered at 24. Conventional butt hinges 26 are suitably fastened to the hinge frame 12 as illustrated in FIG. 1, so as to cooperate with a complementary hinge (not shown) on door 18. Strike frame 14 is essentially identical to hinge frame 12 and includes a mitered and reverse mitered top end 28 and 29, respectively, and door stop 30 (see FIG. 4), the upper edge of which is mitered at 32. In like manner, head or top frame 16 is essentially identical to the hinge frame and includes a longitudinally extending door stop 34. However, both ends 36 and 38 of the head frame are mitered and both preferably have a groove, or slot, 39 that receives a spline therein (see FIGS. 5 through 7, for more detail, where spline 84 is received in groove 82). Both ends 40 and 42 of door stop 34 are also mitered.
Turning to FIGS. 2-4, one of the frame sections, for example, strike frame 14 is shown in detail. As illustrated, this frame 14 includes two elongated members 44 and 46, which respectively display essentially L-shaped cross-sections and which together display essentially a U-shaped cross-section (see FIG. 4). Hence, longitudinal edges 48 of member 44 are positioned in confronting relationship with longitudinal edges 50 of member 46.
In order that frame 14 may be made adjustable so as to fit stud members of varying sizes, members 44 and 46 are movable between a first position such that longitudinal edges 48 and 50 engage one another, as illustrated in FIG. 2, and a second position such that the longitudinal edges are spaced apart but parallel to one another, as illustrated in FIGS. 3 and 4. This movement may be accomplished by utilizing, for example, a plurality of spring elements 52. Each of these spring elements 52 is positioned within a pair of axially aligned grooves 54 and 56 respectively located in the inside surfaces of leg 58 of member 44 and leg 60 of member 46. As shown, the grooves, which extend in a direction perpendicular to longitudinal edges 48 and 50, are preferably of sufficient depth so as to receive entirely the spring elements 52. In this manner, the spring elements do not interfere with the front face of a stud member. The spring elements are suitably fastened to legs 58 and 60 by any conventional means such as screws 62.
By providing spring elements 52 in the frame members in the foregoing manner, it should be readily apparent that the elongated member, such as members 44 and 46, are movable between the aforedescribed first and second portion, the spring elements biasing the members in the first position. In addition, the spring elements prevent said elongated members from completely separating or disengaging from one another during mounting of the frame about a stud.
As illustrated best in FIG. 3, door stop 30 is either mounted on or is an integral part of elongated member 46 and extends transversely beyond longitudinal edges 48 and 50, even when the elongated members are in their extended second position. Hence, if the members must be so extended to fit about a stud, this will not be visible to the eye. Further, the door stop cooperates with the spring elements to prevent separation of the elongated members of each member one from another such as may occur when one of said elongated members is rotated about its longitudinal axis while the other one of said elongated members remains relatively stationary with respect thereto.
The elongated members 44 and 46 may also be prevented from completely separating during expansion through the use of one and preferably at least two pairs of flat or thin interlocking elements 64 and 66. The elements 64 may be used in conjunction with spring elements 54. As illustrated best in FIG. 2, each of these interlocking elements 64 and 66 is L-shaped, one leg of which is substantially longer than the other. The longer leg of element 64 is positioned flatly against and suitably fastened to the inside surface of leg 58 of member 44 and extends perpendicular to and across longitudinal edges 48 and 50 such that the short leg extends downwardly. In a similar fashion, interlocking element 66 is positioned flatly against and suitably fastened to the inside surface of leg 60 directly below element 64. Element 66 extends perpendicular to and across edges 48 and 50 such that the shorter leg extends upward and behind the shorter leg of element 64. Each of the shorter legs has a side edge disposed parallel with the longitudinal axis of its attached section and one with the other.
When the elongated members 44 and 46 are moved to the aforestated second position, the interlocking elements move therewith until the side edges of the shorter legs engage one another to prevent further movement as illustrated in FIG. 3.
In FIG. 1 two pairs of interlocking elements 64, 66 are shown; however, it will be noted that same are reversed, one with respect to the other, upon mounting thereof. For example, in the upper pair of interlocking elements it will be noted that the upper element 64 is securely attached to the elongated member 44 while the upper element of the lower pair is securely attached to elongated member 46. The purpose of this arrangement is to prevent separation of the elongated members one from the other where one of said elongated members moves longitudinally relative to the other. It will be noted that the doorstop cooperates with the interlocking elements to prevent separation of the elongated members of each frame member one from the other also, to prevent undesirable rotation of one of the elongated members of each frame member about its longitudinal axis relative to the other one of said elongated members.
Turning to FIGS. 8 and 9, attention is directed to a preferred interlocking arrangement 94 which is utilized in lieu of previously described interlocking elements 64 and 66. As illustrated in FIG. 8, arrangement 94 includes a first L-shaped member 96 having a longer leg 98 and a shorter leg 100. The L-shaped member 96 is suitably fastened to the inner surface of one of the L-shaped members of each frame section such as, for example, member 46 (see FIGS. 2 and 3) so that longer leg 98 extends beyond and perpendicular to the longitudinal edges thereof. Arrangement 94 also includes a second L-shaped member 102 having a longer leg 104 and a shorter leg 106. Member 102 is suitably fastened to the inner surface of the other of the L-shaped members of each frame section such as, for example, member 44 so that the longer leg 104 is in alignment with the longer leg 98 of member 96. As illustrated best in FIG. 9, longer leg 104 of member 102 includes a centrally located, longitudinally extending, raised section 108 which extends the length of the longer leg. With member 102 fastened to the L-shaped member in the aforedescribed manner, the raised section 108 and the adjacent inner surface of the L-shaped member define a pocket 110 therebetween.
The raised section 108 is designed so that pocket 110 will receive therein the longer leg 98 of member 96 when the longitudinal edges of the L-shaped members making up the frame section come together. In this manner, the L-shaped members making up the frame section are interlocked against relative longitudinal movement. It will be noted that ease of interfitting by 98 within pocket 110 is accomplished by forming both leg 98 and pocket 110 slightly convergent, taken in a direction proceeding toward the free end of leg 98 and the inner end of pocket 110.
It is to be understood that the foregoing description of strike frame 14 also applies to hinge frame 12 and head frame 16. Hence, a description illustrating the adjustability of these frames will not be necessary, reference being made to the description of frame 14.
Turning to FIGS. 5-7, attention is directed to a fastenerless miter joint assembly 70 which is designed in accordance with the present invention and which is provided to insure perfect register of and connection between a side frame 72 and a top or head frame 74. These frames could be similar in adjustability and basic cross-section as those frames illustrated in FIGS. 1 to 3.
As illustrated best in FIG. 5, adjoining ends of side frame 72 and head frame 74 are mitered or beveled at, for example, approximately 45° angles with respect to their longitudinal axes as designated by the reference numerals 76 and 78, respectively. It should be noted, however, that the top of the jamb portion 77 of side frame 72 is reverse mitered, i.e., mitered perpendicularly to the mitered head frame which, as will become apparent below, simplifies installation of the miter joint.
In accordance with the present invention, miter joint 70 includes, in the mitered end 78, a slot or groove 82 which extends into top frame 74 at an angle approximately perpendicular to the mitered surface (see FIG. 5) and which extends across its mitered surface substantially parallel with the mitered surfaces upper and lower edges (see FIG. 7).
As illustrated best in FIG. 5, when the two mitered ends engage one another as shown, the groove 82 is positioned in cooperating alignment with the reverse mitered surface 76. A rectangularly shaped spline 84, also comprising part of the miter joint and displaying a cross-section approximately equal in shape and dimension to that of the groove and a length approximately equal to that of the groove and mitered surface 76 together, is rigidly positioned within the groove. This serves a two fold purpose. Firstly, it securely connects the side frame to the head frame without the use of fasteners and secondly, it aids in aligning the two frames perpendicular to one another which, of course, is important for proper alignment about a rough door opening.
As illustrated in FIGS. 6 and 7, where the frames are constructed in the manner set forth in FIGS. 1 to 3, i.e., when they each include two adjustable sections or members, the grooves would preferably extend into both sections.
With miter joint 70 constructed in the foregoing manner and with frames 12, 14, and 16 constructed in the foregoing manner, attention is now directed to the manner of assembling the frames. For purposes of simplicity it will be assumed that frames 12, 14 and 16 of FIG. 1 include the fastenerless miter joints of FIGS. 5. Specifically, one of the frames, e.g., the head frame 16, is adjusted to fit about the top of a rough door opening. Fastening means (not shown) may be desired or necessary for fastening the head frame to the rough door opening. In any case, the fact that the width of the door opening may vary in small degrees from one door opening to another, does not prevent proper fitting of the frame.
After the top frame has been assembled to the door opening in the foregoing member, the two side frames 12 and 14 are adjusted to fit about opposite sides of the rough opening simultaneously therewith, the splines are positioned against reverse mitered ends of the side frames. Again, the side frames, like the head frame, may be suitably fastened to the rough door opening.
To further secure the head frame, the present invention contemplates the use of a flexible shim 90 (FIGS. 1 and 2) which are constructed of deformable plastic, rubber or other suitable compressible material. As illustrated in FIG. 1, these shims 90 are positioned behind and against both ends of the head frame section between the latter and the rough door opening. In a preferred embodiment, the shims display sufficient recoil to apply approximately seventy pounds or more of force at each miter joint, which is sufficient to insure tight fitting miter joints during the installation process. In addition, the shims minimize the effect of tolerance variations along the height of the rough door opening and thereby act as a stabilizer between the opening and frames. The side frames, on the other hand, may include frame anchors 92 suitably fastened to the inside of the frames, see FIG. 1.
It is to be understood that this invention is not limited to the exact embodiments of the door frame assemblies and door frame sections described and shown which are merely by way of illustration and not limitation, as various other forms and modifications will be apparent to those skilled in the art.
1. Field of the Invention
The present invention relates generally to door frame assemblies and more particularly to a prefabricated door frame assembly and door frame section or arrangement therefor.
2. Discussion of the Prior Art
Heretofore, doors have been hung by shimming the door frame or jamb around a rough opening with, for example, wooden shingles so that it is plumb and square and held tightly in place, after which the door is cut to the plumbed door jamb. This method has long since been found to be less than completely satisfactory. For example, in addition to being time consuming, complicated and expensive, the wood shingles are no longer suitable for the new advanced door frame assemblies of today. One reason for this is that there is no access to the space between the jamb member and the studs which define the rough opening when the door frame is positioned for installation about the studs.
Many of the previous door frames were constructed with a single piece jamb member which limited the use of that product to the exact thickness of the wall for which is was designed. Since wall thickness is quite variable in both commercial and residential construction, the single piece jamb members had to be stocked in a variety of sizes which, of course, is expensive and can easily lead to providing the wrong size jamb member in the field.
Various attempts have been made to rectify the foregoing problems. For example, prefabricated door units comprising a unitary door and door frame assembly have been used for years. The size and bulk of these units have caused much difficulty, especially during on-site installation. On the other hand, the heretofore used split door jamb arrangements, i.e., those arrangements including separate sections positionable on opposite sides of a stud, have been found to be difficult to assemble in the field.
SUMMARY OF THE INVENTION
In accordance with the foregoing difficiencies of the prior art as well as other difficiencies thereof, an object of the present invention is to provide a new and novel door frame assembly and door frame section therefor.
Another object of the present invention is to provide a new and improved door frame assembly which is uncomplicated in design and economical to manufacture.
Still another object of the present invention is to provide a new and improved door frame assembly which is uncomplicated to assemble about a rough door opening.
Another object of the present invention is to provide a new and improved door frame assembly which provides for faster on-site installation, improved quality and lower shipping costs.
Still another object of the present invention is to provide a new and improved door frame assembly which adjustably fits to varying wall thickness.
Another object of the present invention is to provide a new and improved door frame assembly which, in the main, requires only three fully assembled frame sections, i.e., two side frame sections and a head frame section.
Another object of the present invention is to provide a frame assembly of the last-mentioned type wherein each of the frame sections are adjustable so as to fit about studs of varying wall thicknesses.
Another object of the present invention is to provide a door frame assembly of the last-mentioned type wherein each of said frame sections provides new and improved means for imparting adjustability thereto.
Another object of the present invention is to provide a door frame assembly of the last-mentioned type including a novel means for connecting the side frame sections to the head frame section.
Another object of the present invention is to provide a door frame assembly of the last-mentioned type wherein the connecting means include fastenerless miter joints.
Another object of the present invention is to provide a door frame assembly of the last-mentioned type wherein the miter joints aid in aligning the side frame sections perpendicular to the head jamb section and maintaining such alignment.
Another object of the present invention is to provide a novel shim means between the aforedescribed door frame assembly and a rough door opening thereby to act as stabilizers therebetween.
These and other objects and features of the present invention will become apparent from the following descriptions.
DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 is an exploded perspective view of a door frame assembly constructed in accordance with the present invention and illustrating a door connectable thereto;
FIG. 2 is an enlarged partially broken away perspective view of one of the frame sections utilized with the assembly of FIG. 1;
FIG. 3 is a view similar to that of FIG. 2 with the frame sections being illustrated in an extended position;
FIG. 4 is a top view taken generally along line 4--4 in FIG. 3;
FIG. 5 is a frontal view of two frame sections connected together by a fastenerless miter joint constructed in accordance with the present invention;
FIG. 6 is a sectional view taken along line 6--6 in FIG. 5;
FIG. 7 is a sectional view taken along line 7--7 in FIG. 5;
FIG. 8 is a perspective view of a preferred interlocking frame anchor utilized with the door frame assembly of FIG. 1 and constructed in accordance with the present invention; and
FIG. 9 is a sectional view taken generally along line 9--9 in FIG. 8.
DETAILED DESCRIPTION
The present invention is directed to a new and novel door frame assembly which, in the main, includes three frame sections, i.e., two side sections and a head or top section. Each frame section is a preassembled unit for easy installation in the field.
In accordance with one aspect of the present invention, each of the frame sections is comprised of two elongated members which alone display L-shaped cross-sections and which together display a U-shaped cross-section. The two elongated members are connected together and allowed to move towards and away from one another in a direction perpendicular to their respective longitudinal axes by a predetermined amount without becoming disconnected from one another. In this manner, the two members of each frame section may be spread apart, if necessary, to fit about a stud member which defines a section of a rough door opening. Hence, the frame section does not have to be custom designed in accordance with the dimensions of a particular stud member. In addition, because the two elongated members making up to form each frame section remain engaged to one another during this adjustment procedure, mounting of the frame section to the stud member is greatly facilitated.
Another aspect of the present invention resides in the manner in which the two side frame sections are connected to the head section. Specifically, the top end of each side section is mitered, actually reversed mitered, so as to define a plane substantially perpendicular with a respective mitered end of the head section so that when these mitered and reverse mitered ends are assembled to one another, the side sections extend in the same direction from opposite ends of the head section and perpendicular thereto.
As will be seen hereinafter, a groove and spline arrangement is provided in each of the cooperating mitered and reverse mitered ends so as to provide a rigid joint or connection without the necessity of fastener means. In addition, the groove and spline arrangments aid in aligning accurately the side frame section in a direction perpendicular to the head section which is, of course, important for properly fitting the door frame assembly about a rough door opening. The reverse mitered ends of the side sections simplify installation of the joints.
The foregoing aspects of the present invention as well as other aspects thereof will become apparent from the following description of the drawings, wherein like components are designated by like reference numerals throughout the various figures. Turning specifically to FIG. 1, a door frame assembly constructed in accordance with the present invention is illustrated and generally designated by the reference numeral 10. The assembly 10 includes a first side or hinge frame section 12, a second side or strike frame section 14 and a top or head jamb section 16, which together form a frame assembly for a door 18.
As illustrated, hinge frame 12 displays a U-shaped cross-section so as to fit about a stud member (not shown) and has its top end mitered at 20 and reverse mitered at 21, the top of the jamb portion of the hinge frame. The hinge frame 12 includes a longitudinally extending door stop 22 which extends the entire length of the frame and which has its upper edge mitered at 24. Conventional butt hinges 26 are suitably fastened to the hinge frame 12 as illustrated in FIG. 1, so as to cooperate with a complementary hinge (not shown) on door 18. Strike frame 14 is essentially identical to hinge frame 12 and includes a mitered and reverse mitered top end 28 and 29, respectively, and door stop 30 (see FIG. 4), the upper edge of which is mitered at 32. In like manner, head or top frame 16 is essentially identical to the hinge frame and includes a longitudinally extending door stop 34. However, both ends 36 and 38 of the head frame are mitered and both preferably have a groove, or slot, 39 that receives a spline therein (see FIGS. 5 through 7, for more detail, where spline 84 is received in groove 82). Both ends 40 and 42 of door stop 34 are also mitered.
Turning to FIGS. 2-4, one of the frame sections, for example, strike frame 14 is shown in detail. As illustrated, this frame 14 includes two elongated members 44 and 46, which respectively display essentially L-shaped cross-sections and which together display essentially a U-shaped cross-section (see FIG. 4). Hence, longitudinal edges 48 of member 44 are positioned in confronting relationship with longitudinal edges 50 of member 46.
In order that frame 14 may be made adjustable so as to fit stud members of varying sizes, members 44 and 46 are movable between a first position such that longitudinal edges 48 and 50 engage one another, as illustrated in FIG. 2, and a second position such that the longitudinal edges are spaced apart but parallel to one another, as illustrated in FIGS. 3 and 4. This movement may be accomplished by utilizing, for example, a plurality of spring elements 52. Each of these spring elements 52 is positioned within a pair of axially aligned grooves 54 and 56 respectively located in the inside surfaces of leg 58 of member 44 and leg 60 of member 46. As shown, the grooves, which extend in a direction perpendicular to longitudinal edges 48 and 50, are preferably of sufficient depth so as to receive entirely the spring elements 52. In this manner, the spring elements do not interfere with the front face of a stud member. The spring elements are suitably fastened to legs 58 and 60 by any conventional means such as screws 62.
By providing spring elements 52 in the frame members in the foregoing manner, it should be readily apparent that the elongated member, such as members 44 and 46, are movable between the aforedescribed first and second portion, the spring elements biasing the members in the first position. In addition, the spring elements prevent said elongated members from completely separating or disengaging from one another during mounting of the frame about a stud.
As illustrated best in FIG. 3, door stop 30 is either mounted on or is an integral part of elongated member 46 and extends transversely beyond longitudinal edges 48 and 50, even when the elongated members are in their extended second position. Hence, if the members must be so extended to fit about a stud, this will not be visible to the eye. Further, the door stop cooperates with the spring elements to prevent separation of the elongated members of each member one from another such as may occur when one of said elongated members is rotated about its longitudinal axis while the other one of said elongated members remains relatively stationary with respect thereto.
The elongated members 44 and 46 may also be prevented from completely separating during expansion through the use of one and preferably at least two pairs of flat or thin interlocking elements 64 and 66. The elements 64 may be used in conjunction with spring elements 54. As illustrated best in FIG. 2, each of these interlocking elements 64 and 66 is L-shaped, one leg of which is substantially longer than the other. The longer leg of element 64 is positioned flatly against and suitably fastened to the inside surface of leg 58 of member 44 and extends perpendicular to and across longitudinal edges 48 and 50 such that the short leg extends downwardly. In a similar fashion, interlocking element 66 is positioned flatly against and suitably fastened to the inside surface of leg 60 directly below element 64. Element 66 extends perpendicular to and across edges 48 and 50 such that the shorter leg extends upward and behind the shorter leg of element 64. Each of the shorter legs has a side edge disposed parallel with the longitudinal axis of its attached section and one with the other.
When the elongated members 44 and 46 are moved to the aforestated second position, the interlocking elements move therewith until the side edges of the shorter legs engage one another to prevent further movement as illustrated in FIG. 3.
In FIG. 1 two pairs of interlocking elements 64, 66 are shown; however, it will be noted that same are reversed, one with respect to the other, upon mounting thereof. For example, in the upper pair of interlocking elements it will be noted that the upper element 64 is securely attached to the elongated member 44 while the upper element of the lower pair is securely attached to elongated member 46. The purpose of this arrangement is to prevent separation of the elongated members one from the other where one of said elongated members moves longitudinally relative to the other. It will be noted that the doorstop cooperates with the interlocking elements to prevent separation of the elongated members of each frame member one from the other also, to prevent undesirable rotation of one of the elongated members of each frame member about its longitudinal axis relative to the other one of said elongated members.
Turning to FIGS. 8 and 9, attention is directed to a preferred interlocking arrangement 94 which is utilized in lieu of previously described interlocking elements 64 and 66. As illustrated in FIG. 8, arrangement 94 includes a first L-shaped member 96 having a longer leg 98 and a shorter leg 100. The L-shaped member 96 is suitably fastened to the inner surface of one of the L-shaped members of each frame section such as, for example, member 46 (see FIGS. 2 and 3) so that longer leg 98 extends beyond and perpendicular to the longitudinal edges thereof. Arrangement 94 also includes a second L-shaped member 102 having a longer leg 104 and a shorter leg 106. Member 102 is suitably fastened to the inner surface of the other of the L-shaped members of each frame section such as, for example, member 44 so that the longer leg 104 is in alignment with the longer leg 98 of member 96. As illustrated best in FIG. 9, longer leg 104 of member 102 includes a centrally located, longitudinally extending, raised section 108 which extends the length of the longer leg. With member 102 fastened to the L-shaped member in the aforedescribed manner, the raised section 108 and the adjacent inner surface of the L-shaped member define a pocket 110 therebetween.
The raised section 108 is designed so that pocket 110 will receive therein the longer leg 98 of member 96 when the longitudinal edges of the L-shaped members making up the frame section come together. In this manner, the L-shaped members making up the frame section are interlocked against relative longitudinal movement. It will be noted that ease of interfitting by 98 within pocket 110 is accomplished by forming both leg 98 and pocket 110 slightly convergent, taken in a direction proceeding toward the free end of leg 98 and the inner end of pocket 110.
It is to be understood that the foregoing description of strike frame 14 also applies to hinge frame 12 and head frame 16. Hence, a description illustrating the adjustability of these frames will not be necessary, reference being made to the description of frame 14.
Turning to FIGS. 5-7, attention is directed to a fastenerless miter joint assembly 70 which is designed in accordance with the present invention and which is provided to insure perfect register of and connection between a side frame 72 and a top or head frame 74. These frames could be similar in adjustability and basic cross-section as those frames illustrated in FIGS. 1 to 3.
As illustrated best in FIG. 5, adjoining ends of side frame 72 and head frame 74 are mitered or beveled at, for example, approximately 45° angles with respect to their longitudinal axes as designated by the reference numerals 76 and 78, respectively. It should be noted, however, that the top of the jamb portion 77 of side frame 72 is reverse mitered, i.e., mitered perpendicularly to the mitered head frame which, as will become apparent below, simplifies installation of the miter joint.
In accordance with the present invention, miter joint 70 includes, in the mitered end 78, a slot or groove 82 which extends into top frame 74 at an angle approximately perpendicular to the mitered surface (see FIG. 5) and which extends across its mitered surface substantially parallel with the mitered surfaces upper and lower edges (see FIG. 7).
As illustrated best in FIG. 5, when the two mitered ends engage one another as shown, the groove 82 is positioned in cooperating alignment with the reverse mitered surface 76. A rectangularly shaped spline 84, also comprising part of the miter joint and displaying a cross-section approximately equal in shape and dimension to that of the groove and a length approximately equal to that of the groove and mitered surface 76 together, is rigidly positioned within the groove. This serves a two fold purpose. Firstly, it securely connects the side frame to the head frame without the use of fasteners and secondly, it aids in aligning the two frames perpendicular to one another which, of course, is important for proper alignment about a rough door opening.
As illustrated in FIGS. 6 and 7, where the frames are constructed in the manner set forth in FIGS. 1 to 3, i.e., when they each include two adjustable sections or members, the grooves would preferably extend into both sections.
With miter joint 70 constructed in the foregoing manner and with frames 12, 14, and 16 constructed in the foregoing manner, attention is now directed to the manner of assembling the frames. For purposes of simplicity it will be assumed that frames 12, 14 and 16 of FIG. 1 include the fastenerless miter joints of FIGS. 5. Specifically, one of the frames, e.g., the head frame 16, is adjusted to fit about the top of a rough door opening. Fastening means (not shown) may be desired or necessary for fastening the head frame to the rough door opening. In any case, the fact that the width of the door opening may vary in small degrees from one door opening to another, does not prevent proper fitting of the frame.
After the top frame has been assembled to the door opening in the foregoing member, the two side frames 12 and 14 are adjusted to fit about opposite sides of the rough opening simultaneously therewith, the splines are positioned against reverse mitered ends of the side frames. Again, the side frames, like the head frame, may be suitably fastened to the rough door opening.
To further secure the head frame, the present invention contemplates the use of a flexible shim 90 (FIGS. 1 and 2) which are constructed of deformable plastic, rubber or other suitable compressible material. As illustrated in FIG. 1, these shims 90 are positioned behind and against both ends of the head frame section between the latter and the rough door opening. In a preferred embodiment, the shims display sufficient recoil to apply approximately seventy pounds or more of force at each miter joint, which is sufficient to insure tight fitting miter joints during the installation process. In addition, the shims minimize the effect of tolerance variations along the height of the rough door opening and thereby act as a stabilizer between the opening and frames. The side frames, on the other hand, may include frame anchors 92 suitably fastened to the inside of the frames, see FIG. 1.
It is to be understood that this invention is not limited to the exact embodiments of the door frame assemblies and door frame sections described and shown which are merely by way of illustration and not limitation, as various other forms and modifications will be apparent to those skilled in the art.