U.S. patent application number 10/688048 was filed with the patent office on 2004-06-17 for gate or door frame assembly and method of making a gate or door.
Invention is credited to Boroviak, Richard.
Application Number | 20040111974 10/688048 |
Document ID | / |
Family ID | 32477050 |
Filed Date | 2004-06-17 |
United States Patent
Application |
20040111974 |
Kind Code |
A1 |
Boroviak, Richard |
June 17, 2004 |
Gate or door frame assembly and method of making a gate or door
Abstract
A frame assembly for making a gate or door comprising an upper
horizontal member, a lower horizontal member, a first vertical
member and a second vertical member, one or more support members
provided along the length of each of the upper and lower horizontal
members, first connection means to connect an upper end of the
first vertical to one end of support member provided along the
length of the upper horizontal member, second connection means to
connect lower end of the first vertical to one end of support
member provided along the length of the lower horizontal member,
third connection means to connect an upper end of the second
vertical to a second end of support member provided along the
length of the upper horizontal member and fourth connection means
to connect a lower end of the second vertical to a second end of
support member provided along the length of the lower horizontal
member.
Inventors: |
Boroviak, Richard; (Ontario,
CA) |
Correspondence
Address: |
GREER, BURNS & CRAIN, LTD.
Suite 2500
300 South Wacker Drive
Chicago
IL
60606
US
|
Family ID: |
32477050 |
Appl. No.: |
10/688048 |
Filed: |
October 17, 2003 |
Current U.S.
Class: |
49/501 ; 49/49;
49/504 |
Current CPC
Class: |
E06B 3/9649 20130101;
E05Y 2900/40 20130101; E06B 11/02 20130101; E05D 5/06 20130101;
E06B 11/04 20130101 |
Class at
Publication: |
049/501 ;
049/049; 049/504 |
International
Class: |
E01F 013/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 11, 2002 |
CA |
2,414,416 |
Claims
I claim:
1. A frame assembly for making a gate or door comprising an upper
horizontal member, a lower horizontal member, a first vertical
member and a second vertical member, one or more support members
provided along the length of each of the upper and lower horizontal
members, first connection means to connect an upper end of the
first vertical to one end of support member provided along the
length of the upper horizontal member, second connection means to
connect lower end of the first vertical to one end of support
member provided along the length of the lower horizontal member,
third connection means to connect an upper end of the second
vertical to a second end of support member provided along the
length of the upper horizontal member and fourth connection means
to connect a lower end of the second vertical to a second end of
support member provided along the length of the lower horizontal
member.
2. A frame assembly according to claim 1 wherein support members
provided along the length of each of the upper and lower horizontal
members are threaded metal rods inserted through a longitudinal
hole or bore provided along the length of the upper and lower
horizontal members.
3. A frame assembly according to claim 2 wherein the metal rods
have a cross-section of at least 1/4 inch.
4. A frame assembly according to claim 3 wherein said first
connection means to connect an upper end of the first vertical
member to one end of support member provided along the length of
the upper horizontal member comprises one end of the metal rod
passing through a hole in said upper end of the first vertical
member and a fastener to secure the vertical member to the upper
horizontal member.
5. A frame assembly according to claim 4 wherein said second
connection means to connect a lower end of the first vertical
member to one end of support member provided along the length of
the lower horizontal member comprises one end of the metal rod
passing through a hole in said lower end of the first vertical
member and a fastener to secure the vertical member to the lower
horizontal member.
6. A frame assembly according to claim 5 wherein said third
connection means to connect an upper end of the second vertical
member to one end of support member provided along the length of
the upper horizontal member comprises a second end of the metal rod
passing through a hole in said upper end of the second vertical
member and a fastener to secure the vertical member to the upper
horizontal member.
7. A frame assembly according to claim 6 wherein said fourth
connection means to connect a lower end of the second vertical
member to one end of support member provided along the length of
the lower horizontal member comprises a second end of the metal rod
passing through a hole in said lower end of the second vertical
member and a fastener to secure the vertical member to the lower
horizontal member.
8. A frame assembly according to claim 1, having two or more hinges
secured to either the first vertical member or the second vertical
member.
9. A frame assembly according to claim 2, having two or more hinges
secured to either the first vertical member or the second vertical
member.
10. A frame assembly according to claim 3, having two or more
hinges secured to either the first vertical member or the second
vertical member.
11. A frame assembly according to claim 4, having two or more
hinges secured to either the first vertical member or the second
vertical member.
12. A frame assembly according to claim 5, having two or more
hinges secured to either the first vertical member or the second
vertical member.
13. A frame assembly according to claim 6, having two or more
hinges secured to either the first vertical member or the second
vertical member.
14. A frame assembly according to claim 7, having two or more
hinges secured to either the first vertical member or the second
vertical member.
15. A frame assembly according to claim 7 having two or more hinges
secured to either the first vertical member or the second vertical
member, wherein one end of said support members provided along the
length of the upper and lower horizontal members secures a pair of
hinges to the first or second vertical member.
16. A frame assembly according to claim 15 wherein the lower end of
the first and second vertical members are provided with a plurality
of horizontal holes at designated intervals.
17. A kit for making a frame assembly for making a gate or door to
fit a rough opening comprising upper and lower horizontal members
sized to permit them to be cut to fit rough opening width, two
vertical members sized to permit them to be cut to fit rough
opening height, one or more support members provided along the
length of each of the upper and lower horizontal members,
connection means to connect the ends of the vertical members to the
ends of the support members provided along the length of the upper
and lower horizontal members and two or more hinges.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO A "SEQUENCE LISTING"
[0003] Not Applicable
FIELD OF INVENTION
[0004] The present invention relates to a frame assembly for use in
the construction of gates or doors and, more specifically, to a
frame assembly adapted to provide the vertical and horizontal
support members of a gate or door and rotatably connect these
members to a fixed structural member.
BACKGROUND OF INVENTION
[0005] Gates are used to allow selective access through a wall or
fence. Conventionally, gates are constructed as follows. Two
vertical support members and two horizontal support members are
fastened together in a rectangular shape to form what will be
referred to herein as a gate frame. Fence boards or the like are
fastened to the support members, and one of the vertical support
members is typically attached by two or more hinge assemblies to a
structural member such as a wall or post. Doors are similarly
constructed with vertical and horizontal support members fastened
together to form what will be referred to herein as a door frame. A
sheet of plywood or the like covers one or both sides of the door
frame.
[0006] Using conventional gate/door building techniques, fasteners
such as nails or screws are driven through one support member into
another support member to form the corners of the gate box. Over
time, the force of gravity and wood shrinkage will cause these
fasteners to loosen, allowing the gate/door frame to sag out of its
desired rectangular shape.
[0007] Accordingly, metal L-brackets, wooden brace members,
triangular pieces of plywood, and the like are often fastened to
the adjacent ends of the support members to strengthen the inside
corners of the gate/door frame. In other situations, a wire is
placed in tension between the upper proximal and lower distal
corners of the gate/door frame to support the lower distal corner
of the gate frame and thereby reduce sagging of the gate or door.
Such bracing techniques are somewhat effective but the wire is
aesthetically unappealing and can produce frayed ends which are
potentially dangerous. In addition the bracing commonly employs
fasteners that are susceptible to failure and it can be relatively
time consuming to implement.
[0008] Another problem with conventional gate/door building
techniques is that fasteners such as nails or screws are similarly
used to attach the hinge assemblies to the vertical support member
adjacent to the structural member. The loads are transferred to the
gate/door through the screws placed in tension. As the wood shrinks
and the gate/door is opened and closed, the fasteners under tension
tend to loosen and may eventually fail.
[0009] As the hinge fasteners loosen, the entire gate/door assembly
may sag relative to the hinge assemblies and the structural
members, even if the gate/door frame maintains its rectangular
shape. The use of braces at the corners of the gate/door frame will
worsen sagging at the hinges because the materials and hardware
used for bracing increase the weight of the gate/door; this
increased weight increases the forces of gravity on the fasteners
used to attach the hinge assemblies to the proximal vertical
support member.
[0010] Various solutions have been proposed. One attempt was a
steel gate frame product comprising distal and proximal brace
members, with hinges being attached to the proximal brace member. A
gate assembly constructed using this product would use upper and
lower horizontal wooden support members, but would not use vertical
support members. Instead, the distal and proximal brace members
would form the structure of the vertical sides of the gate. The
product required a plurality of sizes, with each size corresponding
to a given distance between the upper and lower horizontal support
members. The finished gate has excessive flex along the vertical
plane of the gate. This flexing can cause the gate to twist making
installation difficult. Exposed metal bracing are subject to rust
and are aesthetically unattractive.
[0011] Another proposed solution was a set of four metal brackets
as shown in Canadian Industrial Design Registration No. 83049 and
83050. These registrations describe a bracket system for forming
gate assemblies. Four separate brace members are provided, and two
of the brace members are rigidly attached to hinge assemblies. The
brace members are adapted to be attached to support members to form
the corners of a gate frame functioning as the structural portion
of the gate assembly. The hinge assemblies are adapted to be
rigidly attached to a fence post to allow the gate assembly to
pivot relative to the fence post. Gate assemblies of arbitrary
height and width can be formed using this bracket system although
wooden members must be trimmed to accommodate weld filets of the
brackets. As there is no direct connection between the horizontal
and vertical wooden support members they can over time twist and
warp independently of each other. While the finished gate is
extremely rigid, light weight and flex resistant, exposed metal
bracing and parts are subject to rust and are unattractive. Costs
of manufacture, quality control at welded connections and shipping
costs are additional problems associated with this product.
[0012] From the foregoing, it should be clear that one object of
the present invention is to develop a method and frame for making a
gate or door that is easy and inexpensive to use, and which allow
significant flexibility in the final design of the gate or door
assembly.
SUMMARY OF THE INVENTION
[0013] It is an object of the invention to provide a frame for
making a gate or door that is extremely rigid, light weight, flex
resistant and with a minimum of exposed metal bracing and
parts.
[0014] A further object of the present invention is to provide a
frame for making a gate or door with improved method of securing
the hinges to the frame.
[0015] Thus in accordance with the present invention there is
provided a frame assembly for making a gate or door comprising an
upper horizontal member, a lower horizontal member, a first
vertical member and a second vertical member, one or more support
members provided along the length of each of the upper and lower
horizontal members, first connection means to connect an upper end
of the first vertical to one end of support member provided along
the length of the upper horizontal member, second connection means
to connect lower end of the first vertical to one end of support
member provided along the length of the lower horizontal member,
third connection means to connect an upper end of the second
vertical to a second end of support member provided along the
length of the upper horizontal member and fourth connection means
to connect a lower end of the second vertical to a second end of
support member provided along the length of the lower horizontal
member.
[0016] Further features of the invention will be described or will
become apparent in the course of the following detailed
description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Preferred embodiments of the invention are shown in the
drawings, wherein:
[0018] FIG. 1 is a perspective view of an assembly drawing for a
frame assembly for making a gate or door in accordance with the
present invention.
[0019] FIG. 2 is a front plan view of the horizontal and vertical
members of the frame assembly of FIG. 1.
[0020] FIG. 3 is an enlarged view of a hinge attachment detail of
the frame assembly of FIG. 1.
[0021] FIG. 4 is an enlarged perspective view of a portion of a
horizontal member of FIG. 3 with a groove to accept a support
rod.
[0022] FIG. 5 is an end plan view of the horizontal member of FIG.
4 with the support rod inserted.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] With reference to FIG. 1, one embodiment of a frame assembly
for making a gate or door in accordance with the present invention
is generally indicated at 1. The frame assembly comprises an upper
horizontal member 2, a lower horizontal member 3, a first vertical
member 4 and a second vertical member 5. In the preferred
embodiment illustrated when assembled, the horizontal 2, 3 and
vertical 4, 5 members form a rectangular frame.
[0024] One or more support members are provided along the length of
each of the upper and lower horizontal members to strengthen the
resulting frame and prevent sagging. In the embodiment shown
support rod 6 is provided along the length of the upper horizontal
member 2. In the embodiment shown (see FIGS. 2, 4 and 5), provision
is made for one support rod, provided it has sufficient cross
section to provide the strength required to support the frame
assembly. The support rod 6 preferably is a steel rod with a cross
section of at least 1/4 inch. In order to connect the support rod 6
to the upper horizontal member 2 so that it is strengthened against
sagging by support rod 6, a longitudinal hole or bore 7 is provided
along the length of the upper horizontal member 2. The hole or bore
7 can be drilled or provided in some other manner. In the
embodiment shown, hole or bore 7 is formed by making a groove 8
half the thickness of the upper horizontal member 2 in the face 9
of upper horizontal member 2 along its length. In the embodiment
shown the upper and lower horizontal members 2, 3 have nominal
dimensions of 1.5.times.3.5.times.48 inches. Groove 8 is {fraction
(5/16)} inches wide by 3/4 inches deep. A filler strip 10 is placed
into the mouth 11 of groove 8 to form hole or bore 7. In the
example shown filler strip 10 is {fraction (5/16)} inches wide by
{fraction (3/8)} inches deep. Hole or bore 7 is sized and shaped to
permit support rod 6 to pass through it. In the embodiment shown
support rod 6 is a threaded {fraction (5/16)} inch steel rod.
[0025] Other materials and dimensions for the support member are
possible so long as it provides the necessary support to the frame
assembly. The support member could be a thin flat section inserted
in saw curfs in the horizontal and vertical members. Another
alternative is the use of U-shaped metal inserts or tubes that act
as a receiver for a threaded rod or bolt used to attach the
hinge.
[0026] The lower horizontal member 3 is similarly provided with a
support rod 12.
[0027] Connection means are provided to connect the upper and lower
ends of the first and second vertical members to opposite ends of
the support members provided along the length of the upper and
lower horizontal members.
[0028] In the embodiment shown, each of the first and second
vertical members 4, 5 are provided with a plurality of horizontal
holes. The upper end 13 of vertical member 4 is provided with at
least one horizontal hole 14 sized and located to permit support
rod 6 to pass through. If a second support rod is provided in upper
horizontal member 2, a second horizontal hole can be located in the
upper end 13 of vertical member 4 to permit the second rod to pass
through. The upper end 15 of vertical member 5 is similarly
provided with at least one horizontal hole 16 sized and located to
permit support rod 6 to pass through. If a second support rod is
provided in upper horizontal member 2, a second horizontal hole can
be located in the upper end 15 of vertical member 5 to permit the
second rod to pass through.
[0029] The lower end 17 of the vertical member 4 is provided with
at least one horizontal hole 18 sized and located to permit support
rod 12 to pass through. In the preferred embodiment a plurality of
horizontal holes 18 are provided in the lower end 17 at six inch
intervals to permit the length of vertical member 4 to be adjusted
to accommodate different sizes of frame assembly. Similarly the
lower end 19 of vertical member 5 is provided with at least one
horizontal hole 20 sized and located to permit support rod 12 to
pass through. In the preferred embodiment a plurality of horizontal
holes 20 are provided in the lower end 19 at six inch intervals to
permit the length of vertical member 5 to be adjusted to
accommodate different sizes of frame assembly. In the embodiment
shown the first and second vertical members 4, 5 have nominal
dimensions of 1.5.times.3.5.times.72 inches before being cut to fit
the opening.
[0030] In order to assemble the frame assembly 1 for making a gate
or door in accordance with the present invention, support rods 6
and 12 are removed from the upper and lower horizontal members 2,
3. The upper and lower horizontal members 2, 3 are cut to the
desired length based on the width of the desired gate or door.
Usually the width of the opening is measured ("rough opening") and
the width of the finished frame assembly is calculated at one inch
narrower than the rough opening. The length of the horizontal
support member 2, 3 and the width of the two vertical support
members 4, 5 should equal one inch narrower than the rough opening.
For example, where the vertical support members are made from
2.times.4 lumber having nominal dimensions of 1.5.times.3.5 inches,
the horizontal support members 2, 3 are cut eight inches narrower
than the rough opening. Similarly the first and second vertical
support members 4, 5 are cut to the desired length based on the
height of the desired gate or door. Typically this desired height
is height of the fence or door opening less clearance required at
the bottom to permit the gate or door to open and close. The
vertical support members, as noted, are preferably predrilled with
horizontal holes at six inch intervals to accommodate various sizes
of gates. In the preferred embodiment the frame assembly is
designed to build gates or doors from three feet to six feet high,
the normal maximum required. Anything shorter than three feet
typically does not require the added strength provided by the
present invention. If a gate of a height does not meet the
predrilled holes, for example a gate fifty two inches high, the
verticals can be cut using the holes drilled at forty-eight inches
and the fence boards can hang down below the lower horizontal
support member.
[0031] Support rod 6 is inserted through the hole 14 in the upper
end of vertical member 4, through the hole or bore 7 in upper
horizontal member 2 and hole 16 in the upper end of vertical member
5. Support rod 12 is inserted through the hole 18 in the lower end
of vertical member 4, through the hole or bore 7 in lower
horizontal member 3 and hole 20 in the lower end of vertical member
5. Hinges 21, 22 are connected to one end 23, 24 of support rods 6
and 12 respectively. The end 23 of support rod 6 extending through
vertical member 4 passes through a first hole 25 in hinge 21. A
threaded insert nut 26 or other suitable means can be used to
fasten hinge 21 to the outer side 27 of the upper end 13 of
vertical member 4. If two support rods are used with the upper
horizontal member, the end of the second support rod would pass
through a second hole 28 on hinge 21 and be secured by a threaded
insert nut or other suitable means. Where only one support rod 6 is
utilized, as shown in FIG. 3, a lag screw 29 or other suitable
fastener can be screwed through the second hole 28 in hinge 21 into
the outer side 27 of the upper end 13 of vertical member 4 and into
the end of the upper horizontal member 2. A pilot hole 37 in the
vertical member 4 can be predrilled.
[0032] The other end 31 of support rod 6 extending through vertical
member 5 is secured with a threaded end cap fastener and tightened
to snug the vertical members 4, 5 to the upper horizontal member 2.
If two support rods are used with the upper horizontal member, the
end of the second support rod would pass through a second hole in
vertical member 4 and be secured by a threaded end cap fastener or
other suitable means. Where only one support rod 6 is utilized a
lag screw or other suitable fastener can be screwed through the
vertical member 4 into the end of horizontal member 2.
[0033] The end 24 of support rod 12 extending through vertical
member 5 passes through a first hole 30 in hinge 22. A threaded
insert nut 40 or other suitable means can be used to fasten hinge
22 to the outer side 32 of the lower end 19 of vertical member 4.
If two support rods are used with the upper horizontal member, the
end of the second support rod would pass through a second hole 33
on hinge 22 and be secured by a threaded insert nut or other
suitable means. Where only one support rod 12 is utilized, as shown
in FIG. 3 with respect to hinge 21, a lag screw 36 or other
suitable fastener can be screwed through the second hole in hinge
22 into the outer side 32 of the lower end 19 of vertical member 4
and into the end of the lower horizontal member 3. A pilot hole 38
can be predrilled in vertical member 5 to accommodate the lag screw
36. Hinges 21, 22 in the embodiment illustrated are standard
4.times.4 butt hinges.
[0034] The other end 34 of support rod 12 extending through
vertical member 5 is secured with a threaded end cap fastener and
tightened to snug the vertical members 4, 5 to the lower horizontal
member 3. If two support rods are used with the lower horizontal
member 3, the end of the second support rod would pass through a
second hole in vertical member 5 and be secured by a threaded end
cap or other suitable means. Where only one support rod 12 is
utilized a lag screw or other suitable fastener can be screwed
through the vertical member 5 into the end of lower horizontal
member 3.
[0035] The end 23, 24 of support rods 6 and 12 can be threaded
through the threaded insert nuts 26, 40 and when the hinges and
frame are secured, the ends 23, 24 of support rods 6 and 12
projecting beyond the threaded insert nuts can be cut off.
[0036] The hinges can be attached to a fixed structural member such
as a fence post or doorjamb. The hinges can be located to have the
gate swing in or out and a left or right opening gate or door.
[0037] Once the frame assembly is complete fence boards or facing
material can be fastened to one or both sides of the frame assembly
to complete the gate or door. Braces 35 can optionally be provided,
if desired, in the inside corners of the assembled frame assembly 1
to provide additional rigidity.
[0038] The frame assembly is preferably provided as a complete kit
to build a gate frame or door frame including all hardware and
structural members. One kit can build any normal sized gate or
door. The present invention does not depend on steel brackets to
provide strength but rather the support rods that run through the
structural members and used to tie the whole frame assembly
together. The present invention provides an extremely strong gate
or door with no exposed steel parts to rust or corrode other than
the hinges.
[0039] The design of the present invention is easier to use than
the prior art bracket systems and builds a superior gate that will
not twist or warp as is common due to the use of fencing lumber
which is green (not kiln dried). The present invention can be used
with horizontal and vertical members of different sizes and
materials (including composite materials) without departing from
the scope of the present invention.
[0040] In addition to garden or fence gates the present invention
can be used to build odd sized doors for garden and storage sheds,
cold cellars, basements, storage lockers or other applications that
require a custom size of door.
[0041] Although various preferred embodiments of the present
invention have been described herein in detail, it will be
appreciated by those skilled in the art, that variations may be
made thereto without departing from the spirit of the invention or
the scope of the appended claims.
* * * * *