Note: Descriptions are shown in the official language in which they were submitted.
DOOR ASSEMBLY
This application claims priority to US Application Serial No. 15/911,256 filed
March 5, 2018.
Field of Technology
The present disclosure relates generally to entryways for a building and, more
lo particularly, to frame members and a door assembly for a residence.
Background
Frame components, such as, jambs and mullions, for exterior door systems are
exposed to environmental elements and extremes such as moisture, temperature,
and
sunlight, which can attack and break down the frame material. Protective
coatings such
as exterior grade paints are typically used not only to improve appearance but
also to
protect the underlying material, which is traditionally and typically wood.
These frame
components are also prone to moisture wicking up from their bottom ends. This
type of
moisture can lead to decay over time, which compromises the appearance and
structural
integrity of the frame. Alternates to a traditional wood frame include
aluminum cladded
wood frames, which can be expensive, vinyl cladded wood frames, which are not
very
resistant to impact damage, or all-plastic extruded frames, which are not very
rigid and
are also susceptible to deformation under heat.
While all-plastic frames are typically more resistant to environmental
degradation
and may decrease maintenance needs, conventional all-plastic frames often
include
reduced structural strength. Other frames have included stiffening components
of
laminated wood or metallic type extrusions in attempts to address structural
integrity
limitations, however, such stiffening components create other challenges, by
way of
example, interfering with hardware fasteners used to anchor frames and frame
components.
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a
Thus, there remains a need for a new and improved door assembly and frame
members that are decay resistant while, at the same time, have the appearance
and
strength of a traditional wood frame door assembly.
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Summary
The present disclosure is directed in one embodiment to a door assembly. The
door assembly includes at least one door panel and a door frame having a
plurality of
frame members including a header and at least a pair of side jambs. The frame
member
includes a core; and a two-piece top piece adjoining the core to form a
structural member
with the core and the top piece is a composite of cellulosic material and at
least one other
material. The door assembly may further include an adjacent panel. The
adjacent panel
may be, in one example, at least one side light panel. In other examples, the
panel may be
a passive panel.
The core may be formed of a non-metallic material and preferably, in one
embodiment, the core is a wood. Also, the core may further include a lower
portion
formed of a decay resistant material. In one embodiment, the lower portion
formed of a
decay resistant material is a cellulosic-plastic composite. The cellulosic
portion of the
cellulosic-plastic composite preferably is wood fiber. Also, the plastic
portion of the
cellulosic-plastic composite preferably is a themroplastic. In one embodiment,
the
thermoplastic is a polyethylene.
In one embodiment, a door assembly may be considered a door frame member
including at least one door panel. The door frame may have a plurality of
frame members
including a header and at least a pair of side jambs. The one frame member may
include a
core and at least one top piece. The top piece may include one or more hollow
cavities.
The top piece may adjoin to the core to form a structural member with the
core. The door
frame assembly may also include a trim profile.
The top piece may be a two-piece top piece and includes a stop portion and a
rabbet portion. In one embodiment, the stop portion and the rabbet portion are
generally
L-shaped and the proximate end of the stop portion overlaps the corresponding
proximate
end of the rabbet portion. The overlapping proximate ends of the rabbet
portion and the
stop portion may form a weather strip slot and may further include a weather
strip
adapted to be received by the weather strip slot. In addition, the stop
portion and the
rabbet portion may be generally L-shaped and the distal ends of the stop
portion and the
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4
rabbet portion may each or all overlap the sides of the underlying core. The
top piece
may include hollow cavities.
In other embodiments, the top piece may be a linear piece, the rabbet portion
may
be a linear piece, and/or may take on other configurations.
In one embodiment, the two-piece top piece is formed of a decay resistant
material. The two-piece top piece may be a cellulosic-plastic composite.
Preferably, the
cellulosic portion of said cellulosic-plastic composite is wood fiber. The
plastic portion
of the cellulosic-plastic composite preferably is a thermoplastic. In one
embodiment, the
plastic is a polyvinyl chloride.
The amount of cellulosic material in the cellulosic-plastic composite may be
between about 20 wt. % and about 70 wt. % of the weight of the cellulosic-
plastic
composite. Preferably, in one embodiment, the amount of cellulosic material in
the
cellulosic-plastic composite is between about 25 wt. % and about 45 wt. % of
the weight
of the cellulosic-plastic composite. In another embodiment, the amount of
cellulosic
material in the cellulosic-plastic composite is about 35 wt. % of the weight
of the
cellulosic-plastic composite.
The thickness of the two-piece top piece may be between about 10% and about
50% of the thickness of the frame member. In other embodiments, the thickness
of the
two-piece top piece is between about 10% and about 50% of the thickness of the
frame
member. In one embodiment, the thickness of the two-piece top piece is about
30% of
the thickness of the frame member.
The frame member may further include a binder between the core and the two-
piece top piece for attaching the core to the two-piece top piece to form the
frame
member. Preferably, in some examples, the binder is an adhesive. In one
embodiment,
the adhesive is a hot melt adhesive.
In one embodiment of the door assembly, each adjacent panel adjoins a mullion
extending between the header and the base of the door assembly. Also, the door
assembly may further include a sill extending underneath the at least one door
panel.
Further, the at least one door panel may be a raised panel door. In one
embodiment, the
door panel further includes at least one window panel.
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The door assembly may further include hinges located between the door panel
and
the door frame or a mullion. Also, the door assembly may further include
locking
hardware to secure the at least one door panel to the door frame.
A frame member may be a door jamb and/or a door mullion, in various examples.
Accordingly, one aspect of the present disclosure is to provide a door
assembly,
the door assembly including at least one door panel and a door frame having a
plurality of
frame members including a header and at least a pair of side jambs; wherein
the frame
member includes a core and at least one top piece adjoining the core to form a
structural
member with the core and wherein the top piece is a composite of cellulosic
material and
at least one other material.
Another aspect of the present disclosure is to provide in a door assembly,
including a door frame having a plurality of frame members, including a header
and at
least a pair of side jambs, the frame member including a core and a two-piece
top piece
adjoining the core to form a structural member with the core. The top piece,
in this
.. embodiment may be a composite of cellulosic material and at least one other
material.
Still another aspect of the present disclosure is to provide a door assembly,
the
door assembly including at least one door panel and a door frame having a
plurality of
frame members including a header and at least a pair of side jambs. The frame
member
may include a core and a two-piece top piece adjoining the core to form a
structural
.. member with the core and the top piece is a composite of cellulosic
material and at least
one other material; and at least one side panel. The side panel, by way of
example may be
a light panel and/or a fixed panel.
Still in other embodiments, the present disclosure may be considered a frame
member including a core and a two-piece top piece adjoining the core to form a
structural
.. member with the core and the top piece being a composite of cellulosic
material and at
least one other material. The top piece may be a 2-piece top piece and include
a top piece
cover and a top piece base.
The top piece cover may be a removable cover and fit removably with a top
piece
base. A hollow cavity may be formed between the top piece base and the top
piece cover.
A level assembly may be incorporated into a hollow portion of the top piece.
The level
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assembly may be encased within the hollow cavity between the top piece base
and the top
piece cover. The level assembly may only be viewable atitemally when the top
piece
cover is removed. The level may provide installation feedback to assist in
assembly and
installation of frame members and door assemblies.
Examples may also include a door frame member for a door frame assembly
including a hybrid jamb member. The hybrid jamb member may include a core and
a top
piece. The top piece may be formed of a rigid extrusion of a cellulosic-
plastic composite
material. The top piece may align with the core along the length of the core.
There may
be at least one hollow portion formed in the top piece between a top of the
top piece and
a base of the top piece. The hybrid jamb member may also include a trim
profile. A
length of the trim profile may be perpendicularly fitted to the length of the
core and a
length of the top piece. The top piece cover may include a downwardly
projecting outer
leg, a midleg, and an inner leg. The top piece base may include an upwardly
projecting
outer leg, a mid leg, and an inner leg. The outer leg of the cover may mate
with the outer
leg of the base and the mid leg of the cover. The mid leg of the base and of
the cover may
be configured to contact each other in a biased position, securing the cover
to the base.
In other examples, a door assembly may include a door frame member in.eluding
a
core, a top piece and a vertically oriented trim profile/ brick mould. The top
piece may
adjoin the core to form a structural member with the core. The top piece may
include a
stop portion and a rabbet portion adjoining to form a slot. The vertically
oriented trim
profile may mate with the core and the top piece_ The trim profile may include
at least
one hollow cavity.
The frame members may be jambs. The frame members may be mullions.
The frame members may be for inswing and/or outswing door assemblies. The
frame member may include a bracket for forming a secure joint between a trim
profile
and a core/top piece.
Date Recue/Date Received 2022-01-27 6
In a broad aspect, the present invention pertains to a door assembly including
a door
frame member. The door assembly comprises at least one door panel, and has a
plurality of
frame members including a header and at least a pair of side jambs. At least
one frame member
of the plurality of frame members includes a core, and at least one top piece
having one or more
hollow enclosed cavities. The top piece adjoins the core to form a structural
member with the
core, the top piece including a rabbet portion and extending along a width of
the core from one
side of the core to an opposite side of the core to cover a distal end of the
core at a distal end of
the rabbet portion, and a stop portion. The core extends the length of the top
piece between the
distal end of the rabbet portion and a distal end of the stop portion.
In a further aspect, the present invention provides a door assembly comprising
a door
frame member including a core, and a top piece adjoining the core to form a
structural member
with the core. The top piece includes an enclosed hollow potion, and a stop
portion and a rabbet
portion adjoining to form a slot. The top piece extends along a width of the
core from one side
of the core to an opposite side of the core to cover a distal end of the core
at a distal end of the
rabbet portion. The core extends the length between the distal end of the
rabbet portion and a
distal end of the stop portion, and there is a vertically oriented trim
profile mating with the core
and the top piece.
In a still further aspect, the present invention provides a door assembly
comprising at
least one door panel, and at least one top piece having at least two hollow
cavities separated by a
rib, the top piece adjoining the core along a length of the core to form a
structural member with
the core. A second core separates from the core, and the core and the second
core are aligned
along a length of each of the core and the second core along a midline of the
side frame member,
the top piece surrounding outside surfaces of the aligned core and second
core. Further, there is
a trim profile engaging with the at least one top piece to enclose the aligned
core and second core
along distal ends of rabbet and stop portions.
6a
Date Recue/Date Received 2022-01-27
In a yet further aspect, the present invention provides a door frame member
for a door
frame assembly, comprising a hybrid jamb member. The hybrid jamb member
includes a core, a
top piece formed of a rigid extrusion of a cellulosic-plastic composite
material, the top piece
aligning with the core along the length of the core along one side of the
core, and at least one
hollow portion formed in the top piece between a top of the top piece and a
base of the top piece.
There is a second core mirroring the core and aligned with the core along the
length of the core
on an opposite from the top piece, and a second top piece mirroring the top
piece and aligning
with the second core along the length of the second core on an opposite side
from the core. The
top piece and the second top piece enclose the core and second core along a
distal rabbet end.
These and other aspects of the inventions of the present disclosure will
become apparent
to those skilled in the art after a reading of the following description of
embodiments when
considered with the drawings.
6b
Date Recue/Date Received 2022-01-27
Brief Description of the Drawings
Figure 1 is a front elevation view of one embodiment of a door assembly
constructed according to the present disclosure;
Figure 2 is cross-sectional view of one embodiment of a frame member having a
core, a trim profile and a top piece;
Figure 2A is an alternative cross-sectional view of one embodiment of the
frame
member of Figure 2;
Figure 3 is another cross-sectional view of one embodiment of a frame member
having a core, a trim profile and a top piece;
Figures 3A ¨ 3B show cross-sectional views of embodiments of a frame member
having a core, trim profile and a top piece;
Figure 3C is a cross-sectional view of one embodiment of frame members in a
back to back arrangement as a mullion;
Figure 3D is a perspective view of the one example of the mullion arrangement
of
Figure 3C;
Figure 3E is a cross-sectional view of one embodiment of a frame member for an
outswing door assembly;
Figure 3F is an exploded view of one example of the frame member for an
outswing door assembly of Figure 3E;
Figure 3G is an interior view of one example of the frame member for an
outswing door assembly of Figure 3E;
Figure 4 is another cross-sectional view of one embodiment of a frame member
having a core, a trim profile and a top piece;
Figure 4A is a cross-sectional view of one example of the frame member of
Figure 4 with a portion of the top piece removed;
Figure 4B is a perspective view of one embodiment of a frame member having a
level assembly;
Figure 4C is a cross-sectional view of one embodiment of the frame member of
Figure 4B having a level assembly;
Figures 4D-F show various views of the level assembly of Figure 4B;
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Figures 5A ¨ 5C shows one embodiment of an outer leg configuration of one
example of a top piece according to the present disclosure;
Figure 5D is a perspective view of one embodiment of a frame member including
a pull according to the present disclosure;
Figure 6 is one example of a trim profile constructed according to the present
disclosure;
Figure 7 is another example of a trim profile constructed according to the
present
disclosure;
Figure 8 is another example of a trim profile constructed according to the
present
disclosure;
Figures 8A and 8B show alternate examples of the trim profile of Figure 8;
Figure 9 is another example of a trim profile including a trim profile cover
constructed according to the present disclosure;
Figures 9A-D show alternate examples of the trim profile including a cover
according to Figure 9;
Figure 10 is a side perspective view of one example of a frame member having a
lower portion;
Figure 11 is a graphical representation of a response surface illustrating the
relationship of the thickness of the top piece and the amount of cellulosic
material in the
cellulose-plastic composite on the performance of a frame member constructed
according
to some examples of the present disclosure;
Figure 12 is a front elevation view of one embodiment of a door assembly
constructed according to the present disclosure;
Figure 13 is a front elevation view of another embodiment of a door assembly
constructed according to the present disclosure;
Figure 14 is a front perspective view of another embodiment of a door assembly
including at least one mullion frame member and constructed according to the
present
disclosure;
Figure 15 is a cross-sectional view of one embodiment of a mullion frame
member having a reinforced core and a top piece; and
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Figures 16A ¨ 16C are alternative examples of cross-sectional views of
embodiments of a mullion frame member having a reinforced core and a top
piece.
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Description of Embodiments
In the following description, like reference characters designate like or
corresponding parts throughout the several views. Also in the following
description, it is
to be understood that such terms as "forward," "rearward," ''left," "right,"
"upwardly,"
.. "downwardly," and the like are words of convenience and are not to be
construed as
limiting terms.
Referring now to the drawings in general and Figure 1 in particular, it will
be
understood that the illustrations are for the purpose of describing a
preferred embodiment
of the inventions and are not intended to limit the inventions thereto. As
best seen in
.. Figure 1, a door assembly, generally designated 8, is shown constructed
according to the
present disclosure. The door assembly 8 includes a door frame 10 and at least
one door
panel 12.
The door frame 10 may include one or more frame members 29 (see Figure 2). A
plurality of frame members may include any combination of a header 14 and a
pair of
side jambs 16' and 16". Header 14 may be generally placed toward the top of
the door
panel 12. Side jambs 16' and 16" may be generally placed at opposing sides of
the door
panel 12. However, in some embodiments, the side jambs are not directly
adjacent to the
door panel 12. Door panel 12 may further include hinges 20. Hinges 20 may
connect
door panel 12 to at least one of the frame members. In another embodiment,
hinges 20
.. may connect door panel 12 to a mullion. There may be one, two, three or
more hinges 20.
In other embodiments, the door panel 12 may also include locking hardware that
enables the door panel to be secured to at least one of the frame members; for
example,
side jamb 16". Some examples of locking hardware include latches and
deadbolts.
Alternatively, door panel 12 may include locking hardware that enables it to
be secured
.. to a second door panel. Still in other embodiments, door panel 12 may
include locking
hardware to secure it to a mullion. More than one type of locking hardware
mechanism
may be used in certain embodiments; for instance, wherein at least two door
panels may
be used to constitute a French door assembly. In another embodiment, the door
panel 12
is a raised panel door. The door panel 12, in one example, may include
adjacent panels,
for example, side light panels 42' and 42"and in other examples may include
side light
CA 3004654 2018-05-11
panels (see Figures 12 and 14). The door panel 12 may also include raised
panels and/or
glass panels, for example, 24' and 24".
Turning to Figures 2 - 3, and in some examples, the frame member 29 may
include a core 26 and a top piece 30, as seen in Figures 2 through 4, and
generally
throughout the figures. The top piece 30 may include a binder (not shown) that
attaches
it to the core 26. The binder may be an adhesive. In one embodiment, the
binder may be
an adhesive such as a hot melt adhesive. Core 26 may be of a material that
provides
additional structural stability while top piece 30 can be included, for
example, for
structural stability and/or aesthetic features. Core 26, may, by way of
example, be of
.. wood, part wood, and/or all or part wood/plastic composite, laminated
veneer lumber,
and/or wood and another material. Top piece 30 may also serve other functions
such as
protecting the core 26. The core 26 may further include back out grooves 27
(not shown)
on a face that is not attached to the top piece 30.
In one embodiment, the top piece 30 may be comprised of one piece. In another
embodiment, top piece 30 may be comprised of two joined pieces, a first piece
and a
second piece, and/or may be comprised of two or more joined, connecting and/or
non-
joined pieces. Other embodiments of top piece 30 may include additional pieces
and/or
separate pieces. Still in other embodiments, top piece 30 is a single piece.
As shown in
the embodiment in Figure 2, the two piece top piece 30 is, in this embodiment,
comprised
of a rabbet portion 32 and a separate stop portion 34. hi one embodiment, the
two top
pieces are generally L-shaped. The top piece may be linear and other shapes
may
alternatively be used.
The core 26 may be of any shape with any defined length ("CL"), width ("CW")
and depth ("CD"). The two-piece top members are flexible dimensionally in
design and
can accommodate any span of core sizes, including multiple cores. In one
embodiment
the core width is about 5 1/4 inches. In another embodiment the core width is
about 7 'A
inches. In another embodiment, the core width may be from about 4" to about
8". Either
the rabbet portion 32, the stop portion 34 or both can be adjusted in their
respective
widths ("RW" and "SW") to accommodate the core's width to maintain the overlap
at the
proximate ends 31, 33. In a number of embodiments, the rabbet portion 32 is at
a fixed
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standard width while the stop portion 34 can be accommodating and manufactured
at a
variety of widths. Still, the rabbet portion 32 may also be manufactured at a
variety of
widths to accommodate the needs of the installation/application.
In some embodiments, the core 26 may include a partially raised portion 23 to
support at least one of the top pieces. Raised portion 23 may be a portion of
the core that
is raised, non-linear, in a different plane and parallel to the main core
portion. This
portion 23 may be integrally formed with the main core from one core material.
Alternatively, this portion 23 may be adjoined from separate components to
wholly form
the core 26. In the embodiment shown in Figure 2A, the core 26 has a first
portion 21
(having a length ("CL1"), width ("CW1") and depth ("CD1")) to support the
rabbet
portion 32. The core may also include a second raised portion 23 (having a
length
("CL2"), width ("CW2") and depth ("CD2")) to support the stop portion 34. The
first
and second portions of the core 26 may be of any length, width and depth. The
second
raised portion 23 of the core 26 may enable the stop portion 34 to at least
partially
overlap the rabbet portion 32. In yet other embodiments, the first and second
portions of
the core are attached to a single top piece molded to fit both portions of the
core 26.
Figures 2 through 4 show that the top piece may include an overlap and form a
slot 36. The slot 36 may be a weather strip slot that further includes a
weather strip 40.
Weather strips are useful for preventing water and air from entering the
interior of a
building. The slot 36 may accept the weather strip between the proximate ends
31 and
33.
In some embodiments, where the stop portion 34 extends over the rabbet portion
32 to form an overlap, the rabbet portion 32 and stop portion 34 of the top
piece 30
embodiments may overlap in any number of configurations. In one embodiment,
the
proximate end 33 of the stop portion 34 overlaps with a corresponding
proximate end 31
of the rabbet portion 32. In some examples, the proximate end 33 of stop
portion 34
meets the proximate end 31 of rabbet portion 32 by about an overlap of about
0" to about
1/2".
Still in other embodiments, the overlap may be substantially medially located
over
the core. The location of the overlap with respect to the core 26 may depend
on the
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dimensions of its portions, particularly CW1 and CW2. In some embodiments, CW1
and
CW2 may be of widths such that the overlap is closer to a distal end 35 of the
rabbet
portion 32 than a distal end 37 of the stop portion 34. In other embodiments,
the overlap
is closer to the distal end 37 of the stop portion 34 than distal end 35.
The extent of overlap may also depend on the depths and widths of the rabbet
and
stop portions of the top piece. In one embodiment, the stop portion 34 has a
greater
width ("SW") than the width of the rabbet portion 32 ("RW"). In another
embodiment,
the proximate end 33 of stop portion 34 has a greater depth ("SPD") than the
proximate
end 31 of the rabbet portion 32 ("RPD").
The top piece/pieces may also sit on top of the core 26 in a variety of
configurations. As shown in Figure 2, the distal ends 35, 37 of the rabbet
portion 32 and
stop portion 34 both overlap the sides of the underlying core 26. In one
embodiment, the
depth of the core ("CD1/CD2"), at least at the core's greatest depth, is
greater than the
depths of the distal ends 35, 37 of the rabbet portion 32 ("RDD") and stop
portion 34
("SDD"). In other embodiments, the depths of the distal ends 35 and 37 are
equal to or
greater than the depth of core 26. Furthermore, the depth of distal end 37 may
be greater
than distal end 35.
In other embodiments, the core 26 is non-metallic. By way of example, the non-
metallic material may be wood. The core 26 may also further include a decay
resistant
material. Decay resistant materials are useful for extending the lifespan of
the core, such
as through preventing water damage. In one embodiment, the decay resistant
material
may be a cellulosic-plastic composite. The cellulosic portion of the composite
may be
wood fiber. The plastic portion of the composite can be a thermoplastic such
as
polyethylene. In other embodiments, the entire core may include a decay
resistant
material. The core may include a first portion made of a first material and a
second
portion made of a second material. The first material may be a material
different from the
second material.
As seen in Figure 10, the decay resistant material may be generally located on
a
lower portion 28 of the core. The lower portion 28 of the core may generally
refer to a
portion that is closer to the ground. The lower portion 28 may be an
integrally formed
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segment as depicted in Figure 10. This segment can be an extruded profile that
matches
the profile of the wood core. In the embodiment shown in Figure 10, the
integral
segment is joined to the core 26 by a finger joint. However, the decay
resistant material
may be joined to the core 26 by any mechanical or chemical means and is not
limited to
connecting via a particular type of joint. Further, the integrally foimed
segment may be
of any length with respect to the core. By way of example, the length of the
segment may
be about 4". In some examples, the lower portion 28 may be formed of foamed
PVC.
The top piece 30 may also be a decay resistant material. This decay resistant
material may be a cellulosic-plastic composite. In one embodiment, the
cellulosic portion
of this composite is a wood fiber. In another embodiment, the plastic portion
of the
composite is a thermoplastic such as polyvinyl chloride. In some examples, the
top piece
may be a resin and filler combination material.
The amount of cellulosic material may vary within the top piece composite. In
one embodiment, the top piece composite is between about 20 weight percent and
about
70 weight percent of the weight of the cellulosic-plastic composite. In
another
embodiment, the amount of cellulosic material within the composite is about 35
weight
percent of the total weight of the cellulosic-plastic composite. The thickness
of the top
piece 30 may also vary among different embodiments of the invention. In one
example,
the thickness of the top piece 30 is between about 10% and about 50% of the
thickness of
the total frame member, including the core. In one embodiment, the thickness
of the top
piece 30 is about 30% of the thickness of the door frame member 29.
Figure 11 is a graphical representation of a response surface illustrating the
relationship between the percent thickness of the top piece and the amount of
cellulosic
material in embodiments where the top piece is a cellulosic-plastic composite.
Percent
thickness of the top piece is defined as the thickness of the top piece with
respect to the
total thickness of the frame member. The response surface provides a visual
illustration
of the effects of both thickness and percent amount of cellulosic material
within the
composite via a two-dimensional surface plot of a three-dimensional surface.
The
boundary conditions in Figure 11 are denoted with dashed lines, and indicate a
minimum
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percent thickness and a percent amount of cellulosic material for use with
some examples
within the present disclosure.
Accordingly, in this example, the expected characteristics of various
embodiments of top piece 30 were plotted and zones on the response surface
were ranked
.. from 1 to 5, with 1 being the poorest performing top pieces and 5 being the
best
performing top pieces in terms of strength, durability and resistance to
decay.
Figures 3 - 4 show top piece 30 may include at least one hollow cavity 38.
More
than one hollow cavity may be separated by a support rib 39. Top piece 30 may
include
both a horizontal hollow cavity 38a spanning longitudinally along the length
of the top
piece and a vertical hollow cavity 38b spanning along the depth of the top
piece. Cavity
38 may allow for placement of items such as installation anchors and/or level
indicators
49. Hollow cavity 38 inclusion in top piece 30 may allow for more consistent
extrusion
of top piece 30. The hollow cavities 38 may span the entire width of the top
piece 30. The
frame member may include a series of hollow cavities included in top piece 30.
In some embodiments, examples as seen in Figures 3A and 3B, the top piece 30
may include a seal 97. The seal 97 may be a projection into recess 99. The
seal 97 may be
a flexible seal. The seal 97 may be co-extruded with top piece 30. The seal 97
may foini a
barrier to entry of water and weathering at the juncture between the top piece
30, other
part/s of the frame member 29 and the flange 77.
Figures 3C-3D show examples of frame members 29 arranged back to back to
form a mullion embodiment. Top piece 30 may be mated with a core 26. In some
examples, an adhesive may be used to secure the top piece 30 to core 26. Two
jamb
assemblies may be interfaced along their respective cores 26. The jamb
assemblies may
be mated in a plane as mirror images of each other. The distal ends 35 of each
jamb
assembly may be covered by an end extension piece of top piece 30 and the end
extension pieces of each jamb assembly may meet to cover the distal end of the
fointed
mullion assembly. The jamb assemblies may be secured to one another, forming a
mullion embodiment, by way of example, by fasteners and/or adhesive. The top
pieces 30
in the mullion assembly may be opposing top pieces. The top piece 30 may
include a seal
97. The seal 97, in one embodiment, may be fin shaped. The seal 97 may be a
flexible
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sealing fin. A trim profile 70 may serve as a cover at distal end 37 for the
core 26. The
core 26 may be a solid, one piece core with two top pieces and a trim profile
70 covering
the exterior of the core. The core may include a core extension 26 toward the
distal end
37, that may extend beyond top pieces 30. . The core extension 26' may be a
separate
core, or may be integral with one or both of the jamb assembly cores 26. In
some
instances, the core extension 26' may be joined to the core 26 with fasteners,
by way of
example nails or staples, and/or adhesive. The trim profile 70 may cover the
core
extension 26' and fit into recesses 99 in each top piece 30. Trim profile 70
may include
flanges 77 that overlap with the top pieces 30. Seal 97 may retain or assist
in retaining
trim profile 70 in place. Adhesive and/or fasteners may also be used to secure
trim profile
70 in place.
While Figures 3A and 3B are examples of jamb assemblies for inswing door
applications, Figures 3E-3G show embodiments of frame members 29 for outswing
door
applications. Outswing embodiments may include the elements as disclosed
herein for
inswing embodiments. In one example of the outswing embodiment, core 26 may
include
an arm 25 forming a shelf above a core recess 25a. The arm 25 may be molded to
fit with
the top portion 30. The arm 25 may fit into the top portion 30 to form a flush
under
surface. A bracket 85 may extend along a surface of the core 26 and extend
into the core
recess 25a. A recess 99' may be formed between the bracket 85 and the flush
surface of
the arm 25 and the top portion 30. A flange 77 extending from a trim profile
70, may be
formed to fit into the recess 99' with the bracket 85 biased against the
flange 77 to hold
the flange 77 in place to secure the trim profile to the frame member 29.
Bracket 85 secures to core 26 along an inside of the core. Bracket 85 may
include
a projection that forms an L-shaped portion for fitting with an inside corner
of the core
26. The bracket 85 may include a diagonal section 89, that spans the recess
99' along a
diagonal trajectory, resting against the flange 77. The diagonal section may
be biased
against the flange 77, by way of example, spring loaded and/or urged against
flange 77.
One of the terminal ends of bracket 85 may rest against an inside of the trim
profile 70.
The bracket may be wedged between the trim profile 70 and the core 26 so that
a
contraction in the bracket at a bracket peak creates the upward bias of the
bracket to
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secure the flange 77 in place. The bracket 85 assists in holding the trim
profile 70 in
place, forming an overall stronger frame member and attachment point between
the trim
profile 70 and top portion/core 30/29 in outswing embodiments.
Top piece 30 may also, in some embodiments, include a top piece cover 41. The
top piece may also include a top piece base 55 (see Figures 4 - 5C). The top
piece base
may include, by way of example, a part of the rabbet portion 32 that houses,
is covered
by and/or interfaces with the top piece cover 41. The top piece cover 41 may
interface
with top piece base 55 and rabbet portion 32 to form the complete top piece,
however, in
some examples the rabbet portion and stop portion 34 farmed by interface of
the cover 41
may be separate pieces. Figures 5A-C show examples of a top piece base 55
interfacing
with top piece cover 41. In one example, an outer leg 43 of the cover 41
hooks/mates
with the outer leg 53 of base 55. The outer leg of the cover 41 may include a
lip 44A. The
outer leg 53 of base 55 may include a lip 44B. The outer leg lip 44A and the
top piece lip
44B may overlap to secure the cover 41to the base 55. A mid leg 45A of the
cover may
contact with a mid leg 45B of the base. The interaction of the mid leg of the
cover 45A
and the mid leg 45B of the base may cause the cover to bias in one direction,
away from
the interface of the outer leg lip 44B and the cover lip 44A, further securing
the interface
between the outer leg lip and the cover lip. The cover 41 and the base 55 may
also both
include an inner leg 46, 47. Each of the inner legs may include an inner leg
lip 48A, 48B.
The inner leg lip 48A of the cover 41 may snap and/or slide onto the inner leg
lip 48B of
the base 55, securing the cover 41 in place on the base 55. The top piece in
this example
may be considered a top piece assembly including a core 26 and a top piece 30,
with the
top piece including a rabbet 32 and a stop 34. The stop 34 may include a base
55 and a
cover 41. The cover 41 may secure onto the base 55 such that the cover and the
base form
the stop face. The cover 41 and the base 55 may form at least one or more
hollow cavity
38.
A level assembly 49 may be situated in the hollow cavity 38 between the top
piece base 55 and the top piece cover 41. The hollow cavity can be foimed by
removing
ribs 39 as needed, by machining. Figures 4B ¨ 4D show examples of a level
assembly
incorporated in a frame member. The level assembly may be of a height and of
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dimensions to be accommodated within the hollow cavity 38. The top piece cover
41 and
the top piece base 55 may enclose the level assembly 49. The level assembly
may include
a body 90, fittings 98 along the perimeter of the body 90, a level site 94, a
bubble level 96
and indicators 92.
One example of a door assembly may include a pull 91 fitted between a
removable top piece cover 41 and a top piece base 55 to assist with removal of
the top
piece cover 41 from the top piece base 55 (as seen in Figure 5D). The pull 91
may be
made of a durable material, by way of example, the pull may be a mylar pull.
The door
assembly may include multiple pulls. A pull 91may be configured across a width
of the
top piece cover. A pull 90 may be attached to an underside of a cover 41, in
one example,
by an adhesive 93. The pull 90 may span from one underside edge of the cover
to another
underside edge of the cover and extend outside of the cover between the cover
and the
base to be exposed on the outside of the door frame member. The pull is thin
enough to
not impede the closure of the cover 41 onto the base 55, and may be fitted
between a mid
leg of the cover 45A and a mid leg of the base 45B without interrupting the
biasing
position exerted by the placement of the mid legs 45A, 45B. The pull is also
strong
enough to withstand repeated removal of the cover by way of tension on the
pull 91.
Frame member 29 may also include, in some examples, trim profile 70, as seen
in
Figures 2 through 4. Trim profile 70 may be incorporated as a part of the
frame member
in any of a variety of ways and may take on a variety of shapes. Trim profile
70 may be a
one piece trim profile. Trim profile 70 may include multiple portions,
segments, and/or
attachments. Trim profile 70 may take on a vertical orientation and be
adjustable relative
to the jamb portion of the frame member 29.
Figures 6 through 9 show enlarged views of examples of a trim profile 70, by
way
of example, a brick mould. In one embodiment, trim profile 70 may include a
linear side
71 that abuts the top piece 30 and/or core 26 and/or a portion of the top
piece 30. Trim
profile 70 may also include a non-linear side 72. Trim profile 70 may include
a first
portion 75 and a second portion 76.
First portion 75 may take on an enclosed square or rectangular shape. First
portion
75 may have two linear sides that are parallel with each other and with distal
end 37.
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First portion 75 may include one or more hollow portions 73. First portion 75
may be an
enclosed portion. First portion 75 may be separated from second portion 76 by
a support
rib 39. First portion 75 may also include a stop flange 77. Stop flange 77 may
be joined to
linear side 71substantially perpendicularly, forming about a ninety degree
angle between
the flange 77 and side 71. Flange 77 may fit in a recess 99 formed between an
underside
of the stop 34 and the core 26. The flange 77 may clearance fit with recess
99. The trim
profile 70, in one example, may overlap with the stop 34 of top piece 30. The
frame
member 29 may include reciprocal recesses at both terminal ends of the stop
portion 34,
by way of example at the distal end 37 and at the proximate end/stop face end
33.
Second portion 76 may include a linear side and a non-linear side. Second
portion
may include one or more hollow portions 74. Second portion 76 may be enclosed
and/or
may take on a non-enclosed shape. Second portion 76 may include a flange 78
extending
from linear side 71 and projecting beyond portion 76. Second portion 76 may
include a
projecting segment 78 that forms the termination of linear side 71 on one end.
A
projecting segment 79 may extend from non-linear side 72 and be separated from
the
linear side 71 by a hollow cavity/portion 74. Cavity 74 may be formed by
projecting
segment 79 and may be configured for the cavity of a corner key (not shown) to
connect
horizontal and vertical pieces at a miter joint.
The trim profile 70 may be at least a two piece trim profile. Trim profile 70
may
include a base segment 82 and a cover segment 80. Base segment 82 may form the
linear
side 71 and may include a flange 77 and/or a recess 83. Cover 80 may adjoin
base
segment 82. Cover 80 may include a lip 84 that fits into recess 83 to secure
cover 80 to
base segment 82. Trim profile 70, in this example, may include a horizontally
oriented
hollow portion 74 and/or a vertically oriented hollow portion 74 and a series
of hollow
.. portions 73. Support ribs 39 and hollow portions 73/74 may take on varying
configurations, by way of example 6-9D. In one example, support ribs 39 may
take on
vertical, linear, and/or combinations of orientations to form segmented hollow
portions
73/74 in configurations that assist in structure and the extruding process.
Applicant
realizes benefits in material minimization and cost efficiency, particularly
in the top piece
30 and the trim profile 70. The material minimization is balanced against
shape control
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and stability factors. The support ribs 39 may be minimized for material
minimization
and also intentionally configured and shaped to provide adequate or improved
structure to
the top piece 30 and trim profile 70.
In other embodiments, trim profile 70 may include an insert 81. Insert 81 may,
by
way of example, be wood or other suitable material to provide an anchor point
for
fasteners, for example storm door fasteners.
Figures 8A and 8B show that a portion of the trim profile between projecting
segments 79 and 78, shown present in Fig. 8A and removed in Fig. 8B, may be
cut away.
The removable segment between projecting segments 78 and 79 may be cut away to
allow, for example, vinyl siding J-Channel fitment.
Frame members 29 may be a part of any type of door assembly. For instance, the
door assembly 8 may include at least one adjacent panel, designated as 42' and
42" in
Figures 12 and 14, such as a side lite panel or a fixed panel. In certain
embodiments,
frame members may also include a mullion 44' and 44". Each adjacent panel may
also
adjoin a mullion 44' and 44" extending between the header and base of the door
assembly 8. The door assembly 8 may further include a sill 46 located
underneath the
door panel. In other embodiments, as shown in Figure 13, the door assembly
includes
two door panels 12' and 12" separated by way of example an astragal and/or a
mullion
50. In yet other embodiments, the frame members described herein are not
necessarily
limited to door jambs and mullions and may alternatively be used for other
assemblies
such as windows.
Some examples include an adjustable frame member 29. An extended length core
26 and an extended length flange 77 may be included in an adjustable width
frame
system. The system may include the extended length core 26 and extended length
flange
77 that are configured to be cut down or adjusted as needed to create a custom
fit and
narrower door jamb upon installation. Jambs are typically plumb and often fit
against
surfaces that may not be plumb. In one example, the adjustable width frame
system may
be a 2-piece system, including an extended length core 26 and/or an extended
length
flange 77, the system configured to also allow a give and positionablility
within the
adjustable frame member 29 to adjust to non-plumb surfaces at installation.
Therefore,
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the adjustable width frame system is configured to accommodate variable door
jamb
sizing requirements and also non-plumb installation surfaces. The core 26 may
extend
beyond the top piece 30 in an adjustable width frame system. The system may
include
any of the jamb embodiments disclosed herein with an extended length core 26
and/or an
extended length flange, by way of example, specifically the jamb frame member
shown
in Figure 3, Figure 3A and Figure 3B.
Frame members may also include one or more cappings (not shown). One
alternative embodiment includes wherein the rabbet portion 32 and stop portion
34 each
further includes a capping. Capping may be co-extruded with the top piece 30,
and is not
necessarily limited to one layer. Alternatively, capping may be independently
extruded
to fit on top of a frame member and may cover at least a portion of a frame
member. In
one embodiment, the capping is a thermoplastic such as acrylic. In another
embodiment,
capping may be a composite of two or more materials. The composite of the
capping
may be comprised of a thermoplastic with a cellulosic filler such as wood. In
other
embodiments, the capping can be made of plastic without cellulosic filler,
with another
type of filler, or include a blowing agent. In other embodiments a capping may
be placed
onto core 26 without top piece 30. A capping may comprise two or more pieces,
but in
other embodiments, may comprise one piece covering at least a portion of core
26.
Figures 15 and 16A-C show embodiments where at least one frame member is a
mullion having a core and a top piece. The top piece may be a 2-piece top
piece. The
mullion frame member may be structured similarly, as described herein
throughout, as a
jamb frame member, for example, of Figures 2-9.
Figures 15 and 16 show another example of embodiments of a frame member 29
including a mullion component according to the present disclosure. The mullion
component may be made of a durable material, resistant to degrading effects of
moisture,
heat and fungal attack. The mullion component may include an extruded aluminum
reinforced core. In some examples, the mullion frame member 29 includes a stop
component and a rabbet component, each formed by extruding a combination of
PVC,
wood fibers and a foaming agent. The components may be joined to an aluminum
reinforced core by an adhesive. The aluminum extrusion is able to mate with
slots
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integrally formed in the composite extrusions for proper positioning. The
reinforced core
and top piece are positioned to maximize contribution to structural and
shaping integrity,
to eliminate issues related to thermal transfer and interior moisture
condensation, to
accommodate placement of hardware fasteners without the need to pre-drill
through the
reinforced core, and to maximize hardware fastener holding strength.
In some examples, the invention of the disclosure may be considered an
exterior
door mullion including extrusions joined to a reinforced core member 26. In
some
examples, the extrusions may be a rabbet extrusion 32 and a stop extrusion 34
made of a
moisture and decay resistant material, by way of example, all-plastic, a resin
and plastic
combination with wood or another suitable filler, and/or a blowing agent. The
reinforced
core member 26 may be a rigid member made of a rigid material, by way of
example,
aluminum. The reinforced core member 26 may be secured to the extrusions 32,
34, in
one example, by way of adhesive. The reinforced core member and multiple
extrusions
may be configured to form a slot 36, the slot being configured to accept a
weather
.. stripping piece 40.
In other examples, the frame member 29 may be considered a mullion component
including a one piece stop portion 34, a one piece rabbet portion 32 and a
reinforced core
26. The stop portion may include a stop face 33, a recessed area 86 at the
stop face, and a
set of recessions 88. The rabbet portion 32 may include a recessed area 87.
The
.. reinforced core may take on the shape of at least a double-pronged fork and
be sized and
shaped to correspond to the recesses 88, 87 in the stop portion 34 and rabbet
portion 32.
The reinforced core may on the pronged side mate with the stop portion 34,
with the
prongs fitting into the recessions 88. The reinforced core on an opposite
side, may mate
with the rabbet portion 32 and extend into the recessed area 87. The
reinforced core 26
.. may span the depth of the rabbet portion 32. The recessed area 86 may be
configured to
faun a slot 36 when the rabbet portion and stop portions are joined. The stop
portion and
rabbet portion may be separated by the reinforced core except along an inner
interface
adjacent to the the slot 36. Shapes and sizes of the mullion components may
vary as seen
in the examples of Figure 16A-C to accommodate various door assemblies, and
are
considered within the scope of this invention.
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Certain modifications and improvements will occur to those skilled in the art
upon
a reading of the foregoing description. By way of example, the top piece can
be of a
unitary construction. The thickness of the top piece can be less than 10% of
the total
thickness in other embodiments. The plastic portion of the top piece may
comprise all
polyvinyl chloride. Moreover, the top piece can be made of plastic without
cellulosic
filler, with another type of filler, or include a blowing agent.
Alternatively, the core's
lower portion may be made from plastic without cellulosic filler, with another
type of
filler, or include a blowing agent. It should be understood that all such
modifications and
improvements have been deleted herein for the sake of conciseness and
readability but
are properly within the scope of the following claims.
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