Note: Descriptions are shown in the official language in which they were submitted.
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BACKGROUND
This invention pertains to prefabricated and otherwise assembled
aluminum door frames.
When installing a door frame into a door opening in a building, it is
desirable to have a strong, durable, rot and decay resistant, frame which is
either prefabricated or easily assembled on the construction site. Preferably,
the frame can be assembled at an off-site manufacturing location. In the
alternative, it is desirable to have frame elements which are easily assembled
l0 at the construction site.
In a typical construction project involving doors, door frames are
fabricated by a frame fabricator, and are thence shipped to a door assembler.
The door assembler receives the frames as fabricated, and assembles e.g.
the frames to respective door slabs. The slabs are also commonly purchased
separately from slab manufacturers. The door assembler adds the desired
glass inset, if any, to the door slab, assembles the door slab to a selected
door frame, and ships the thus assembled door, including frame and slab, to
the construction site for installation on the building.
In the known art, the basic frame of the door is commonly wood. The
2o door assembler can up-grade the quality and value of the frame, and thus
the
quality and value of the door assembly, to some extent, by installing e.g.
aluminum cladding to the left, right, and top frame wood substrate members,
thus to provide maintenance free, tough, and durable exterior surfaces to the
frame.
However, even where the jamb substrate is up-graded with aluminum
cladding, the properties of the wood substrate still have substantial affect
on
the use life, and ongoing properties of the door frame. Such wood substrate
can be subject to attack by rot, insects, and other invasive organisms which
cause the properties of the wood to deteriorate.
3 o For example, the bottom of the wood frame commonly is supported
directly by an underlying surface such as concrete, dirt, or the like. Where
the door frame is mounted as an exterior entrance to a building, the
outwardly-disposed side of the door frame is subjected the weather,
including rain, snow, changes in temperature, changes in humidity, and the
like. Such environmental conditions are detrimental to the long-term stability
of the wood substrate. As a first example, the wood readily absorbs and
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holds water. So any rain can be a source of moisture which is absorbed by
that portion of the wood which interfaces with the underlying ground or
concrete.
The moisture, as absorbed, can be wicked upwardly into a few inches
s of the wood. While present in the wood, the moisture supports bacteria or
other life forms which feed on the substances of the wood, causing loss of
strength in the wood. Over a period of time, and with repeated such
exposures to water, the wood eventually decays to a form commonly known
as rotten wood. Rotten wood does not have the structural qualities of wood
to which has not been so decayed, whereby the resulting door frame does not
provide the desired degree of support for the door, and the frame fails.
Wood is also subject to attack by insects, which also causes structural
deterioration of the wood, and thus deterioration of support for the door.
Certainly, the door frame can be replaced or repaired. However, it
15 would be preferable to avoid the deterioration which accompanies wood
structures at the doorway.
Thus, it is an object of the invention to provide door jambs and door
frames which are not subject to deleterious affects such as those which are
visited on wood by weather and/or insects.
2o It is another object to provide door jambs and door frames which are
made with materials all of which withstand weather and insects for
substantially longer periods of time than wood which is subjected to the
same conditions.
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SUMMARY
This invention provides a door frame which employs jambs or jamb
assemblies which are essentially devoid of wood and other materials which
are susceptible to being damaged by the affects of weather, in those areas
of the frame which will be subjected to substantial affects of weather.
Thus, the side jambs are fabricated of e.g. extruded aluminum moldings
which extend from e.g. the floor, concrete, or other underlying substrate, to
the header, which can be fabricated from a common-profile extruded
aluminum molding. A nosing can be provided with the aluminum molding,
either integral with the aluminum molding or snap assemblable to the
aluminum molding. The molding can include a nail fin kerf at or adjacent an
outer panel of the jamb, or on the nosing, whereby the door frame can
include a nailing fin. Such nailing fin can be a rigid e.g. aluminum molding
nailing fin, or can be a flexible e.g. polymeric nailing fin. An e.g.
polymeric
insert can be provided, assembled to the aluminum molding, which can
receive nails or screws, optionally without pre-drilling, much in the same
manner as wood receives nails or screws. Nails and/or screws can thus be
driven through the insert and into adjacent framing members of the building,
2 o thus to mount the door, door frame to the building.
In a first family of embodiments, the invention comprehends a door
jamb, having a length, and being adapted to be received into a rough opening
in a building, the door jamb comprising an aluminum molding, the aluminum
molding comprising (a) an aluminum jamb element having a length, and
comprising (i) a first side panel facing toward such rough opening, (ii) a
second side panel facing away from such rough opening, (iii) an outer panel
facing outwardly of such building, and (iv) an inner panel facing inwardly
into
such building; and (b) an aluminum nosing element, integral with the
3o aluminum jamb element and extending outwardly of such building from the
outer panel of the jamb element, along a substantial portion of the length of
the aluminum jamb element.
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In some embodiments, the nosing having a first side facing toward
such rough opening, the first side of the nosing being located away from
such rough opening relative to the first side panel of the jamb element.
In some embodiments, the door jamb further comprising at least one
of (1) a nailing fin kerf, (2) a casing-receiving recess extending along the
length of the door jamb, and (3) a cavity in the aluminum jamb element
adapted to receive a durable nail-receptive and/or screw-receptive insert
along at least a substantial portion of the length of the jamb element.
In some embodiments, the aluminum molding comprising a cavity
l0 adapted to receive an insert thereinto, and further comprising an insert in
the
cavity, the insert being defined by a durable, rot and decay resistant,
material.
In some embodiments, the insert extends along a substantial portion
of the length of the aluminum molding.
In some embodiments, the insert extends along substantially the full
length of the aluminum molding.
In some embodiments, the insert is made from a material which is
receptive to nails and/or screws, as fasteners fastening the insert to a
building.
2o In some embodiments, a portion of the insert abuts against an edge or
surface of the aluminum molding.
In some embodiments, the aluminum molding extends along
substantially the full length of the door jamb.
In some embodiments the nosing comprising a mounting fin kerf.
In some embodiments, the door jamb further comprising a mounting
fin in the mounting fin kerf.
In some embodiments, the aluminum molding defining a casing-
receiving recess extending along the length thereof, further comprising a
casing received in the recess.
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In some embodiments, the casing comprising one of (i) a brick mold
casing and (ii) a flat casing.
In some embodiments, the casing comprising a flat casing, an outer
surface of the casing, which faces outwardly away from such building, being
substantially co-planar with an outer surface of the nosing.
In some embodiments, the nosing defining a closed cross-section of
the nosing.
In some embodiments, the aluminum jamb element defining a closed
cross-section of the jamb element.
to In some embodiments, the aluminum jamb element comprising
longitudinally spaced mounting holes in the first and second side panels, the
mounting holes in the first and second side panels being registered with each
other so as to enable fasteners to pass through both of the first and second
side panels along straight line paths.
In some embodiments, the insert is made of hydrophobic material
which does not readily absorb a substantial quantity of water, and wherein
the hydrophobic material is selected from the group consisting of (i)
polymeric resin, and (ii) polymeric resin in combination with filler material
which is compatible with the polymeric resin, wherein the polymeric resin is
2o sufficiently continuous in the combination to prevent substantial
absorption
of water into the combination.
In some embodiments, the filler material is selected from the group
consisting of wood particles, other cellulosic material, fibrous material,
other
organic and/or inorganic fillers, and combinations thereof.
In some embodiments, the aluminum jamb element further having a
rear defining a closed cross-section of the jamb element, the insert
extending, along the length of the jamb element, rearwardly of the rear,
whereby the insert can be fastened to such building by driving fasteners
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through the insert at locations disposed rearwardly of the rear of the jamb
element.
In a second family of embodiments, the invention comprehends a door
jamb adapted to be received into a rough opening in a building, the door
jamb having a length, a rough opening side, and an opposing side, and
comprising: (a) an aluminum molding, the aluminum molding defining an
aluminum jamb element having a length, and comprising (i) a first side panel
facing toward such rough opening, (ii) a second side panel facing away from
such rough opening, (iii) an outer panel facing outwardly of such building,
(iv) a rear opposing the outer panel, and (v) a cavity extending along the
length of the aluminum jamb element, the cavity being adapted to receive an
insert thereinto; and (b) an insert in the cavity, the insert extending along
the
length of the aluminum jamb element, the insert having a front disposed
toward the outer panel and a back disposed relatively toward the rear, the
insert being defined by a durable, rot and decay resistant, material which is
receptive to nails and/or screws, as fasteners adapted to fasten the insert to
such building, the combination of the aluminum jamb element and the insert
providing straight-line paths from the rough opening side of the door jamb to
2o the opposing side of the door jamb, by which nails and/or screws can be
driven through the insert without having to create new holes in either the
first side panel or the second side panel of the aluminum jamb element, the
straight-line paths being located between the back of the insert and a mid-
point between the outer panel and the rear of the aluminum molding.
In some embodiments, the cavity extends along the length of the
aluminum jamb element, and wherein the cavity is defined by first and
second cavity side panels defined inwardly of the rough opening side of the
door jamb and the opposing side of the door jamb, and wherein the cavity is
further defined by a front cavity panel disposed between the outer panel and
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the rear of the aluminum jamb element, an elongate opening extending along
a substantial portion of the length of the aluminum jamb element and into
the cavity, between the first and second side panels at the rear of the
aluminum jamb element.
In some embodiments, the straight-line paths are defined between the
rear and the outer panel, and further comprising fastener holes spaced
longitudinally along the aluminum jamb element and through the first and
second side panels.
In some embodiments, the door jamb further comprising locking
1o structure on the aluminum jamb element, extending outwardly of such
building from the outer panel and, as a separate element, a nosing mounted
to the aluminum jamb element at the outer panel by the locking structure.
In some embodiments, the aluminum jamb element extends along a
substantial portion of the length of the door jamb.
In some embodiments, the aluminum jamb element extends along
substantially all of the length of the door jamb.
In some embodiments, the door jamb further comprising a nosing
extending outwardly from the outer panel and away from such building.
In some embodiments, the nosing and the jamb element being defined
2 o in a common unitary body.
In some embodiments, the nosing comprising a mounting fin
receptacle.
In some embodiments, the door jamb further comprising a mounting
fin in the mounting fin receptacle.
In a third family of embodiments, the invention comprehends a door
frame adapted to be mounted in a rough opening in a building, the door
frame comprising first and second side jamb assemblies, and a header jamb
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assembly extending between the first and second side jamb assemblies, at
least one side jamb assembly having an upper member and a lower member,
the upper member having a length, and defining at least one cavity extending
along the length thereof, the lower member defining an insert portion
received into the cavity and an extension portion extending downwardly
from the lower edge of the upper member a distance sufficient to
substantially avoid travel of liquid water, by surface tension, from a lower
edge of the lower member to a lower edge of the upper member, the
extension portion being defined by a durable rot and decay resistant material.
In a fourth family of embodiments, the invention comprehends a door
frame adapted to be mounted in a rough opening in a building, the door
frame comprising: (a) first and second side jamb assemblies, at least one of
the side jamb assemblies comprising an aluminum jamb element having a
length, and comprising (i) a first side panel facing toward such rough
opening, (ii) a second side panel facing away from such rough opening, (iii)
an outer panel facing outwardly of such building, and (iv) an inner panel
facing inwardly into such building at or proximate a rear of the aluminum
jamb element, the aluminum jamb element extending substantially the
2 o entirety of the length of the jamb assembly such that the at least one
side
jamb assembly is supported, by the aluminum extrusion, from an underlying
support, within a distance of such underlying support to enable travel of
liquid water, by surface tension, from a lower edge of the side jamb
assembly to the aluminum jamb element; and (b) a header extending
between the first and second side jamb assemblies.
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BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 shows a pictorial view of a first embodiment of door frames
of the invention, with parts cut away, as a garage door, with the garage
door partially lifted.
FIGURE 2 shows a cross-section of a first embodiment of door jambs,
including integral nosing structure, used in door frames of the invention.
FIGURE 3 shows a cross-section of a brick mold casing which can be
mounted to the jamb of FIGURE 2.
1o FIGURE 4 shows a cross-section of an assembly of the jamb of
FIGURE 2 and the brick mold casing of FIGURE 3.
FIGURE 5 shows a cross-section of a flat add-on casing which can be
mounted to the jamb of FIGURE 2.
FIGURE 6 shows a cross-section of an assembly of the casing of
FIGURE 5, the jamb of FIGURE 2, including a durable mounting member
insert received in an open-edged cavity of the jamb.
FIGURE 7 shows an enlarged cross-section of the jamb assembly of
FIGURE 1, and is taken at 7-7 of FIGURE 1 .
FIGURE 8 shows an end view of an "L-shaped" spring clip which can
2 o be used at mitered corners of jamb elements used in door frames of the
invention.
FIGURE 9 shows a bottom view of the spring clip of FIGURE 8.
FIGURE 10 shows an edge view of a corner gusset which is employed
in the jamb elements at right-angle corners of a door frame of the invention.
FIGURE 11 shows an enlarged front elevation view of an upper corner
of a garage door frame of the invention, with parts cut away, incorporating
the corner gusset of FIGURE 10, and is taken at dashed circle 11 in FIGURE
1.
FIGURE 12 shows a rear view of the upper corner of the door frame of
3 o FIGURE 1 1, as seen from inside the building.
FIGURE 13 shows an edge view of a corner gusset which is employed
in jamb elements at gusseted corners of a door frame of the invention.
FIGURE 14 shows an enlarged front elevation view of an upper corner
as in F1GURE 1 1 and wherein the corner structure includes use of an angled
3 5 gusset.
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FIGURE 15 shows a cross-section of a second embodiment of door
jamb assemblies of the invention, showing a second embodiment of the
jamb, including a durable, non-wood mounting member insert received in a
cavity of the jamb.
FIGURE 16 shows a cross-section of a third embodiment of door jamb
assemblies of the invention, showing a third embodiment of the jamb,
including a durable non-wood mounting member insert received in a cavity of
the jamb.
FIGURE 17 shows a cross-section of a fourth embodiment of door
to jamb assemblies of the invention, showing a fourth embodiment of the jamb,
including a durable non-wood mounting member insert received in a cavity of
the jamb.
FIGURE 18 shows a cross-section of a further embodiment of door
jambs of the invention, wherein the durable, member-holding cavity has been
deleted; and wherein registered mounting holes have been added along the
length of the jamb, to opposing faces of the jamb.
The invention is not limited in its application to the details of
construction or the arrangement of the components set forth in the following
2 o description or illustrated in the drawings. The invention is capable of
other
embodiments or of being practiced or carried out in other various ways.
Also, it is to be understood that the terminology and phraseology employed
herein is for purpose of description and illustration and should not be
regarded as limiting. Like reference numerals are used to indicate like
components.
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DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
Turning now to the drawings, FIGURE 1 shows a garage door 10
mounted in a rough opening 12 in a building 14. As illustrated, the garage
door is partially open, such that only two of the commonly-used four garage
door panels 16 are visible.
FIGURE 1 shows, in general, a door frame 18, which includes left 20A
and right 20B side jamb assemblies generally designated 20, and a header
assembly 22 extending across the top of the rough opening and connected
to to the two side jamb assemblies. The side jamb assemblies and the header
assembly have generally common cross-sections, whereby the description of
one of the side jamb assemblies is effective to describe the header and the
other side jamb assembly. The rough opening, and correspondingly the
finished opening, is sized, adapted, and configured to cooperate with a door
to be used in conjunction with the frame. Thus, when the frame is used in
entry door applications, the distance between the side jamb assemblies has a
magnitude of at least about 2 feet 8 inches, and others. Alternatively, when
the frame is used in garage door applications, the distance between the side
jamb assemblies has a magnitude of at least about 3 feet, at least about 4
feet, at least about 7 feet, at least about 10 feet, and others.
FIGURE 2 shows an aluminum extrusion/molding in the form of a jamb
element, e.g. jamb 24, having a nosing element illustrated as integral nosing
26 whereby the jamb element and the nosing together, at least partially,
define a generally common unitary body. As used herein, the terms
extrusion, molding, extruded, and molded, refer to numerous forming
methodologies and end-production, which include, but are not limited to,
extrusions, castings, moldings, forgings, stampings, and/or others.
Jamb 24 further includes a cavity 28 adapted to receive an insert 30.
A nailing fin 32 is shown mounted in a nailing fin receptacle, namely fin kerf
34, in the nosing. Jamb 24 is generally defined by left 36A and right 36B
side panels, outer panel 38, and inner panel 40. In the assembled, installed,
jamb 24, the left side panel 36A faces into the doorway opening and right
side 36B faces the building framing members which define the rough
opening. Outer panel 38 faces outwardly of the building and inner panel 40
faces inwardly toward the inside of the building.
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Nosing 26 is defined by outer wall 42, inner wall 44, and sides 46,
48. In the embodiment of FIGURE 2, the inner wall of the nosing and the
outer panel of the jamb are each defined in part by a common strip of metal.
Side 46 faces into the doorway opening and is located away from the rough
opening relative to jamb element left side panel 36A.
Cavity 28 defines an elongate opening 50 open to the rear of the
extrusion/molding and extending along a substantial portion of the length of
the jamb, optionally along substantially the full length of the jamb,
optionally
along the entirety of the length of the jamb. Cavity 28 is in general defined
1o by left and right side walls 52, which are extensions of side panels 36A
and
36B, by front wall 54 which corresponds to inner panel 40 of the jamb, as
well as by opening 50. Thus, left and right side walls 52 at least partially
define a rearmost portion, e.g. rear of the aluminum extrusion/molding jamb
element, at or adjacent, for example their terminal ends which are distal the
remaining components of jamb 24.
Protuberances 56, project into the cavity from side walls 52.
Protuberances 56 are designed with abutting surfaces which face toward
nosing 26 and which are designed to interface with corresponding
rearwardly-facing surfaces of insert 30, which can be parts of channels,
2o grooves, chamfers, bevels, or other inward projections and/or other
structure, formed into or extending from (as will be explained in greater
detail elsewhere herein), insert 30 which mechanically corresponds to
protuberances 56 thereby to impede withdrawal of the insert from the cavity
toward the rear of the jamb, namely toward the interior of the building.
An elongate recess 58, e.g. a casing-receiving recess, extends along
the length of the nosing, proximate the outer surface of the nosing, and is
adapted to receive thereinto, and hold, an elongate casing such as a brick
mold 60 or a generally flat casing, e.g. extended-width casing 62. FIGURE 3
illustrates a brick mold casing 60. Casing 60 includes left and right side
3 o walls 64A, 64B and an outer wall 66. An elongate mounting stub 68
extends parallel to, and offset from, side wall 64A and extending away from
outer wall 66. Stub 68 is sized and configured to fit into, and to generally
fill, ~ recess 58, thereby to mount the casing to the nosing by friction
engagement between the nosing and the casing.
FIGURE 5 shows extended-width flat casing 62. Casing 62 includes
left and right side walls 70A, 70B, and an outer wall 72. Stub 74 is sized
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and configured to fit into, and to generally fill, recess 58, thereby to mount
casing 62 to the nosing by friction engagement between the nosing and the
casing. In the assemblage of casing 62 and jamb 24, the outer, flat, surface
of casing 62 is substantially co-planar with an outer surface of the nosing of
jamb assembly 20. As can be seen by comparing FIGURES 4 and 6, in
general, casing 60 or casing 62, but not both, may be mounted to a given
recess 58.
Referring now to FIGURES 1, 6, and 7, a given side jamb assembly 20
typically includes an extruded/molded aluminum jamb 24, and can include a
1o nosing 26 integral with the jamb or, as discussed hereinafter, attached to
the
jamb as a separate element. A casing 60, 62, or both, can be, as illustrated
in FIGURES 4, 6, and 6A, mounted to the jamb, either directly or through the
nosing. A nailing fin 32 can be mounted directly to the frame or frame
elements, including to the jamb, or to the nosing, or to the casing.
A durable, rot and decay resistant, and insect resistant, insert 30 can
be mounted in the jamb to serve as a stiffening member, and/or to serve as
an attachment structure, whereby the jamb assembly can be nailed or
screwed to one or more building framing members. Insert 30 has a jamb
facing portion "J FP" and a building facing portion "BFP". Jamb facing
2o portion "JFP" of insert 30 generally faces and communicates with jamb 24,
and building facing portion "BFP" of insert 30 generally faces "into" the
building (in the installed product). As exemplarily illustrated, a terminal
end
surface of jamb facing portion "J FP" interfaces with, abuts, and/or
otherwise communicates with, an edge or surface of the aluminum
extrusion/molding, e.g. cavity front wall 54 or other edges and/or surfaces of
jamb 24.
In the exemplary embodiment illustrated in FIGURES 6 and 7, at least
part of insert 30's jamb facing portion "J FP" has a width dimension which
is of lesser magnitude than the width dimension of the building facing
3 o portion "BFP". Preferably, the difference in the magnitudes of the jamb
facing portion "JFP" and building facing portion "BFP" widths corresponds
to the magnitude of the sum of the thickness dimensions of left and right
cavity sidewalls 52 which generally extend from side panels 36A, 36B,
respectively.
Thus, when insert 30 is housed in cavity 28, the outer surface of left
side panel 36A and the portion of the outer surface of the left side of insert
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30 which extends beyond the cavity side wall 52 generally collectively
define a generally planar surface e.g. with no substantial step-change in
surface profile height along at least a major portion of the collective
surface
thereof. Likewise, when insert 30 is housed in cavity 28, the outer surface
of right side panel 36B and the portion of the outer surface of the right side
of insert 30 which extends beyond the cavity side wall 52 generally
collectively define a generally planar surface e.g. with no substantial step-
change in surface profile height along at least a major portion of the
collective surface thereof.
to Also as exemplarily illustrated, the jamb facing portion "JFP " has at
least one interfacing structure which is adapted and configured to interface
with the protuberances of the cavity sidewalls 52. In the illustrated
embodiments, each of the interfacing structures is a "V-typ e" groove, which
has first and second terminally intersecting groove walls. One of the groove
walls extends generally perpendicularly into insert 30 and the other of the
groove walls extends angularly into insert 30. Other interfacing structures
are contemplated and are well within the scope of the invention, including,
but not limited to, channels, grooves, chamfers, bevels, or other inward
projections and/or other structure, formed into or extending from, insert 30.
Insert 30 can be disposed in a location generally toward the interior of
the building such as inwardly of front wall 54 of the cavity, and generally to
the rear of jamb 24. In such instance, and as illustrated in FIGURE 7, nails
76 or screws (not shown) can be driven through the insert much like nails
and screws are commonly driven through wood structural members, since
the insert extends along the length of the jamb element, and e.g. rearwardly
of a rear portion of the jamb element and since insert 30 can accept
fasteners and/or hardware therethrough.
Depending on the material composition of insert 30, and the structure
of the respective nails or screws, mounting holes 78 may or may not be pre
3 0 drilled or punched, as round or slotted holes in insert 30. Where a softer
material such as polyethylene, nylon or the like is used, pre-drilled holes
are
generally not required. Where a harder material such as polycarbonate or an
acrylic is used in fabricating insert, pre-drilled holes may be desirable.
Regarding materials from which insert 30 can be fabricated, there can
be mentioned for example and without limitation, various of the
polyethylenes, polyamides such as nylon, vinyl, acrylic, polycarbonate, or the
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like. Typically, a generally hydrophobic thermoplastic material is selected as
the base material for use in insert 30. As additional compositional
ingredients, there can be mentioned a wide array of additives and fillers
which can be used to enhance the properties of the resultant insert, and/or
to reduce the cost of the insert. In general, any additive such as a filler
must
be compatible with the polymeric resin, and the proportion of the ingredients
must be such that the polymeric resin is sufficiently continuous in the
combination to prevent substantial absorption of water into the finished
combination. Suitable fillers include, but are not limited to, wood particles,
l0 other cellulosic material, fibrous material, other organic and/or inorganic
fillers, combinations thereof, and others.
Thus, in general, the polymeric resin is a continuous phase in the
combination, and any hygroscopic filler or other inclusions are discontinuous
inclusions in the continuous resin phase. A modest level of foaming, namely
voids, is acceptable in insert 30 so long as the hydrophobic properties of the
insert are preserved.
In some embodiments, the insert, or a portion of the insert, or a
second insert, can be disposed frontwardly of the inner panel 40 of the
jamb, which corresponds to the front wall 54 of the cavity, thus between
2 o inner panel 40 and outer panel 38. Thus, the rib which extends between the
left 36A and right 36B side panels of the jamb serves both as the inner wall
of the jamb 24 and as the front wall of cavity 28. Where the insert is
disposed frontwardly of the inner panel of the jamb, the insert is desirably,
but not necessarily, disposed proximate the inner panel. In such instance,
and contrary to the illustration of FIGURE 7, insert 30 is located inside the
tubular cavity 80 defined between side panels 36A, 36B, outer panel 38,
and inner panel 40.
Mounting holes 78, shown in dashed outline in FIGURE 7, are pre
drilled through aluminum side panels 36A, 36B of jamb 24 as well as
3o through insert 30 (illustrated in solid outline), all longitudinally spaced
from,
and in registration with, each other, whereupon nails or screws can be driven
through insert 30, alternatively through side panels 36A, 36B, generally
along a straight line path, and into the respective framing members 82 of the
building which define the rough opening in the building.
In the embodiments illustrated in FIGURES 1, 2, 6, and 7, insert 30
generally fills cavity 28 between left and right walls 52, and extends to the
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rear of the cavity, to the rear of the jamb, by a sufficient distance to
provide
a substantial nailing surface 84 for driving nails or screws through and into
framing members 82 of the building well ahead (outwardly of the building) of
the inward edges of the framing members.
s FIGURE 5 shows a cross-section of extended-width casing 62 which,
as discussed above, can be received in the elongate recess in nosing 26. A
spring clip 86, illustrated in more detail in FIGURES 8 and 9, is shown
assembled to the casing in FIGURE 5. The assembly of the extended-width
casing to the nosing is illustrated in FIGURE 6. Assembly of spring clip 86 to
to the casing is illustrated in FIGURE 5. As illustrated there, outer side
wall
70B of casing 62 includes an elongate mounting fork 88 having a pair of
elongate tines 90 extending along the length of the casing. Each tine has an
elongate channel 92 extending along the length of the casing, along the
length of the tine, and spaced from a distal edge of the respective tine.
15 Referring still to FIGURES 5, 8, and 9, spring clip 86 generally defines
an "L-shaped" channel 94 having first and second legs 96 which meet at a
corner 98. FIGURE 8 shows a view from the end of one of the legs of the
spring clip. FIGURE 9 shows a view from the open-channel side of the
spring clip. Referring specifically to FIGURE 9, in general, channel 94
2 o extends at a constant cross-section from a first end 100 at one of the
legs
through corner 98 to a second end 102 at the other of the legs. As viewed
in FIGURE 8, channel 94 has a top wall 104, and two downwardly-
depending side walls 106 which terminate at distal ends 108. Each side
wall 106 has an inwardly-projecting ridge 1 10 which constricts the width of
25 the channel proximate the distal ends of the legs, namely near the open
bottom of the channel.
Referring, now to FIGURE 5, the ridges 110 in the side walls of the
spring clip are resiliently received in channels 92 of tines 90 whereby the
ridges and channels cooperate in holding the spring clip mounted on the
3o casing. FIGURE 12 shows the corner structure of the frame as viewed from
inside the building, looking outwardly of the building through the doorway
which is being framed by frame 18. FIGURE 12 shows that the spring clip
bridges the corner 111 of frame 18, which is defined between one of the
side jamb assemblies and the header jamb assembly.
35 In the assemblage of jamb assembly 20 and header assembly 22, first
and second miter joints are defined at the intersection of jamb assembly 20A
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and header assembly 22, and at the intersection of jamb assembly 20B and
header assembly 22. The mitered portion of jamb assembly 20 and the
mitered portion of header assembly 22 interface with each other and are
snugly held in such interfacing relationship by ones of spring clips 86.
Accordingly, spring clips 86 control movement of respective ends of header
jamb assembly 22 and the corresponding side jamb assembly 20 with
respect to each other, in a direction toward and/or away from such building,
and/or in a direction generally toward and/or away from the rough opening
which extends through the building.
Stated another way, the first and second legs of the spring clip
resiliently grip the outwardly disposed edges of the respective mitered ends
of the extended casing 62 at the corner defined by a side jamb assembly and
the header jamb assembly. Since ridges 1 10 are at a common distance from
top wall 104 on both legs, since channels 92 are located a common distance
from outer wall 72 of the casing, the ridges gripping the tines at channels 92
positively seat the respective casings on the header jamb and the side jamb
relative to each other such that the outside surfaces of the respective
casings are located in a common plane which extends generally parallel to
the outer surface of the building. Stated another way, the spring clip holds
the two mitered ends of the casing flush with each other, at a common
distance from the outer surface of the building.
Referring to FIGURE 6, polymeric, flexible, nailing fin 32 is shown in
nailing fin kerf 34 in the nosing, under the extended-width casing.
Accordingly, the nailing fin is commonly nailed, or otherwise mounted, to the
building framing before the extended casing is installed in recess 58 of the
nosing.
As indicated earlier, FIGURE 7 illustrates the jamb assembly of FIGURE
6 mounted to a double stud structure, exemplarily illustrated as the two
adjacent framing members 82, of the building frame using nails 76, either
3o through insert 30 as shown, or as indicated in dashed outline, through pre
drilled holes in side panels 36A, 36B of the jamb. FIGURE 7 further
illustrates weather stripping 1 12 mounted to the insert by e.g. nails 1 14,
and
adapted to interface with a garage door mounted in the frame opening. Nails
114 can be inserted through pre-punched or pre-drilled, round or slotted
holes, or can be driven through material which has no pre-formed holes.
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FIGURE 10 shows a side elevation view of a corner gusset 116A
which is used to join a side jamb assembly 20 to header assembly 22. A
such corner gusset is used at each of the corners 111 (FIGURES 11 and 12)
at the tops of the respective side jamb assemblies, namely at, for example
the miter joints. Gusset 116A includes a pair of legs extending from a
common corner. Each leg is defined by an inner panel 118A and an outer
panel 120A, and one or more bridging panels 122A which extend as
reinforcement members between the inner and outer panels. Each of the
inner and outer panels, and the bridging panels, are shown in edge view in
to FIGURE 10. The widths of panels 118A, 120A, 122A extend generally from
the outer panel of the extruded/molded aluminum jamb 24 to the inner panel
of jamb 24, thus to generally fill the cross-sectional dimensions of tubular
cavity 80, at the respective ends of the jamb assemblies.
As illustrated in FIGURES 11 and 12, the respective two legs of
gusset 1 16A are received in the respective tubular cavities of the side jamb
and the header jamb at each of the respective corners 1 1 1 of the frame, and
generally fill the tubular cavities along much of the lengths of the legs.
Chamfers at the ends of the respective legs assist in aligning the legs with
the tubular cavities as the gussets are installed in the respective cavities.
Gussets 116A thus provide location, guidance, and rigidity of the frame, at
corners 111 .
FIGURE 13 shows a side elevation view of a second exemplary corner
gusset, e.g. corner gusset 1168 which is used to join a side jamb assembly
20 to header assembly 22. A such corner gusset is used at each of the
corners 111 at the tops of the respective side jamb assemblies and in
conjunction with an angled cross-member 126 (FIGURE 1 1 ), namely at, for
example the miter joints. Cross-member 126 has an extruded profile, the
same as that of jamb 24.
Gusset 1 16B includes a pair of legs extending from a common corner.
3 o Each leg is defined by an inner panel 1 18B and an outer panel 120B, and
one
or more bridging panels 122B which extend as reinforcement members
between the inner and outer panels.
Each of the inner and outer panels, and the bridging panels, are shown
in edge view in FIGURE 13 which shows a side elevation view of corner
gussets 1 16B which are used to join a side jamb to a header jamb, using a
gusseted corner of the door frame. The widths of panels 1 18B, 120B, 1228
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extend generally from the outer panel of the extruded/molded aluminum jamb
24 to the inner panel of jamb 24, thus to generally fill the cross-sectional
dimensions of tubular cavity 80, at the respective ends of the jamb
assemblies. As illustrated in FIGURE 13, the respective two legs of gusset
1168 are received in the respective tubular cavities of the side jamb and the
gusset 126 and/or the side jamb and header jamb at each of the respective
corners of the frame, and generally fill the tubular cavities along much of
the
lengths of the legs. Chamfers at the ends of the respective legs assist in
aligning the legs with the tubular cavities as the gussets are installed in
the
1o respective cavities. Gussets 1168 thus provide location, guidance, and
rigidity of the frame, at the frame corners similar to gussets 1 16A.
Also as illustrated in FIGURE 13, respective ones of inner panels 1 188
define an angle of about 135 degrees therebetween. Corner gusset 1168
thus forms an e.g. 45 degree angle, relative to what would be the projected
90 degree angle (FIGURE 141, at the respective corner and is fabricated
using inner and outer panels as in gusset 116A, as well as bridging panels.
A pair of gussets shown in the corner assembly of FIGURE 14 turns the full
90 degree corner, aided by gusset 126 which is shown in part.
FIGURE 15 shows a second embodiment of extruded/molded
2o aluminum jambs 224 of the invention, including a narrow-profile aluminum
nosing 226 snap locked to the outer panel of the aluminum jamb
extrusion/molding. Mounting structure and/or locking structure, namely legs
228A, 2288, extends outwardly from the outer panel of the jamb
extrusion/molding, and snap locks 230A, 2308 on legs 228A, 2288 and
engages corresponding snap locks 232A, 2328 on respective legs 234A,
2348 of the nosing. Jamb 224 extends from outer panel 238 through side
walls 236A, 2368 to inner panel 240. Cavity 231 extends from inner panel
240 along cavity side walls 252 to the distal ends of the cavity. Insert 233
is received in cavity 231 much like insert 30 is received in cavity 50.
3o FIGURE 16 shows a third embodiment of extruded/molded aluminum
jambs of the invention, also including a narrow-profile nosing snap locked to
the outer panel of the aluminum jamb extrusion/molding. Namely, the
embodiment of FIGURE 16 shows yet another embodiment of
extruded/molded aluminum jambs of the invention, again including a separate
nosing. A durable plastic insert is mounted in a rearwardly open, rearwardly
facing cavity in each of the jambs of FIGURES 15 and 16.
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As illustrated in FIGURE 16, in some exemplary embodiments,
mounting structure and/or locking structure, namely legs 328A, 3288,
extends outwardly from the outer panel of the jamb extrusion/molding, and
snap locks 330A, 3308 on legs 328A, 3288 and engages corresponding
snap locks 332A, 3328 on respective legs 334A, 3348 of the nosing. Jamb
224 extends from outer panel 238 through side walls 236A, 2368 to inner
panel 240. Cavity 231 extends from inner panel 240 along cavity side walls
252 to the distal ends of the cavity. Insert 233 is received in cavity 231
much like insert 30 is received in cavity 50.
1o As in the embodiment of FIGURE 15, the exemplary outer panel of the
jamb illustrated in FIGURE 16 has first and second legs extending toward the
outer wall of the nosing, and the nosing has a pair of legs which extend
toward, to the outer panel of the jamb. In this embodiment, one of the
nosing legs also overlies the otherwise-exposed portion of the outer panel of
the jamb. One leg on the outer panel of the jamb is quite short and ends at
the nailing fin kerf. The other leg on the jamb is substantially longer. Both
legs have snap lock structures at the ends of the legs. One of the legs on
the nosing has a snap lock for engaging a leg of the jamb at the end of the
nosing leg. The other leg of the nosing has a snap lock structure mid-way of
2o the height of the leg between the outer wall of the nosing and the outer
panel of the jamb.
FIGURE 17 shows another embodiment of extruded/molded aluminum
jambs of the invention, including an aluminum nosing snap locked to the
outer panel of the aluminum jamb extrusion/molding as in FIGURES 15 and
16. The nosing includes a reverse-brick-mold casing wing. A rigid aluminum
nailing fin is snap locked to the extruded/molded aluminum jamb.
As illustrated in FIGURE 17, in some exemplary embodiments,
mounting structure and/or locking structure, namely legs 428A, 4288
extends outwardly from the outer panel of the jamb extrusion/molding, and
3o snap locks 430A, 4308 on legs 428A, 4288 and engages corresponding
snap locks 432A, 4328 on respective legs 434A, 4348 of the nosing. Jamb
224 extends from outer panel 238 through side walls 236A, 2368 to inner
panel 240. Cavity 231 extends from inner panel 240 along cavity side walls
252 to the distal ends of the cavity. Again, insert 233 is received in cavity
231 much like insert 30 is received in cavity 50.
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Thus, FIGURE 17 shows still another embodiment of extruded/molded
aluminum jambs of the invention, yet again including a separate nosing. In
this instance, both legs extending from the jamb are quite short, such that
the legs extend only far enough to form snap locks, such that the snap locks
form substantially the entireties of the legs. Correspondingly, the nosing
legs extend substantially the full height of the nosing between the nosing
outer wall and the outer panel of the jamb. The nosing incorporates a casing
design extending outwardly from the front wall of the nosing in a generally
reverse-design brick mold casing panel. A rigid e.g. aluminum nailing fin is
mounted to the jamb beyond the side wall of the jamb and beyond the
nosing. An insert is received in the cavity as in FIGURES 15 and 16.
In general, the embodiments of FIGURES 15, 16, and 17 have
common design with each other, as well as with the embodiments of
FIGURES 4 and 6, when considered from, and excluding, the outer panel of
the jamb to the back edge of the insert. Accordingly, the embodiments of
FIGURES 15, 16, and 17 differ from each other, and from the embodiments
of FIGURES 4 and 6, largely at the outer panel, at the nosing, at the nailing
fin, and at the casing. The various alternative structures offered with
respect to FIGURES 4 and 6 inwardly of the outer panel can as well be
2o applied to the embodiments of FIGURES 15, 16, and 17.
FIGURE 18 shows yet another embodiment which omits insert 30,
233. In such embodiment, the width of jamb side panels 36 is relatively
lengthened between outer panel 38 and inner panel 40 such that inner panel
40 is moved to the location which had been occupied by the back edge of
the insert. As desired, an additional reinforcing web, shown in dashed
outline in FIGURE 18 can be employed to provide additional side-to-side
support in tubular cavity 80. Mounting holes 78 are pre-drilled, pre-formed in
side panels 36A, 36B so as to facilitate nailing or screwing the jamb to the
framing members of the building. As seen in FIGURE 18, in this
3o embodiment, the nosing is formed in common with the jamb such that the
nosing and the jamb are integral with each other.
Aluminum extrusion/moldings, including but not limited to jamb 24, nosing
26, brick mold casing 60, extended width casing 62, and other
extrusion/moldings, are preferably extrusions wherein the respective profile
3 5 elements of the extrusions have profile thicknesses "T" of about 0.04 inch
to
about 0.10 inch, with preferred thicknesses of about 0.06 inch. A highly
preferred
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thickness is about 0.062 inch. Those skilled in the art are well aware of
suitable
aluminum extrusion processes, e.g. mechanical and/or thermal treatments, and
corresponding hardware, e.g. presses, dies, and/or others, to achieve the
desired
temper, shape, and/or other properties of the extruded aluminum product.
Insert 30, 233 is sized and configured for a tight fit in cavity 50, 231 .
Insert 30, 233 is installed in the cavity by placing the insert alongside the
cavity, in the same orientation as shown in e.g. FIGURES 6 and 15, and is
then pushed laterally toward front wall 54. Generally, pressure is applied at
a first end of the insert pushing the insert into the cavity at a given
location
to along the length of the insert, namely at the end. With the insert
installed at
the first end, the force is progressively moved along the length of the
insert,
progressively forcing the insert into the cavity as the lateral force moves
along the length of the cavity. Thus a wheel can be used to apply the force
at one end of the insert, whereupon the force can be maintained on the
wheel, and the insert and jamb moved progressively past the wheel while the
wheel continues to apply the lateral pressure, thus to progressively move the
insert into the cavity, along the length of the insert. Thus, in the
assemblage
of insert 30, 233 and jamb 24, insert 30, 233 is frictionally and/or
mechanically housed in cavity 50, 231.
2o In the alternative, insert 30, 233 can be slidingly inserted into cavity
50, 231, longitudinally along the length of the cavity. Insert 30, 233 and/or
cavity 50, 231 can be lubricated with e.g. wet or dry lubricant as necessary
or desired.
In some embodiments, side jamb assembly 20 includes a plurality of
jamb components in vertical alignment with each other, e.g. " stacked" on
top of each other. Namely, side jamb assembly 20 can include an upper
member and a lower member. The upper member has a length, and defines
at least one cavity which extends along its length. The lower member
defines an insert portion received into the cavity and an extension portion
3o which is made of a durable rot and decay resistant material. The extension
portion extends downwardly from the lower edge of the upper member a
distance sufficient to substantially avoid travel of liquid water, by surface
tension, from a lower edge of said lower member to a lower edge of said
upper member. Exemplary lengths of extension of the extension portion
include at least about two inches, at least about four inches, at least about
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six inches, at least about ten inches, at least about twenty inches, at least
about thirty inches, and others.
To install the door frame, the rough opening must first be "framed
into" the building/structure. This is not typically done by the door
installer,
rather is typically done by the carpenter, and/or other onsite worker,
building
the building/structure. Namely, the onsite worker installs appropriate header
and trimmer studs, such as framing members 82, sufficiently strong and
durable to support the span of the rough opening, and the door to be
installed therein.
Next, the onsite worker installs the door and/or corresponding door
frame. The onsite worker may install the frame as separate components in
sequence, e.g. jamb assemblies 20 (which may or may not include nosing
261, header assembly 22, brick mold casing 60 or extended width casing 62,
and/or others. In the alternative, the installer may pre-assemble the frame,
on site or at a remote location, and "tip" the assembly into the rough
opening and subsequently secure it to e.g. the framing members.
Non-metallic materials suitable for components of, and/or attachment
structures and accessories, including but not limited to, jamb 24, nosing 26,
nailing fin 32, brick mold casing 60, extended width casing 62, and other
2o extrusion/moldings, fins, and related components, are various polymeric
compounds. Such polymeric compounds, as for example and without
limitation, include various of the polyolefins, such as a variety of the
polyethylenes, e.g. high density polyethylene, or polypropylenes. There can
also be mentioned as examples such polymers as polyvinyl chloride and
chlorinated polyvinyl chloride copolymers, various of the polyamides,
polycarbonates, and others.
For any polymeric material employed in structures of the invention,
any conventional additive package can be included such as, for example and
without limitation, slip agents, anti-block agents, release agents, anti-
oxidants, fillers, and plasticizers, to control e.g. processing of the
polymeric
material as well as to stabilize and/or otherwise control the properties of
the
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finished processed product, also to control hardness, bending resistance, and
the like.
Common industry methods of forming such polymeric compounds will
suffice to form non-metallic components disclosed herein. Exemplary, but
not limiting, of such processes are the various commonly-known plastics
converting processes.
Those skilled in the art will now see that certain modifications can be
made to the apparatus and methods herein disclosed with respect to the
illustrated embodiments, without departing from the spirit of the instant
1o invention. And while the invention has been described above with respect to
the preferred embodiments, it will be understood that the invention is
adapted to numerous rearrangements, modifications, and alterations, and all
such arrangements, modifications, and alterations are intended to be within
the scope of the appended claims.
To the extent the following claims use means plus function language,
it is not meant to include there, or in the instant specification, anything
not
structurally equivalent to what is shown in the embodiments disclosed in the
specification.
