Title:
BRICK MOLD ASSEMBLY, CONNECTOR FOR SAME AND KIT FOR ASSEMBLY OF SAME
Kind Code:
A1


Abstract:
A brick mold assembly for a door frame comprises a brick mold portion configured to be installed adjacent a door jamb portion, and a connector configured for connecting the brick mold portion to the door jamb portion. The connector comprises a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member. The second longitudinal clip member is oriented relative to the first longitudinal clip member so as to define an angle therebetween.



Inventors:
Rochman, Oded Eddy (Thornhill, CA)
Application Number:
14/068814
Publication Date:
04/17/2014
Filing Date:
10/31/2013
Assignee:
ROCHMAN ODED EDDY
Primary Class:
Other Classes:
52/717.01
International Classes:
E04F19/02; E04F19/06
View Patent Images:
Related US Applications:
20040003566Exterior siding panel with slidable fastening hemJanuary, 2004Sicuranza
20050257473Anchor and anchoring systemNovember, 2005Shaw et al.
20030233796Roof panel for a sun roomDecember, 2003Walz et al.
20030136068Internal compression mount for hollow postsJuly, 2003Forbis et al.
20070017176Masonry wall systemJanuary, 2007Gray
20080313985METHOD FOR INCREASING WIND UPLIFT RESISTANCE OF WOOD-FRAMED ROOFS USING CLOSED-CELL SPRAY POLYURETHANE FOAMDecember, 2008Duncan
20090194575Anchoring Pin Insertion Unit and MethodAugust, 2009Hamman
20090025327Furring Strip Alignment SystemJanuary, 2009Albracht
20080040989Pipe construction kit for sewer pipelineFebruary, 2008Hegler
20050188644Prefabricated Structural Panel of Post-Stressed Wood for the Manufacture of Immovable PropertiesSeptember, 2005Moure
20040035068Modular wall segments and method of making such segmentsFebruary, 2004Eliyahu et al.



Primary Examiner:
FONSECA, JESSIE T
Attorney, Agent or Firm:
Marks & Clerk (Toronto, ON, CA)
Claims:
What is claimed is:

1. A brick mold assembly for a door frame, comprising: a brick mold portion configured to be installed adjacent a door jamb portion; and a connector configured for connecting the brick mold portion to the door jamb portion, the connector comprising a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.

2. The brick mold assembly of claim 1, wherein the first longitudinal clip member is configured to engage the brick mold portion.

3. The brick mold assembly of claim 2, wherein the brick mold portion comprises at least one feature configured for receiving the first longitudinal clip member.

4. The brick mold assembly of claim 3, wherein the at least one feature is a longitudinal channel comprising a longitudinal clip member configured to cooperate with the first longitudinal clip member.

5. The brick mold assembly of claim 4, wherein the connector further comprises a longitudinal intermediate portion joining the first longitudinal clip member and the second longitudinal clip member.

6. The brick mold assembly of claim 5, wherein the intermediate portion comprises a longitudinal channel for receiving the longitudinal clip member of the brick mold portion.

7. The brick mold assembly of claim 1, wherein the second longitudinal clip member is configured to engage the door jamb portion.

8. The brick mold assembly of claim 7, wherein the door jamb portion comprises at least one feature configured for receiving the second longitudinal clip member.

9. The brick mold assembly of claim 8, wherein the at least one feature is a longitudinal channel comprising a longitudinal clip member of the door jamb portion configured to cooperate with the second longitudinal clip member.

10. The brick mold assembly of claim 7, wherein the connector further comprises a longitudinal corner configured to abut a corresponding corner of the door jamb portion when the second longitudinal clip member engages the door jamb portion.

11. The brick mold assembly of claim 1, wherein the angle defined by the first and second longitudinal clip members is about 90 degrees.

12. The brick mold assembly of claim 1, wherein the connector is extruded.

13. A kit for assembly of a brick mold assembly for a door frame, comprising: a brick mold portion configured to be installed adjacent a door jamb portion; and a connector configured for connecting the brick mold portion to the door jamb portion, the connector comprising a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.

14. A connector for connecting a brick mold portion to a door frame, the connector comprising: a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.

15. The connector of claim 14, wherein the first longitudinal clip member is configured to engage the brick mold portion.

16. The connector of claim 14, wherein the second longitudinal clip member is configured to engage a door jamb portion member.

17. The connector of claim 14, wherein the connector further comprises a longitudinal intermediate portion joining the first longitudinal clip member and the second longitudinal clip member.

18. The connector of claim 17, wherein the intermediate portion comprises a longitudinal channel for receiving a feature of the brick mold portion.

19. The connector of claim 18, wherein the feature is a longitudinal clip member of the brick mold portion.

20. The connector of claim 14, wherein the connector is extruded.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 13/908,369 filed on Jun. 3, 2013, which claims the benefit of provisional U.S. Application No. 61/713,834 filed on Oct. 15, 2012, the contents of which are herein incorporated by reference in their entireties.

FIELD OF THE INVENTION

The present invention relates generally to door jambs and in particular, to a brick mold assembly, and a connector for same and a kit for assembly of same.

BACKGROUND OF THE INVENTION

Door frames of dwellings and other buildings are often constructed by installing wooden side plates and a wooden top plate around a doorway opening. Wooden casings are typically attached to the edges of the side and top plates. Hinges and lock set recesses are then added to opposite side plates.

As will be appreciated, this approach requires considerable handiwork and the exercise of some degree of skill. It also requires significant on site labour, and is typically time-consuming. Additionally, this approach also does not provide for weather proofing, and weather proofing typically needs to be improvised by attaching weather stripping around the edges of the doorway opening.

To facilitate door frame construction, it may be desirable and more cost-effective to utilize a pre-fabricated door jamb comprising inexpensive structural materials such as plastic. Door jambs comprising extruded plastic have been previously described. For example, U.S. Pat. No. 6,557,309 to Johnson discloses a door jamb assembly having an interchangeable multi-component design allowing for the framing of doorways with different configurations by first selecting a main frame and a decorative trim that conforms with the doorway, and then securing a first end of the main frame, being attached to the decorative trim, onto a wall with the use of an attachment flange and securing a second end of the main frame to an interior jamb with the use of a fastener.

U.S. Pat. No. 7,472,519 to Careri discloses a plastic door jamb member for forming a portion of a door jamb, the plastic member having a recess for receiving a wooden door jamb portion, and an interlocking attachment recess for interconnection with a metal reinforcement plate. The plastic door jamb member may be interengaged with the wooden door jamb portion, and further interengaged with the metal reinforcement plate, and installed in position as a combination door jamb assembly.

Brick mold systems for door frames have also been disclosed. For example, U.S. Patent Application Publication No. 2010/0263307 to Gilles et al. discloses a method of manufacturing of a brick molding system for window frames and door frames that includes providing a frame member which is used to form a frame to accommodate a variety of styles of window or doors in accordance with customer requirements. The frame member has a female brick molding attachment receptacle. A plurality of brick molding variations is provided, all of which have a male coupling engageable with the female brick molding receptacle. An order is received from a customer for a selected style of frame with a selected style of brick molding. Lengths of the frame member are secured together to form the selected style of frame and in the process of forming the frame the male coupling of the selected style of brick molding is inserted into the female brick molding receptacle.

Improvements are generally desired. It is therefore an object at least to provide a novel brick mold assembly, and a connector for the same and a kit for assembly of the same.

SUMMARY OF THE INVENTION

In one aspect, there is provided a brick mold assembly for a door frame, comprising: a brick mold portion configured to be installed adjacent a door jamb portion; and a connector configured for connecting the brick mold portion to the door jamb portion, the connector comprising a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.

The first longitudinal clip member may be configured to engage the brick mold portion. The brick mold portion may comprise at least one feature configured for receiving the first longitudinal clip member. The at least one feature may be a longitudinal channel comprising a longitudinal clip member configured to cooperate with the first longitudinal clip member. The connector may further comprise a longitudinal intermediate portion joining the first longitudinal clip member and the second longitudinal clip member. The intermediate portion may comprise a longitudinal channel for receiving the longitudinal clip member of the brick mold portion.

The second longitudinal clip member may be configured to engage the door jamb portion. The door jamb portion may comprise at least one feature configured for receiving the second longitudinal clip member. The at least one feature is a longitudinal channel comprising a longitudinal clip member of the door jamb portion configured to cooperate with the second longitudinal clip member. The connector may further comprise a longitudinal corner configured to abut a corresponding corner of the door jamb portion when the second longitudinal clip member engages the door jamb portion.

The angle defined by the first and second longitudinal clip members may be about 90 degrees.

The connector may be extruded.

In another aspect, there is provided a kit for assembly of a brick mold assembly for a door frame, comprising: a brick mold portion configured to be installed adjacent a door jamb portion; and a connector configured for connecting the brick mold portion to the door jamb portion, the connector comprising a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.

The first longitudinal clip member may be configured to engage the brick mold portion. The brick mold portion may comprise at least one feature configured for receiving the first longitudinal clip member. The at least one feature may be a longitudinal channel comprising a longitudinal clip member configured to cooperate with the first longitudinal clip member. The connector may further comprise a longitudinal intermediate portion joining the first longitudinal clip member and the second longitudinal clip member. The intermediate portion may comprise a longitudinal channel for receiving the longitudinal clip member of the brick mold portion. The second longitudinal clip member may be configured to engage the door jamb portion. The door jamb portion may comprise at least one feature configured for receiving the second longitudinal clip member. The at least one feature may be a longitudinal channel comprising a longitudinal clip member configured to cooperate with the second longitudinal clip member.

The connector may further comprise a longitudinal corner configured to abut a corresponding corner of the door jamb portion when the second longitudinal clip member engages the door jamb portion.

The angle defined by the first and second longitudinal clip members may be about 90 degrees.

The connector may be extruded.

In another aspect, there is provided a connector for connecting a brick mold portion to a door frame, the connector comprising: a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.

The angle may be about 90 degrees.

The first longitudinal clip member may be configured to engage the brick mold portion.

The second longitudinal clip member may be configured to engage a door jamb portion. The connector may further comprise a longitudinal intermediate portion joining the first longitudinal clip member and the second longitudinal clip member. The intermediate portion may comprise a longitudinal channel for receiving a feature of the brick mold portion. The feature may be a longitudinal clip member of the brick mold portion.

The connector may be extruded.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described more fully with reference to the accompanying drawings in which:

FIG. 1 is a perspective view of a door jamb assembly;

FIGS. 2a and 2b are exploded sectional and sectional views, respectively, of a door jamb portion forming part of the door jamb assembly of FIG. 1, and taken along the indicated section line;

FIG. 3 is an exploded, upper perspective view of a portion of the door jamb assembly of FIG. 1;

FIG. 4 is an exploded, lower perspective view of the portion of the door jamb assembly of FIG. 3;

FIG. 5 is a lower perspective view of the portion of the door jamb assembly of FIG. 3;

FIG. 6 is a perspective view of the door jamb assembly of FIG. 1, installed in a doorway opening;

FIG. 7 is a sectional view of the door jamb portion of FIG. 2b, installed in a doorway opening and having a brick mold fitted thereto;

FIG. 8 is a perspective view of another embodiment of a door jamb assembly, installed in a doorway opening;

FIGS. 9a and 9b are exploded sectional and sectional views, respectively, of a door jamb portion, a brick mold portion and a connector forming part of the door jamb assembly of FIG. 8;

FIG. 10 is a sectional view of the connector of FIG. 9a;

FIG. 11 is an enlarged fragmentary view of a portion of the door jamb portion, the brick mold portion and the connector of FIG. 9b, identified by reference numeral 11; and

FIG. 12 is a sectional view of the door jamb portion, the brick mold portion and the connector of FIG. 9b, installed in the doorway opening.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Turning now to FIG. 1, a door jamb assembly is shown and is generally indicated by reference numeral 20. Door jamb assembly 20 is configured to be installed in a doorway opening (not shown) of a wall for accommodating a door (not shown). The door jamb assembly 20 comprises three (3) door jamb portions 22 that are connected by two (2) corner keys 24.

The door jamb portion 22 may be better seen in FIGS. 2 to 5. Each door jamb portion 22 comprises an extruded, longitudinal door jamb member 30 and a longitudinal frame member 32. In this embodiment, the door jamb member 30 is fabricated of polyvinyl chloride (PVC) “cap stock”, and is formed by co-extrusion of recycled (or “regrind”) PVC and new PVC so as to provide a body of recycled PVC that is coated with layer of new PVC, as is known in the art. The door jamb member 30 comprises a plurality of longitudinal internal cavities, which extend the length of the door jamb member 30 and which are separated by longitudinal internal webs. In the embodiment shown, the door jamb member 30 comprises a first internal cavity 34, a second internal cavity 36 and a third internal cavity 38.

The door jamb member 30 also comprises a plurality of longitudinal channels that extend the length of the door jamb member 30. In the embodiment shown, the door jamb member 30 comprises a rounded channel 40 that extends the length of the door jamb member 30, and which is configured to engage the frame member 32 as described below. The door jamb member 30 further comprises a biased, longitudinal clip member 42 disposed along a first side of the rounded channel 40, and a longitudinal rib 44 disposed along a second side of the rounded channel 40. Additionally, the door jamb member 30 comprises a channel 46 that is sized and shaped for accommodating a longitudinal reinforcement member (not shown) having a corresponding profile. The door jamb member 30 further comprises a channel 47 that is sized and configured to accommodate weather stripping, and a biased, longitudinal clip member 48 spaced from a longitudinal external corner 49 which together define an external, longitudinal channel 51 therebetween. The channel 51 is configured to accommodate trim surrounding the exterior of the doorway opening, such as for example a brick mold portion.

In this embodiment, each frame member 32 is formed by machining a longitudinal wooden board. In the embodiment shown, the frame member 32 comprises a rounded longitudinal edge 50, a longitudinal groove 52 disposed along a first side of the rounded longitudinal edge 50, and a longitudinal notch 62 disposed along a second side of the rounded longitudinal edge 50.

The rounded longitudinal edge 50 of the frame member 32 and the rounded channel 40 of the door jamb member 30 are configured to matingly engage so as to form a “bullnose” joint therebetween. When engaged in this manner, the longitudinal rib 44 matingly engages the longitudinal notch 62, and maintains the door jamb member 30 and the frame member 32 in a parallel relationship. Additionally, when engaged in this manner, the biased, longitudinal clip member 42 engages the longitudinal groove 52 so as to secure the frame member 32 and the door jamb member 30 to each other. In this embodiment, the frame member 32 and the door jamb member 30 are further secured to each other by glue disposed between the rounded longitudinal edge 50 and the rounded channel 40.

The corner key 24 may be better seen in FIGS. 3 and 4. Each corner key 24 is a discrete and separate part from the door jamb portion 22. In this embodiment, each corner key 24 is fabricated of glass-filled nylon by injection molding. Each corner key 24 is generally shaped to engage the internal cavities 34, 36 and 38 of two (2) door jamb members 30, so as to form a generally ninety (90) degree, or a generally “right-angled”, joint between two (2) door jamb portions 22. Each corner key 24 comprises a first panel 70 and a second panel 72 that are connected along a common edge, and which are oriented generally orthogonally to each other. The first and second panels 70 and 72 are supported in relation to each other by gussets 74, and by a first end panel 76 and a second end panel 78. A set of pins extends outwardly from each of the first and second panels 70 and 72. In the embodiment shown, each set of pins comprises a first pin 82, a second pin 84 and a third pin 86 extending from each of the first and second panels 70 and 72, and which are sized and positioned to engage the first internal cavity 34, the second internal cavity 36 and the third internal cavity 38, respectively, of the door jamb member 30. The corner key 24 further comprises a cap pin 88 extending from the first end panel 76, which is sized and positioned to cover the channels 54 and interior cavities 92, when the corner key 24 connects the two (2) door jamb portions 22.

In use, the door jamb assembly 20 is assembled by providing two (2) corner keys 24 and three (3) door jamb portions 22, and namely two (2) door jamb portions 22 having a first length and one (1) door jamb portion 22 having a second length, the first length being greater than the second length. In this embodiment, each door jamb portion 22 is provided with the door jamb member 30 already secured to the frame member 32. Each end of the door jamb portion 22 having the second length is then connected to a corresponding end of a door jamb portion 22 having the first length using a corner key 24. In particular, adjacent door jamb portions 22 are connected by inserting a first pin 82, a second pin 84 and a third pin 86 of the corner key 24 into the first internal cavity 34, the second internal cavity 36 and the third internal cavity 38, respectively, of each adjacent door jamb portion 22. Once assembled, the assembled door jamb assembly may then be installed in a suitably-sized doorway opening in a wall, such that the one (1) door jamb portion 22 having the second length is oriented generally horizontally as a “header” and the two (2) door jamb portions 22 having the first length are oriented generally vertically.

FIG. 6 shows the door jamb assembly 20 installed in a doorway opening of a wall 92. Hinges (not shown) and lock set recesses (not shown) have been added to the frame members of the vertically-oriented door jamb portions 22 for accommodating a door D.

FIG. 7 shows the door jamb portion 22 of the door jamb assembly 20 installed in another embodiment of a doorway opening of an exterior wall of a building, such as for example a house. As may be seen, the door jamb member 30 and the frame member 32 are positioned generally adjacent an inner surface 93 of a frame 94 surrounding the doorway opening. As may be seen, trim in the form of a longitudinal brick mold portion 95 is accommodated by the longitudinal channel 51, for generally finishing the joint between the door jamb portion 22 and an exterior surface 96 of the doorway opening frame 94 and a surface of an exterior brick wall 97. Additionally, in the embodiment shown, a reinforcement member in the form of a bar 98 having a “C”-shaped cross-sectional profile is accommodated by the channel 46, for generally providing reinforcement to the door jamb portion 22.

As will be appreciated, the “bullnose” joint formed between the rounded longitudinal edge 50 of the frame member 32 and the rounded channel 40 of the door jamb member 30 is strong, and is simple in design and may advantageously be fabricated at a low cost. Moreover, the inherent strength of the “bullnose” joint advantageously eliminates the need for additional fasteners between the door jamb member 30 and the frame member 32, such as for example screws. Additionally, the rounded longitudinal edge 50 can advantageously be formed in a facile manner, and without forming burrs or surface roughness that might otherwise occur during formation of non-rounded edges by machining As will be understood, the absence of burrs or surface roughness advantageously ensures a secure fit between the rounded channel 40 and the rounded longitudinal edge 50. Additionally, and as will be understood, the rounded longitudinal edge 50 does not have longitudinal corners or edges that would otherwise be likely to tear or chip upon insertion into a receiving channel of a member fabricated of non-wooden material.

As will be appreciated, the corner key 24 is configured to join two (2) door jamb portions 22 without requiring the ends of the door jamb portions 22 to be cut to a specific angle, other than the 90 degree angle formed during manufacture of the door jamb member 30. As will be appreciated, this eliminates the need to modify the ends of the door jamb portions 22, such as for example by cutting an end to a 45 degree angle by miter saw, during on site assembly of the door jamb assembly 20. This allows the door jamb assembly 20 to be assembled from “stock” or unmodified parts, which advantageously reduces the cost of assembly of the door jamb assembly 20, and which advantageously allows parts that may have been damaged during transport or during assembly to be easily replaced.

The brick mold is not limited to that described above, and in other embodiments, the other brick molds may be used. For example, FIG. 8 shows another embodiment of a door jamb assembly, which is generally indicated by reference numeral 120. Door jamb assembly 120 is configured to be installed in a doorway opening of an exterior wall of a building, such as for example a house, for accommodating a door D. The door jamb assembly 120 is generally similar to the door jamb assembly 20 described above and with reference to FIGS. 1 to 6, and comprises three (3) door jamb portions 22 that are connected by two (2) corner keys 24. In this embodiment, each door jamb portion 22 comprises an extruded, longitudinal door jamb member 30 and a longitudinal frame member 32, as described above and with reference to FIGS. 1 to 6.

The door jamb assembly 120 also comprises a brick mold assembly comprising a plurality of extruded, longitudinal brick mold portions 150. One of the brick mold portions 150 may be better seen in FIGS. 9a and 9b. In this embodiment, each brick mold portion 150 is fabricated of PVC “cap stock”, and is formed by co-extrusion of recycled (or “regrind”) PVC and new PVC so as to provide a body of recycled PVC that is coated with layer of new PVC, as is known in the art. The brick mold portion 150 comprises a plurality of longitudinal internal cavities, which extend the length of the brick mold portion 150 and which are separated by longitudinal internal webs. The brick mold portion 150 further comprises a longitudinal fastening flange 152 extending outwardly from the brick mold portion 150, and which extends the length thereof. The brick mold portion 150 also comprises a longitudinal flange 154 and a biased, longitudinal clip member 156 that extends outwardly from the brick mold portion 150, both of which extend the length of the brick mold portion 150 and which together define an external, longitudinal channel 157 therebetween. The longitudinal clip member 156 has a longitudinal rib 158 disposed along an outer side thereof, and which extends the length thereof.

The brick mold assembly also comprises a plurality of longitudinal connectors 160, each connector 160 being configured for connecting the brick mold portion 150 to the door jamb portion 22. In this embodiment, the connector 160 is formed by extrusion, and is fabricated of extruded PVC. Each connector 160 comprises a biased, first longitudinal clip member 162 and a biased, second longitudinal clip member 164 that are joined by a longitudinal intermediate portion 166. The longitudinal axis of the first longitudinal clip member 162 is parallel to the longitudinal axis of the second longitudinal clip member 164, and the second longitudinal clip member 164 is oriented relative to the first longitudinal clip member 162 so as to define an angle θ therebetween, as may be seen in FIG. 10. In this embodiment, the angle is about ninety (90) degrees. The first longitudinal clip member 162 and the longitudinal intermediate portion 166 define a longitudinal inner channel 168 therebetween, and the second longitudinal clip member 164 and the longitudinal intermediate portion 166 define a longitudinal outer corner 170 therebetween.

The second longitudinal clip member 164 of the connector 160 is configured to matingly engage the channel 51 of the door jamb member 30, and to cooperate with the longitudinal clip member 48 for connecting the connector 160 to the door jamb portion 22. When the connector 160 and door jamb portion 22 are connected in this manner, the longitudinal outer corner 170 abuts a longitudinal corner of the door jamb portion 22 in a nestled manner, as may be seen in FIG. 11.

The longitudinal clip member 156 of the brick mold portion 150 is configured to matingly engage the longitudinal inner channel 168 of the connector 160, and to cooperate with the first longitudinal clip member 162 for connecting the brick mold portion 150 to the connector 160. Reciprocally, the first longitudinal clip member 162 of the connector 160 is configured to matingly engage the longitudinal channel 157 of the brick mold portion 150, for cooperating with the longitudinal clip member 156 of the brick mold portion 150. When the brick mold portion 150 and connector 160 are connected in this manner, the longitudinal rib 158 abuts an outer surface of the longitudinal clip member 48 of the door jamb member 30. As will be understood, when engaged in this manner, the longitudinal rib 158 covers the joint between the longitudinal clip member 48 and the longitudinal clip member 156, and urges the longitudinal clip member 48 toward the second longitudinal clip member, 164 for securing the connection between the door jamb member 30, the brick mold portion 150 and the connector 160.

In use, the brick mold assembly 120 is assembled by providing two (2) corner keys 24 and three (3) door jamb portions 22, and namely two (2) door jamb portions 22 of a first length and configured for being oriented generally vertically and one (1) door jamb portion 22 of a second length and configured for being oriented generally horizontally, and namely as a “header” door jamb portion 22, the first length being greater than the second length. In this embodiment, each door jamb portion 22 is provided with the door jamb member 30 already secured to the frame member 32. Each end of the “header” door jamb portion 22 of the second length is then connected to a corresponding end of a door jamb portion 22 of the first length using a corner key 24, in the manner described above for door jamb assembly 20 and with reference to FIGS. 1 to 6.

Three (3) connectors 160 are provided, namely two (2) connectors 160 each having generally the same length as the door jamb portion 22 of the first length, and one (1) connector 160 having generally the same length as the header door jamb portion 22 of the second length. Each connector 160 is connected to its corresponding door jamb portion 22 by inserting the second longitudinal clip member 164 into the longitudinal channel 51 of the door jamb portion 22, such that the second longitudinal clip member 164 cooperates with the longitudinal clip member 48, and such that the longitudinal outer corner 170 abuts a longitudinal corner of the door jamb portion 22 in a nestled manner.

Three (3) brick mold portions 150 are provided, namely two (2) brick mold portions 150 each having a third length generally corresponding to the length of the door jamb portion 22 of the first length plus the width of one (1) corner key 24, and one (1) brick mold portion 150 having a fourth length generally corresponding to the length of the header door jamb portion 22 of the second length plus the width of two (2) corner keys 24. Both longitudinal ends of the brick mold portion 150 having the fourth length are cut to about a forty-five (45) degree angle, while only one longitudinal end of each brick mold portion 150 having the third length is cut to about a forty-five (45) degree angle. Each brick mold portion 150 is connected to its corresponding connector 160 by inserting the longitudinal clip member 156 into the longitudinal inner channel 168 of the connector 160, such that the longitudinal clip member 156 cooperates with the first longitudinal clip member 162. When connected in this manner, the longitudinal rib 158 of the brick mold portion 150 abuts an outer surface of the longitudinal clip member 48 of the door jamb portion 22. As will be understood, once all three (3) brick mold portions 150 are installed, the ends of the brick mold portions 150 cut to about forty-five (45) degree angles abut to form miter joints, as shown in FIG. 8.

FIG. 12 shows a section of the door jamb assembly 120 installed in the doorway opening of an exterior wall of a building, such as for example a house. As may be seen, the door jamb portion 22 is positioned generally adjacent an inner surface 182 of a frame 180 surrounding the doorway opening. The brick mold portion 150 is connected to the door jamb portion 22 by the connector 160, and generally finishes the joint between the door jamb portion 22 and an exterior surface 184 adjacent the doorway opening.

It will be understood that the brick mold assembly is not limited to use with the door jamb portion described above, and in other embodiments, the brick mold assembly may alternatively be used with a door frame assembly comprising door jamb portions each having a different cross-sectional profile than that of the door jamb portion described above, and/or comprising a header having a different cross-sectional profile than that of the header door jamb portion described above.

Although in the embodiments described above, the door jamb assembly comprises two (2) door jamb portions having a first length and one (1) door jamb portion having a second length, where the first length being greater than the second length, in other embodiments, other configurations are possible depending on the dimensions of the doorway opening. For example, in other embodiments, the first length may alternatively be less than the second length, or the door jamb assembly may alternatively comprise three (3) door jamb portions having the same length.

Although in the embodiment described above, the brick mold portion is fabricated of polyvinyl chloride (PVC) “cap stock”, in other embodiments, the brick mold portion may alternatively be fabricated of virgin PVC, recycled PVC, or of any other suitable extrudable polymer. In still other embodiments, the brick mold portion may alternatively be fabricated of extruded aluminum, extruded aluminum alloy, or pulltruded fiberglass composite.

It will be understood that the cross-sectional profile of the brick mold portion is not limited to that of the embodiment described above, and in other embodiments, the brick mold portion may alternatively have a different cross-sectional profile. For example, the brick mold portion may alternatively have a different configuration of longitudinal internal cavities and flanges.

It will be understood that the cross-sectional profile of the connector is not limited to that of the embodiment described above, and in other embodiments, the connector may alternatively have a different cross-sectional profile. For example, the angle defined between the second longitudinal clip member and the first longitudinal clip member may be different than ninety (90) degrees. In such an embodiment, the brick mold portion and/or the door jamb portion, or other door frame portion to which the connector is configured to be connected, would be suitably configured to accommodate the connector comprising the first and second longitudinal clip members.

Although in the embodiment described above, during assembly of the door jamb assembly, three (3) connectors are provided, each having generally the same length as its corresponding door jamb portion, in other embodiments, a different number of connectors may alternatively be provided, where one or more of the connectors has a shorter length than its corresponding door jamb portion.

Although in the embodiment described above, the connector is formed by extrusion, in other embodiments, the connector may alternatively be formed by another suitable method.

Although in the embodiment described above, the connector is fabricated of PVC, in other embodiments, the connector may alternatively be fabricated of another suitable material.

Although in the embodiment described above, the longitudinal internal cavities and the longitudinal channels of the brick mold portion extend the length of the brick mold portion, in other embodiments, at least one of the longitudinal internal cavities and/or at least one of the longitudinal channels may alternatively not extend the length of the brick mold portion.

The invention also contemplates a kit of parts which, when assembled, forms the door jamb assembly of one or more of the embodiments described above.

Although embodiments have been described above with reference to the accompanying drawings, those of skill in the art will appreciate that variations and modifications may be made without departing from the scope thereof as defined by the appended claims.