Note: Descriptions are shown in the official language in which they were submitted.
CA 02414416 2002-12-11
TITLE: GATE OR DOOR FRAME ASSEMBLY AND METHOD OF MAKING
A GATE OR DOOR
FIELD OF THE INVENTION
The present invention relates to a frame assembly for use
in the construction of gates.or doors and, more
specifically, to a frame assembly acLapted to provide the
vertical and horizontal support members of a gate or door
and rotatably connect these members to a fixed structural
member.
BACKGROUND OF THE INVENTION
Gates are used to allow selective access through a wall
or fence. Conventionally, gates are constructed as
follows. Two vertical support members and two horizontal
support members are fastened together in a rectangular
shape to form what will be referred to herein as a gate
frame. Fence boards or the like are fastened to the
support members, and one of the vertical support members
is typically attached by two or more hinge assemblies to
a structural member such as a wall or post. Doors are
similarly constructed with vertical and horizontal
support members fastened together to form what will be
referred to herein as a door frame. A sheet of plywood or
the like covers one or both sides of the door frame.
Using conventional gate/door building techniques,
fasteners such as nails or screws are driven through one
support member into another support :member to form the
corners of the gate box. Over time, the force of gravity
and wood shrinkage will cause these fasteners to loosen,
allowing the gate/door frame to sag out of its desired
rectangular shape.
Accordingly, metal L-brackets, wooden brace members,
triangular pieces of plywood, and the like are often
fastened to the adjacent ends of the support members to
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strengthen the inside corners of the gate/door frame. In
other situations, a wire is placed in tension between the
upper proximal and lower distal corners of the gate/door
frame to support the lower distal corner of the gate
frame and thereby reduce sagging of the gate or door.
Such bracing techniques are somewhat effective but the
wire is aesthetically unappealing and can produce frayed
ends which are potentially dangerou:~. In addition the
bracing commonly employs fasteners that are susceptible
to failure and it can be relatively time consuming to
implement.
Another problem with conventional gate/door building
techniques is that fasteners such as nails or screws are
similarly used to attach the hinge assemblies to the
vertical support member adjacent to the structural
member. The loads are transferred to the gate/door
through the screws placed in tension. As the wood
shrinks and the gate/door is opened and closed, the
fasteners under tension tend to loo;~en and may eventually
fail.
As the hinge fasteners loosen, the Entire gate/door
assembly may sag relative to the hinge assemblies and the
structural members, even if the gate/door frame maintains
its rectangular shape. The use of braces at the corners
of the gate/door frame will worsen sagging at the hinges
because the materials and hardware used for bracing
increase the weight of the gate/door_; this increased
weight increases the forces of grav~_ty on the fasteners
used to attach the hinge assemblies to the proximal
vertical support member.
Various solutions have been proposed. One attempt was a
steel gate frame product comprising distal and proximal
brace members, with hinges being attached to the proximal
brace member. A gate assembly constructed using this
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product would use upper and lower horizontal wooden
support members, but would not use vertical support
members. Instead, the distal and proximal brace members
would form the structure of the vertical sides of the
gate. The product required a plurality of sizes, with
each size corresponding to a given cListance between the
upper and lower horizontal support members. The finished
gate has excessive flex along the vertical plane of the
gate. This flexing can cause the gage to twist making
installation difficult. Exposed metal bracing are subject
to rust and are aesthetically unattractive.
Another proposed solution was a set of four metal
brackets as shovm in Canadian Industrial Design
Registration No. 83049 and No. 83050. These registrations
describe a bracket system for forming gate assemblies.
Four separate brace members are provided, and two of the
brace members are rigidly attached t.o hinge assemblies.
The brace members are adapted to be attached to support
members to form the corners of a gate frame functioning
as the structural portion of the gate assembly. The
hinge assemblies are adapted to be rigidly attached to a
fence post to allow the gate assembly to pivot relative
to the fence post. Gate assemblies of arbitrary height
and width can be formed using this bracket system
although wooden members must be trin~ed to accommodate
weld filets of the brackets. As there is no direct
connection between the horizontal anal vertical wooden
support members they can over time twist and warp
independently of each other. G~Thile the finished gate is
extremely rigid, light weight and flex resistant, exposed
metal bracing and parts are subject to rust and. are
unattractive. Costs of manufacture, quality control at
welded connections and shipping costs are additional
problems associated with this product.
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From the foregoing, it should be clear that one object of
the present invention is to develop a method and frame
for making a gate or door that is easy and inexpensive to
use, and which allow significant flexibility in the final
design of the gate or door assembly"
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a
frame for making a gate or door that. is extremely rigid,
light weight, flex resistant and with a minimum of
exposed metal bracing and parts.
A further object of the present invention is to provide a
frame for making a gate or door with improved method of
securing the hinges to the frame.
Thus in accordance with the present invention there is
provided a frame assembly for makingwa gate or door
comprising an upper horizontal member, a lower horizontal
member, a first vertical member and a second vertical
member, one or more support members provided along the
length of each of the upper and lower horizontal members,
first connection means to connect an upper end of the
first vertical to one end of support member provided
along the length of the upper horizontal member, second
connection means to connect lower end of the first
vertical to one end of support member provided along the
length of the lower horizontal member, third connection
means to connect an upper end of the second vertical to a
second end of support member provided along the length of '
the upper horizontal member and forth connection means to
connect a lower end of the second vertical to a second
end of support member provided along the length of the
lower horizontal member.
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Further features of the invention will be described or
will become apparent in the course of the following
detailed description
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the
drawings, wherein:
Figure 1 is a perspective view of an assembly
drawing for a frame assembly for making a gate or door in
.accordance with the present invention.
Figure 2 is a front plan view of the horizontal
and vertical members of the frame assembly of Figure 1.
Figure 3 is an enlarged view of a hinge attachment
detail of the frame assembly of Figure 1.
Figure 4 is an enlarged perspective view of a
portion of a horizontal member of Figure 3 with a groove
to accept a support rod.
Figure 5 is an end plan view of the horizontal
member of Figure 4 with the support rod inserted.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to Figure 1, one embodiment of a frame
assembly for making a gate or door i.n accordance with the
present invention is generally indicated at 1. The frame
assembly comprises an upper horizontal member 2, a lower
horizontal member 3, a first vertical member 4 and a
second vertical member 5. In the preferred embodiment
illustrated when assembled, the horizontal 2,3 and
vertical 4,5 members form a rectangular frame.
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One or more support members are provided along the length
of each of the upper and lower horizontal members to
strengthen the resulting frame and prevent sagging. In
the embodiment shown support rod 6 i.s provided along the
length of the upper horizontal member 2. In the
embodiment shown (see Figures 2, 4 and 5), provision is
made for one support rod, provided i.t has sufficient
cross section to provide the strength required to support
the frame assembly. The support rod 6 preferably is a
steel rod with a cross section of at: least 1/ inch. In
order to connect the support rod 6 t:o the upper
horizontal member 2 so that it is strengthened against
sagging by support rod 6, a longitudinal hole or bore 7
is provided along the length of the upper horizontal
member 2. The hole or bore 7 can be drilled or provided
in some other manner. In the embodiment shown, hole or
bore 7 is formed by making a groove 8 half the thickness
of the upper horizontal member 2 in the face 9 of upper
horizontal member 2 along its length. In the embodiment
shown the upper and lower horizontal. members 2,3 have
nominal dimensions of 1.5 x 3.5 x 48. inches. Groove 8 is
5/16 inches wide by 3/4 inches deep. A filler strip 10 is
placed into the mouth 11 of groove 8 to form hole or bore
7. In the example shown filler strip 10 is 5/16 inches
wide by 3/8 inches deep. Hole or bore 7 is sized and
shaped to permit support rod 6 to pass through it. In the
embodiment shown support rod 6 is a threaded 5/16 inch
steel rod.
Other materials and dimensions for the support member are
possible so long as it provides the necessary support to
the frame assembly. The support member could be a thin
flat section inserted in saw curfs in the horizontal and
vertical members. Another alternative is the use of U-
shaped metal inserts or tubes that a.ct as a receiver for
a threaded rod or bolt used to attach the hinge.
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The lower horizontal member 3 is similarly provided with
a support rod 12.
Connection means are provided to connect the upper and
lower ends of the first and second vertical members to
opposite ends of the support members provided along the
length of the upper and lower horizontal members
In the embodiment shown, each of the first and second
vertical members 4,5 are provided w_Lth a plurality of
horizontal holes. The upper end 13 of vertical member 4
is provided with. at least one horizontal hole 14 sized
and located to permit support rod 6 to pass through. If a
second support rod is provided in upper horizontal member
2, a second horizontal hole can be located in the upper
end 13 of vertical member 4 to permit the second rod to
pass through. The upper end 15 of vertical member 5 is
similarly provided with at least one horizontal hole 16
sized and located to permit support rod 6 to pass
through. If a second support rod is provided in upper
horizontal member 2, a second horizontal hole can be
located in the upper end 15 of vertical member 5 to
permit the second rod to pass through.
The lower end 17 of vertical member 4 is provided with at
least one horizontal hole 18 sized and located to permit
support rod 12 to pass through. In the preferred
embodiment a plurality of horizontal holes 18 are
provided in the lower end 17 at six inch intervals to
permit the length of vertical membez: 4 to be adjusted to
accommodate different sizes of frame assembly.
Similarly the lower end 19 of vertical member 5 is
provided with at least one horizontal hole 20 sized and
located to permit support rod 12 to pass through. In the
preferred embodiment a plurality of horizontal holes 20
are provided in the lower end 19 at six inch intervals to
permit the length of vertical member 5 to be adjusted to
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accommodate different sizes of frame assembly. In the
embodiment shown the first and second vertical members
4,5 have nominal dimensions of 1.5 :~ 3.5 x 72 inches
before being cut to fit the opening.
In order to assemble the frame assembly 1 for making a
gate or door in accordance with the present invention,
support rods 6 and 12 are removed from the upper and
lower horizontal members 2,3. The upper and lower
horizontal members 2,3 are cut to the desired length
based on the width of the desired gate or door. Usually
the width of the opening is measured ("rough opening'°)
and the width of the finished frame assembly is
calculated at one inch narrower than the rough opening.
The length of the horizontal support. member, 2,3 and the
width of the two vertical support members 4,5 should
equal one inch narrower than the rough opening. For
example, where the vertical support members are made from
2x4 lumber having nominal dimensions of 1.5 x 3.5 inches,
the horizontal support members 2,3 are cut eight inches
narrower than the rough opening. Similarly the first and
second vertical support members 4, 5 are cut to the
desired length based on the height of the desired gate or
door. Typically this desired height is height of the
fence or door opening less clearance required at the
bottom to permit the gate or door to open and close. The
vertical support members, as noted, are preferably
predrilled with horizontal holes at six inch intervals to
accommodate various sizes of gates. In the preferred
embodiment the frame assembly is designed to build gates
or doors from three feet to six feet high, the normal
maximum required. Anything shorter than three feet
typically does not require the added strength provide by
the present invention. If a gate of a height that does
not meet the predrilled holes, for example a gate fifty
two inches high, the verticals can be cut using the holes
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drilled at forty eight inches and th.e fence boards can
hang down below the lower horizontal support member.
Support rod 6 is inserted through th.e hole 14 in the
upper end of vertical member 4, through the hole or bore
7 in upper horizontal member 2 and hole 16 in the upper
end of vertical member 5. Support rod 12 is inserted
through the hole 18 in the lower end. of vertical member
4, through the hole or bore 7 in lower horizontal member
3 and hole 20 in the lower end of vertical member 5.
Hinges 21, 22 are connected to one end 23, 24 of support
rods 6 and 12 respectively. The end 23 of support rod 6
extending through vertical member 4 passes through a
first hole 25 in hinge 21. A threaded insert nut 26 or
other suitable means can be used to fasten hinge 21 to
the outer side 27 of the upper end 13 of vertical member
4. If two support rods are used with the upper horizontal
member, the end of the second support rod would pass
through a second hole 28 on hinge 21 and be secured by a
threaded insert nut or other suitable means. Where only
one support rod 6 is utilized, as shown in Figure 3, a
lag screw 29 or other suitable fastener can be screwed
through the second hole 28 in hinge 21 into the outer
side 27 of the upper end 13 of vertical member 4 and into
the end of the upper horizontal member 2. A pilot hole 37
in the vertical member 4 can be predrilled.
The other end 31 of support rod 6 extending through
vertical member 5 is secured with a threaded end cap
fastener and tightened to snug the vertical members 4, 5
to the upper horizontal member 2. If two support rods are
used with the upper horizontal member, the end of the
second support rod would pass through a second hole in
vertical member 4 and be secured by a threaded end cap
fastener or other suitable means. Where only one support
rod 6 is utilized a lag screw or other suitable fastener
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can be screwed through the vertical member 4 into the end
of horizontal member 2.
The end 24 of support rod 12 extending through vertical
member 5 passes through a first hole 30 in hinge 22. A
threaded insert nut 40 or other suitable means can be
used to fasten hinge 22 to the outer side 32 of the lower
end 29 of vertical member 4. If two support rods are used
with the upper horizontal member, th.e end of the second
support rod would pass through a second hole 33 on hinge
22 and be secured by a threaded insert nut or other
suitable means. Where only one support rod 12 is
utilized, as shown in Figure 3 with respect to hinge 21,
a lag screw 36 or other suitable fastener can be screwed
through the second hole in hinge 22 into the outer side
32 of the lower end 19 of vertical member 4 and into the
end of the lower horizontal member 3. A pilot hole 38 can
be predrilled in vertical member 5 t.o accommodate the lag
'screw 36. Hinges 21, 22 in the embodiment illustrated are
standard 4x4 butt hinges.
The other end 34 of support rod 12 extending through
vertical member .5 is secured with a threaded end cap
fastener and tightened to snug the vertical members 4, 5
to the lower horizontal member 3. If two support rods are
used wi-th the lower horizontal member 3, the end of the
second support rod would pass through a second hole in
vertical member 5 and be secured by a threaded end cap or
other suitable means. Where only one support rod 12 is
utilized a lag screw or other suitable fastener can be
screwed through the vertical member 5 into the end of
lower horizontal member 3.
The end 23, 24 of support rods 6 and. 12 can be threaded
through the threaded insert nuts 26, 40 and when.the
hinges and frame are secured, the ends 23, 24 of support
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rods 6 and 12 projecting beyond the threaded insert nuts
can be cut off.
The hinges can be attached to a fixed structural member
such as a fence post or door_ jamb. The hinges can be
located to have the gate swing in or out and a left or
right opening gate or door.
Once the frame assembly is complete fence boards or
facing material can be fastened to one or both sides of
the frame assembly to complete the gate or door. Braces
35 can optionally be provide, if desired, in the inside
corners of the assembled frame assembly 1 to provide
additional rigidity.
The frame assembly is preferably provided as a complete
kit to build a gate frame or door frame including all
hardware and structural members. One kit can build any
normal sized gate or door. The present invention does not
depend on steel brackets to provide strength but rather
the support rods that run through the structural members
and used to tie the whole frame assembly together. The
present invention provides an extremely strong gate or
door with no exposed steel parts to rust or corrode other
than the hinges.
The design of the present invention is easier to use than
the prior art bracket systems and builds a superior gate
that will not twist or warp as is common due to the use
of fencing lumber which is green (not kiln dried). The
present invention can be used with horizontal and
vertical members of different sizes and materials
(including composite materials) without departing from
the scope of the present invention.
In addition to garden or fence gates the present
invention can be used to build odd sized doors for garden
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and storage sheds, cold cellars, basements, storage
lockers or other applications that require a custom size
of door.
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Although various preferred embodiments of the present
invention have been described herein in detail,. it will
be appreciated by those skilled in the art, that
variations may be made thereto without departing from the
spirit of the invention or the scope of the appended
claims.
