Note: Descriptions are shown in the official language in which they were submitted.
CA 02444374 2003-10-07
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 adapted 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 tow 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 gateldoor 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.
-1-
CA 02444374 2003-10-07
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 strengthen the inside corners of the gateldoor 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 dangerous. 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 gateldoor 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 gateldoor through the screws placed in
tension.
As the wood shrinks and the gateldoor is opened and closed, the fasteners
under tension tend to loosen and may eventually fail.
As the hinge fasteners loosen, the entire gateldoor assembly may sag relative
to
the hinge assemblies and the structural members, even if the gateldoor frame
maintains its rectangular shape. The use of braces at the corners of the
gateldoor 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 gravity on the fasteners used to attach the
hinge
assemblies to the proximal vertical support member.
i/arious 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
product would use upper and lower horizontal wooden support members, but
-2-
CA 02444374 2003-10-07
would not use vertical support members. Instead, the distal and proximal brace
members would form the structure of the vertical sides, with each size
corresponding to a given distance 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 gate 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 shown in
Canadian Industrial Design Registration No. 83040 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 to 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 trimmed to
accommodate weld filets of the brackets. As there is no direct connection
between the horizontal and vertical wooden support members that can over time
twist and warp independently of each other. While the finished gate is
extremely
rigid, light weight and flex resistant, exposed metal bracing and parts are
subject
to rust and are unattractive. Casts of manufacture, quality control at welded
connections and shipping costs are additional problems associated with this
product.
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 ar door that is easy and
inexpensive to use, and which allow significant flexibility in the final
design of the
gate or door assembly.
-3-
CA 02444374 2003-10-07
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 making a gate or door comprising an upper horizontal member, a
lower horizontal member, a first vertical member and a second vertical member,
one or more cylindrical 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 cylindrical member, second connection
means
to connect lower end of the first vertical member to one end of cylindrical
member, third connection means to connect an upper end of the second vertical
member to a second end of cylindrical member and fourth connection means to
connect a lower end of the second vertical member to a second end of
cylindrical
member.
There is also provided in accordance with the present invention a kit for
making a
frame assembly for making a gate or door to fit a rough opening comprising
upper and lower horizontal members sized to permit them to be cut to fit rough
opening width, two vertical members sized to permit them to be cut to fit
rough
opening height, one or more cylindrical members provided along the length of
each of the upper and lower horizontal members, connection means to connect
the ends of the vertical members to the ends of the cylindrical members
provided
along the length of the upper and lower horizontal members and two or more
hinges.
_q,_
CA 02444374 2003-10-07
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 inventi~n.
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 channel to accept a cylindrical member.
Figure 5 is an end plan view of the horizontal member of Figure 4 with the
cylindrical member in place ready to receive the support rod.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to Figures 1 to 5, generally one embodiment of a frame assembly
for making a gate or door in 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.
_5_
CA 02444374 2003-10-07
In the embodiment shown support rods 6, 7 are provided for connecting the
upper horizontal member 2 with first and second vertical members 4, 5. The
support rods preferably are steel rods with a cross section of at least 1/4
inch. In
order to connect the support rods 6, 7 to the upper horizontal member 2 so
that it
is strengthened against sagging, a longitudinal hole or channel 8 is provided
along the length of the upper horizontal member 2 for receiving a cylindrical
member 10. The hole or channel 8 can be drilled, grooved or provided in some
other manner. In the embodiment shown, channel 8 is formed by making a
groove a third of the thickness of the upper horizontal member 2 in the lower
section 9 of said 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 24 inches. In the case where a channel 8 is provided, and not a
hole,
means for securely positioning the cylindrical member 10 within said channel 8
are provided. Nole or channel 8 is sized and shaped to permit cylindrical
member 10 to pass through it. The combination support rod and cylindrical
member are defined herein as the support member.
Other materials and dimensions for the support member are possible so tong as
it provides the necessary support to the frame assembly. Alternatively, one or
more support members can be provided along the length of each of the upper
and lower horizontal members 2, 3 to further strengthen the resulting frame
and
prevent sagging.
The lower horizontal member 3 is similarly provided with a channel 8 and
support
rods 6, 7.
Connection means i.e. the support rods which serve a double purpose are
provided to connect the upper and lower ends of the first and second vertical
members 4, 5 to opposite ends of the cylindrical members provided slang the
length of the upper and lower horizontal members 2, 3.
-6-
CA 02444374 2003-10-07
The upper end 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 of vertical member 4 to permit the second rod
to
pass through. The upper end of vertical member 5 is similarly provided with at
least one horizontal hole sized and located to permit support rod 7 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 of vertical member 5 to
permit the second rod to pass through.
Similarly, the lower ends of vertical members 4, 5 are provided with at least
one
horizontal hole sized and located to permit support rods to pass through, in
the
preferred embodiment a plurality of horizontal holes can be provided in the
lower
ends at six inch intervals to permit the length of vertical members 4, 5 to be
adjusted to accommodate different sizes of frame assembly.
The present invention also provides for easy adjusting of the width of the
frame
assembly. By providing a cylindrical member 10 to a standard length of 24
inches, for instance, considering that a narrower frame is quite rare and not
that
useful, it can be seen that the horizontal members 2, 3 can be longer and yet
cut
to length without having to do the same with the cylindrical member 10. Once
the horizontal member is cut to one°s desired length, the cylindrical
member 10
can easily be reinserted in said horizontal member for secured positioning
therein before accepting the support rods.
In order to assemble the frame assembly 1 for making a gate or door in
accordance with the present invention, 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
CA 02444374 2003-10-07
opening. The length of the horizontal members 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 2 x 4
lumber having nominal dimensions of 1.5 x 3.5 inches, the horizontal members
2, 3 are cut eight inches narrower than the rough opening. Similarly, the
first and
second vertical 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 members 4, 5, 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 drilled at forty eight inches and the fence boards can hang down below
the
lower horizontal support member.
Discussing the upper section of frame 1, cylindrical member 10 is securely
positioned either in the channel or hole 8 of the horizontal member 2 and is
at
least partially threaded for reciprocally receiving a threaded support rod 6.
~n the hinged side of the frame 1, support rod 6 is inserted first through
hole 11
of hinge 12 then in hole 13 of upper end of vertical member 4. Support rod 6
is
now abutting cylindrical member 10 which is positioned into the horizontal
member 2 and ready to be screwed info cylindrical member 10. End of support
rod 6 is tapered and therefore will not affect the performance of the hinged
frame
when in use as it forms a snug fit.
_g_
CA 02444374 2003-10-07
At the other end of horizontal member 2, support rod 7 is first inserted
through
hole 14 of upper end of vertical member 5 then screwed into cylindrical member
thereby forming the upper section of the frame 1. It will be obvious to
someone skilled in the art that the bottom section of frame 1 can now be
5 constructed as discussed above.
It will be understood that by having the support rods 6, 7 of equal length
that
once screwed into the cylindrical member 10 said member 10 will be centered
relative to horizontal member 2 therefore providing equal support throughout
for
optimum performance. As well, the combination of support rods and cylindrical
10 member provides for flexibility and ease of use when it comes to adjusting
the
size of the frame.
The hinges can then 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 can optionally be provided, 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 and cylindrical
member combinations 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.
_g_
CA 02444374 2003-10-07
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 and storage sheds, cold cellars, basements, storage
lockers or other applications that require a custom size of door.
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.
-10-
