Note: Descriptions are shown in the official language in which they were submitted.
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BRICK MOLD ASSEMBLY, CONNECTOR FOR SAME AND KIT FOR
ASSEMBLY OF SAME
Field of the Invention
[0001] 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
[0002] 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.
[0003] 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.
[0004] 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. Patent 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.
[0005] U.S. Patent No. 7,472,519 to Caren 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
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metal reinforcement plate, and installed in position as a combination door
jamb
assembly.
[0006] 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.
[0007] 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
[0001] 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.
[0002] 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
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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.
100031 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.
100041 The connector may further comprise a longitudinal channel
configured
to receive a feature of the door jamb portion. The feature of the door jamb
portion
may be a longitudinal rib shaped to engage the longitudinal channel. The
longitudinal
rib may define a first longitudinal outer corner and a second longitudinal
outer corner.
The longitudinal rib may have a generally square-shaped profile. The connector
may
further comprise a bracket having a longitudinal flange, the longitudinal
flange being
spaced from the second longitudinal clip member to define the longitudinal
channel
therebetween.
100051 The angle defined by the first and second longitudinal clip
members
may be about 90 degrees.
100061 The connector may be extruded.
[0007] 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.
[0008] 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,
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the second longitudinal clip member being oriented relative to the first
longitudinal
clip member so as to define an angle therebetween.
Brief Description of the Drawings
100091 Embodiments will now be described more fully with reference to the
accompanying drawings in which:
[00010] Figure I is a perspective view of a door jamb assembly;
[00011] Figures 2a and 2b are exploded sectional and sectional views,
respectively, of a door jamb portion forming part of the door jamb assembly of
Figure
1, and taken along the indicated section line;
[00012] Figure 3 is an exploded, upper perspective view of a portion of
the
door jamb assembly of Figure 1;
[00013] Figure 4 is an exploded, lower perspective view of the portion of
the
door jamb assembly of Figure 3;
[00014] Figure 5 is a lower perspective view of the portion of the door
jamb
assembly of Figure 3;
[00015] Figure 6 is a perspective view of the door jamb assembly of Figure
1,
installed in a doorway opening;
[00016] Figure 7 is a sectional view of the door jamb portion of Figure
2b,
installed in a doorway opening and having a brick mold fitted thereto;
[00017] Figure 8 is a perspective view of another embodiment of a door
jamb
assembly, installed in a doorway opening;
[00018] Figures 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 Figure 8;
[00019] Figure 10 is a sectional view of the connector of Figure 9a;
[00020] Figure 11 is an enlarged fragmentary view of a portion of the door
jamb portion, the brick mold portion and the connector of Figure 9b,
identified by
reference numeral 11;
[00021] Figure 12 is a sectional view of the door jamb portion, the brick
mold
portion and the connector of Figure 9b, installed in the doorway opening;
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[00022] Figures 13a and 13b are exploded sectional and sectional views,
respectively, of a door jamb portion, a brick mold portion and a connector
forming
part of another embodiment of a door jamb assembly;
[00023] Figure 14 is a sectional view of the connector of Figure 13a; and
[00024] Figure 15 is an enlarged fragmentary view of a portion of the door
jamb portion, the brick mold portion and the connector of Figure 13b,
identified by
reference numeral 15.
Detailed Description of the Embodiments
[00025] Turning now to Figure 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.
[00026] The door jamb portion 22 may be better seen in Figures 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.
[00027] 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
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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 outer 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.
[000281 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.
[00029] 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.
[00030] The corner key 24 may be better seen in Figures 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
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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.
[00031] 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.
[00032] Figure 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.
[00033] Figure 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
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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.
[00034] 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 folining 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.
1000351 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.
[00036] The brick mold is not limited to that described above, and in
other
embodiments, the other brick molds may be used. For example, Figure 8 shows
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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 Figures 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 Figures 1 to 6.
[00037] 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 Figures 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.
[00038] 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
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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 8therebetween, as shown in Figure 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 comer 170
therebetween.
[00039] 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 shown in Figure 11.
[00040] 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.
[00041] 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
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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
Figures 1 to 6.
[00042] 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.
[00043] 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
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brick mold portions 150 cut to about forty-five (45) degree angles abut to
form miter
joints, as shown in Figure 8.
1000441 Figure 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.
[00045] Other configurations are possible. For example, Figures 13 to 15
show
a door jamb portion, a connector and a brick mold portion forming part of
another
embodiment of a door jamb assembly. Similar to door jamb assembly 120
described
above and with reference to Figures 8 to 12, the door jamb assembly of this
embodiment 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. The door
jamb
assembly of this embodiment is generally similar to the door jamb assembly 20
described above and with reference to Figures 1 to 6, and comprises three (3)
door
jamb portions 22 that are connected by two (2) corner keys 24.
1000461 In this embodiment, each door jamb portion 22 comprises an
extruded,
longitudinal door jamb member 230 and a longitudinal frame member 32. The
longitudinal frame member 32 has been described above and with reference to
Figures
1 to 6. Door jamb member 230 is generally similar to the door jamb member 30
described above and with reference to Figures 1 to 6, but further comprises a
longitudinal rib 253 extending the length thereof. The longitudinal rib 253
has a
generally square-shaped profile that defines a first longitudinal outer corner
249 and a
second longitudinal outer corner 255, as shown in Figure 15. The door jamb
member
230 also comprises a biased, longitudinal clip member 248 spaced from the
longitudinal outer corner 249 which together define an external, longitudinal
channel
251 therebetween.
[00047] The door jamb assembly of this embodiment comprises a plurality of
brick mold portions 150. The brick mold portion 150 has been described above
and
with reference to Figures 8 to 12.
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[00048] The brick mold assembly of this embodiment also comprises a
plurality of longitudinal connectors 260, each connector 260 being configured
for
connecting the brick mold portion 150 to the door jamb portion 22. In this
embodiment, the connector 260 is formed by extrusion, and is fabricated of
extruded
PVC. Each connector 260 comprises a biased, first longitudinal clip member 262
and
a biased, second longitudinal clip member 264 joined thereto. The longitudinal
axis
of the first longitudinal clip member 262 is parallel to the longitudinal axis
of the
second longitudinal clip member 264, and the second longitudinal clip member
264 is
oriented relative to the first longitudinal clip member 262 so as to define an
angle 61
therebetween, as shown in Figure 14. In this embodiment, the angle is about
ninety
(90) degrees. The connector 260 also comprises a longitudinal bracket 266
comprising a longitudinal flange 267 that is spaced from the second
longitudinal clip
member 264 so as to define a longitudinal inner channel 268 therebetween. As
shown
in Figure 14, the second longitudinal clip member 264 and the longitudinal
bracket
266 define a first longitudinal inner corner 269 therebetween, and the
longitudinal
flange 267 of the longitudinal bracket 266 defines a second longitudinal inner
corner
270 therein.
1000491 The second longitudinal clip member 264 of the connector 260 is
configured to matingly engage the channel 251 of the door jamb member 230, and
to
cooperate with the longitudinal clip member 248 for connecting the connector
260 to
the door jamb member 230. Reciprocally, the longitudinal rib 253 of the door
jamb
member 230 is configured to matingly engage the longitudinal inner channel 268
of
the connector 260. When the connector 260 and door jamb member 230 are
connected in this manner, the first and second longitudinal outer corners 249
and 255
abut the first and second longitudinal inner corners 269 and 270,
respectively, in a
nestled manner, as shown in Figure 15.
1000501 The first longitudinal clip member 262 of the connector 260 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. Reciprocally, the longitudinal clip member 156 of the brick mold portion
150 is
configured to abut an end of the longitudinal clip member 248, and to
cooperate with
the first longitudinal clip member 262 for connecting the brick mold portion
150 to
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the connector 260. When the brick mold portion 150 and connector 260 are
connected in this manner, the longitudinal rib 158 abuts an outer surface of
the
longitudinal clip member 248 of the door jamb member 230. As will be
understood,
when engaged in this manner, the longitudinal rib 258 covers the joint between
the
longitudinal clip member 248 and the longitudinal clip member 156, and urges
the
longitudinal clip member 248 toward the second longitudinal clip member 264
for
securing the connection between the door jamb member 230, the brick mold
portion
150 and the connector 260.
[00051] In use, the brick mold assembly of this embodiment 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 Figures 1 to 6.
[00052] Three (3) connectors 260 are provided, namely two (2) connectors
260
each having generally the same length as the door jamb portion 22 of the first
length,
and one (1) connector 260 having generally the same length as the header door
jamb
portion 22 of the second length. Each connector 260 is connected to its
corresponding
door jamb portion 22 by inserting the second longitudinal clip member 164 into
the
longitudinal channel 251 of the door jamb portion 22, such that the second
longitudinal clip member 264 cooperates with the longitudinal clip member 248,
and
such that the first and second longitudinal outer corners 249 and 255 of the
longitudinal rib 253 abut the first and second longitudinal inner corners 269
and 270,
respectively, of the longitudinal channel 268 in a nestled manner.
[00053] 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,
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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 260 by inserting the longitudinal clip member 156
between
the longitudinal clip member 248 and the connector 260, such that the
longitudinal
clip member 156 cooperates with the first longitudinal clip member 262. When
connected in this manner, the longitudinal rib 158 of the brick mold portion
150 abuts
an outer surface of the longitudinal clip member 248 of the door jamb portion
22.
[00054] 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.
1000551 Although in 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.
[00056] Although in embodiments 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.
[00057] It will be understood that the cross-sectional profile of the
brick mold
portion is not limited to that of the embodiments described above, and in
other
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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.
1000581 It will be understood that the cross-sectional profile of the
connector is
not limited to that of the embodiments 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.
1000591 Although in embodiments 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.
1000601 Although in embodiments described above, the connector is formed
by
extrusion, in other embodiments, the connector may alternatively be formed by
another suitable method.
1000611 Although in embodiments described above, the connector is
fabricated
of PVC, in other embodiments, the connector may alternatively be fabricated of
another suitable material.
1000621 Although in embodiments 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.
[00063] 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.
1000641 Although embodiments have been described above with reference to
the accompanying drawings, those of skill in the art will appreciate that
variations and
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modifications may be made without departing from the scope thereof as defined
by
the appended claims.
