U.S. patent application number 14/930715 was filed with the patent office on 2016-05-19 for jamb installation device and method.
The applicant listed for this patent is Therma-Tru Corp.. Invention is credited to Scott B. Eis, Seth Gillen, Thomas A. Topp, Caleb A. Ziebold.
Application Number | 20160138276 14/930715 |
Document ID | / |
Family ID | 51520906 |
Filed Date | 2016-05-19 |
United States Patent
Application |
20160138276 |
Kind Code |
A1 |
Eis; Scott B. ; et
al. |
May 19, 2016 |
JAMB INSTALLATION DEVICE AND METHOD
Abstract
Provided herein are devices for installing jamb assemblies and
like structures within a rough opening. In certain embodiments, the
installation device comprises a guide portion attached to a jamb
assembly and a spacer portion operatively connected to the guide
portion and configured to selectively move relative to the guide
portion to provide adjustment of the jamb assembly relative to the
rough opening.
Inventors: |
Eis; Scott B.; (Holgate,
OH) ; Gillen; Seth; (Hamilton, IN) ; Topp;
Thomas A.; (Albion, IN) ; Ziebold; Caleb A.;
(Defiance, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Therma-Tru Corp. |
Maumee |
OH |
US |
|
|
Family ID: |
51520906 |
Appl. No.: |
14/930715 |
Filed: |
November 3, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14212558 |
Mar 14, 2014 |
9194170 |
|
|
14930715 |
|
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|
61788806 |
Mar 15, 2013 |
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Current U.S.
Class: |
52/745.15 ;
33/194 |
Current CPC
Class: |
E06B 1/603 20130101;
E04F 21/0015 20130101; E06B 1/6053 20130101; E04F 21/003 20130101;
G01B 5/25 20130101; E06B 1/6076 20130101 |
International
Class: |
E04F 21/00 20060101
E04F021/00; G01B 5/25 20060101 G01B005/25 |
Claims
1. A method for aligning and securing a jamb assembly within a
rough opening, the method comprising the steps of: positioning a
threaded guide at a rough opening end of a clearance hole disposed
in a jamb assembly; aligning the jamb assembly within a rough
opening; and extending a spacer at least partially through the
threaded guide and into contact with the rough opening wherein the
threaded guide has a threaded inner surface and the spacer has a
threaded outer surface, and wherein the threaded outer surface of
the spacer engages the threaded guide when extended
therethrough.
2. The method of claim 1 further comprising providing the clearance
hole in the jamb assembly, the clearance hole extending through a
thickness of a jamb of the jamb assembly.
3. The method of claim 1 further comprising extending a fastener
through the spacer and into a framing member of the rough
opening.
4. The method of claim 1, wherein the threaded guide is positioned
within the clearance hole.
5. (canceled)
6. The method of claim 1, wherein the clearance hole is provided on
a vertical portion of the jamb assembly and in proximity to a
corner of the jamb assembly.
7. The method of claim 1, wherein an end of the spacer is adapted
to prohibit an entire length of a fastener from extending through
the spacer.
8. A device for aligning and securing a jamb assembly within a
rough opening, the device comprising: a threaded guide comprising a
hollow open ended cylinder with a threaded inner surface; and a
spacer comprising a hollow open ended cylinder with a threaded
outer surface adapted to engage the threaded inner surface of the
threaded guide when extended therethrough.
9. The device of claim 8, wherein the threaded guide comprises an
outer surface adapted to resist rotation of the threaded guide when
positioned in a jamb assembly.
10. The device of claim 8, wherein the inner surface of the spacer
is adapted to allow a length of a fastener to extend
therethrough.
11. The device of claim 10, wherein an end of the spacer is adapted
to prohibit an entire length of a fastener from extending through
the spacer.
12-20. (canceled)
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a U.S. Non-Provisional Patent
Application which claims priority to U.S. Provisional Patent
Application No. 61/788,806, filed on Mar. 15, 2013 and titled "Door
Installation Hardware," which is hereby incorporated by reference
in its entirety
TECHNICAL FIELD
[0002] The present application is in the field of construction, and
more particularly in the field of devices for adjusting and
aligning a jamb assembly within a structural opening and/or with
another jamb assembly.
BACKGROUND
[0003] Pre-hung windows and doors are conventionally installed via
a "shim and fastener" methodology. Generally, in operation, this
process involves placing the jamb assembly (including the window or
door frame) within the rough opening in the structure, then
adjusting the jamb assembly within the opening so that the jamb
assembly is plum, level, and aligned with walls of the building by
inserting a series of shims at various points around the frame.
This is performed iteratively at several points until the user is
satisfied with the alignment. Once aligned and plum, the user then
drives a fastener through the shims, and into a framing member
(stud) that makes up the rough opening. The fastener holds the
shims in place and secures the window or door within the opening.
The user then trims the shims so that they do not protrude from the
wall and provides a finish over the remainder of the rough opening.
However, this conventional method can be time consuming and not
particularly user-friendly for the non-professional. Further, due
to heat-cold cycling and changes in humidity and weather throughout
the year, structures distort over time. This distortion can affect
the alignment of, for example, a door relative to the remainder of
the structure, preventing the door from operating smoothly. Should
a window or door that was installed using the "shim and fastener"
method become misaligned, it generally cannot be realigned without
essentially starting the entire alignment process over from the
start.
SUMMARY
[0004] Provided herein are devices, systems and methods for
installing jamb assemblies and like structures within a rough
opening. By the use of these devices and systems, a door jamb can
be adjusted until it is in square, plumb, and aligned with a
structural opening.
[0005] In certain embodiments, a jamb assembly installation device
comprises a guide portion attached to a jamb assembly and a spacer
portion operatively connected to the guide portion and configured
to selectively move relative to the guide portion to provide
adjustment of an outside facing surface of the jamb assembly in a
direction away from a rough opening.
[0006] In certain embodiments, a jamb assembly installation device
comprises a first and second adjustment portion. The first
adjustment portion comprises a first guide attached to a jamb
assembly and a spacer operatively connected to the first guide and
configured to selectively move relative to the first guide to
provide adjustment of the jamb assembly in a first direction
relative to a rough opening. The second adjustment portion
comprises a second guide configured to engage a member extending
from the jamb assembly to move the jamb assembly in a second
direction relative to the rough opening while still permitting
movement of the jamb assembly in a first direction relative to the
rough opening. The second adjustment portion comprises an
adjustment member attached to the rough opening that is operatively
connected to the second guide and configured to selectively move
the second guide in the second direction relative to the rough
opening.
[0007] In certain embodiments, the installation device comprises a
threaded guide and a spacer configured to selectively move relative
to the threaded guide to adjust the jamb assembly relative to the
rough opening. The threaded guide generally has a hollow open ended
cylinder with a threaded inner surface. The spacer generally has a
hollow open ended cylinder with a threaded outer surface adapted to
engage the threaded inner surface of the threaded guide when
extended therethrough.
[0008] In certain embodiments, the installation device comprises a
jamb bracket attached to the jamb assembly and a frame bracket
attached to the rough opening. The jamb and frame brackets are
configured to selectively move the jamb assembly relative to the
rough opening. The jamb bracket generally comprises a mating
element, a jamb contact member, and a threaded guide adapted to
receive a spacer therethrough. The spacer comprises an open ended
hollow cylinder with a threaded outer surface. The frame bracket
generally comprises a base member, a threaded member, at least one
threaded member retainer extending from the base member, a
traversing member having a threaded inner surface adapted to
threadably engage the threaded member, and a mating tab adapted for
mating with the mating element of the jamb bracket. The threaded
member is configured to rotate about a traversing member path. The
traversing member moves along the traversing member path as the
threaded member rotates.
[0009] In certain embodiments, the method for aligning and securing
a jamb assembly within a rough opening comprises positioning a
threaded guide at a rough opening end of a clearance hole disposed
in a jamb assembly. The jamb assembly is aligned within a rough
opening and a spacer is extended at least partially through the
threaded guide and into contact with the rough opening. The method
may include providing the clearance hole in the jamb assembly and
extending a fastener through the spacer and into a framing member
of the rough opening.
[0010] These and additional embodiments will become apparent in the
course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the accompanying drawings which are incorporated in and
constitute a part of the specification, embodiments of the
invention are illustrated, which, together with a general
description of the invention given above, and the detailed
description given below, serve to example the principles of the
inventions.
[0012] FIG. 1A shows a front view of a jamb assembly (including a
door) positioned within a rough opening of a structure.
[0013] FIG. 1B schematically illustrates a jamb installation device
according to an embodiment of the present application.
[0014] FIG. 1C schematically illustrates a top plan cross-sectional
view of a jamb installation device according to an embodiment of
the present application.
[0015] FIG. 1D schematically illustrates a top plan cross-sectional
view of a jamb installation device according to an embodiment of
the present application.
[0016] FIG. 2 shows a perspective view of a section of a jamb
assembly positioned in a rough opening of a structure according to
an exemplary embodiment.
[0017] FIG. 3 shows a cross-sectional view of the embodiment shown
in FIG. 2 with an exemplary embodiment of an installation device
for aligning and securing a jamb assembly positioned in the jamb
assembly.
[0018] FIG. 4 shows a further view of the section shown in FIG. 3,
wherein a spacer of the installation device has been threaded to
engage a surface of a framing member.
[0019] FIG. 5 shows a further view of the embodiment shown in FIG.
4, wherein a fastener is positioned to secure the jamb assembly to
the framing member of the rough opening.
[0020] FIG. 6 shows a perspective view of the embodiment shown in
FIG. 5.
[0021] FIG. 7 shows a further view of the embodiment shown in FIG.
5, wherein the fastener is extended through the spacer aligning and
securing the jamb assembly in the rough opening.
[0022] FIG. 8 shows a perspective view of the embodiment shown in
FIG. 7.
[0023] FIG. 9 shows a perspective view of back to back jamb
assemblies according to an exemplary embodiment, wherein a
clearance hole is provided in one of the jamb assemblies.
[0024] FIG. 10 shows a cross-sectional view of the back-to-back
jamb assembly of FIG. 9 with an exemplary embodiment of an
installation device for aligning and securing a jamb assembly
positioned in the clearance hole.
[0025] FIG. 11 shows a further view of the section shown in FIG.
10, wherein a spacer of the exemplary installation device has been
extended through a threaded guide and into contact with a secondary
jamb assembly.
[0026] FIG. 12 shows a further view of the embodiment shown in FIG.
11, wherein a fastener has been extended through the spacer and
into the secondary jamb assembly.
[0027] FIG. 13 shows a perspective view of an embodiment shown in
FIG. 12.
[0028] FIG. 14 shows a perspective view of a portion of a jamb
assembly, the jamb assembly having a clearance hole provided
through a thickness thereof
[0029] FIG. 15 shows a perspective view of a portion of a jamb
assembly with a jamb bracket positioned thereon according to an
exemplary embodiment of an installation device for aligning and
securing a jamb assembly.
[0030] FIG. 16 shows another perspective view of the embodiment
shown in FIG. 15 according to an exemplary embodiment of an
installation device for aligning and securing a jamb assembly.
[0031] FIG. 17 shows a perspective view of a portion of a rough
opening with a frame bracket positioned thereon according to an
exemplary embodiment of an installation device for aligning and
securing a jamb assembly.
[0032] FIG. 18 shows a close-up perspective view of the frame
bracket shown in FIG. 17 according to an exemplary embodiment of an
installation device for aligning and securing a jamb assembly.
[0033] FIG. 19 shows a perspective view of a portion of a jamb
assembly with a jamb bracket being positioned in proximity to a
portion of a rough opening with a frame bracket according to an
exemplary embodiment of an installation device for aligning and
securing a jamb assembly.
[0034] FIG. 20 shows a top view of the installation device shown in
FIG. 19.
[0035] FIG. 21 shows a perspective view of an exemplary
installation device for aligning and securing a jamb assembly
wherein the frame bracket and the jamb bracket are operationally
engaged via a mating tab and a mating element.
[0036] FIG. 22 shows a close-up perspective view of the embodiment
shown in FIG. 21.
[0037] FIG. 23 shows a cross-sectional view of an exemplary
installation device for aligning and securing a jamb assembly
wherein a frame bracket and a jamb bracket are operationally
engaged via a mating tab and a mating element and a spacer is
extended through a threaded guide.
[0038] FIG. 24 shows a cross-sectional view of the embodiment shown
in FIG. 23, wherein the spacer is extended through the guide and
into contact with a framing member and a fastener is positioned to
secure the jamb assembly to the framing member.
[0039] FIG. 25 shows a cross-sectional view of the embodiment shown
in FIG. 24, wherein the fastener is extended through the spacer and
into the framing member.
[0040] FIG. 26 shows a perspective view of a portion of a jamb
assembly with a jamb bracket positioned in proximity to a portion
of a rough opening with a frame bracket according to an exemplary
embodiment of an installation device for aligning and securing a
jamb assembly.
[0041] FIG. 27 shows a perspective view of a portion of a jamb
assembly with a jamb bracket positioned thereon according to an
exemplary embodiment.
[0042] FIG. 28 shows a close-up perspective view of the jamb
bracket shown in FIG. 27.
[0043] FIG. 29 shows a perspective view of a portion of a rough
opening with a frame bracket positioned thereon according to an
exemplary embodiment.
[0044] FIG. 30 shows a close-up perspective view of the frame
bracket shown in FIG. 29.
[0045] FIG. 31 shows a perspective view of a frame bracket
according to an exemplary embodiment showing an optional mating tab
retaining slot positioned in the base member.
[0046] FIG. 32 shows a perspective view of the frame bracket shown
in FIG. 31 showing the traversing member and traversing member
path.
[0047] FIG. 33 shows a perspective view of a portion of a jamb
assembly being positioned in proximity to a portion of a rough
opening with brackets according to an exemplary installation device
for aligning and securing a jamb assembly attached respectively
thereto.
[0048] FIG. 34 shows a top view of the portion of the jamb assembly
positioned in proximity to the portion of the rough opening shown
in FIG. 33.
[0049] FIG. 35 shows a top view of an exemplary embodiment of an
installation device for aligning and securing a jamb assembly in a
rough opening, wherein a frame bracket and a jamb bracket of the
installation device are operationally engaged via a mating tab and
a mating element.
[0050] FIG. 36 shows a perspective view of the installation device
shown in FIG. 35 with the jamb assembly and the rough opening
removed for clarity.
[0051] FIG. 37 shows a cross-sectional view of the installation
device shown in FIG. 35 with a spacer extending through a threaded
aperture.
[0052] FIG. 38 shows a further view of the section shown in FIG.
37, wherein the spacer has been extended into contact with the
framing member.
[0053] FIG. 39 shows a further view of the section shown in FIG.
38, where a fastener is extended through the spacer and into a
framing member.
DETAILED DESCRIPTION
[0054] Provided herein are devices and methods for the installation
of jamb assemblies within a structural opening. The installation
devices of the present application may be comprised of any durable
material, including but not limited to metals and plastics.
[0055] While the embodiments disclosed herein are applicable to the
installation of a variety of building features such as windows,
skylights, etc., for the purposes of brevity, the following
description will focus mainly on uses associated with the
installation of doors. The term "jamb assembly" as used herein
refers to a jamb for a door, window, skylight, door and sidelight
combination or other pre-assembled building feature comprised of an
external frame, that requires installation in a wall opening (also
referred to as a rough opening). Further, it should be understood
that when discussing a jamb assembly, the outside facing surface
refers to the perimeter of the jamb assembly that faces the rough
opening, and is opposite the portion of the jamb assembly where the
building feature (i.e., door, window, etc.) will lie. The term
"rough opening" and "structural opening" are used interchangeably
herein, refer to an opening in a wall or other portion of a
structure intended for the framing or attachment (or both) of a
building feature such as a door, window or the like.
[0056] The installation devices of the present application
facilitate alignment and securement of a jamb assembly within a
rough opening. In certain embodiments, the installation device of
the present application provides adjustment of the outside facing
surface of the jamb assembly in a direction toward or away from the
rough opening. Further, the installation device of the present
application may additionally provide adjustment of the outside
facing surface of the jamb assembly in a direction parallel to the
rough opening (i.e., in and out of the rough opening).
[0057] Referring now to the drawings, FIG. 1A illustrates a jamb
assembly 5 positioned in a rough opening 6. Near the four corners
of the jamb assembly 5 are regions 1-4 where devices of the present
application may be installed for adjusting the gap 10 around the
jamb assembly within the rough opening 6. However, it should be
understood that the devices of the present application may be
installed at any location around the jamb assembly 5 to adjust the
gap 10 around the jamb assembly within the rough opening 6.
Further, the devices of the present application may be included
with the jamb assembly as a system.
[0058] FIG. 1B schematically illustrates a top cross sectional view
of an installation device 50 according to an embodiment of the
present application. As shown, the installation device 50 comprises
a guide portion 52 that is attached to the jamb assembly 5 and a
spacer portion 54 that is operatively connected to the guide
portion and configured to selectively move relative to the guide
portion in a direction D.sub.1. As shown, the spacer portion 54
extends from the installation device 50 to contact the rough
opening 6 and move the jamb assembly 5 in a direction D.sub.1
relative to the rough opening. Thus, the installation device 50
provides adjustment of the outside facing surface of the jamb
assembly 5 in a direction toward or away from the rough opening
6.
[0059] Once the jamb assembly 5 is satisfactorily positioned
relative to the rough opening 6, a fastener 56 may be used with the
device 50 to secure the jamb assembly to the rough opening. As
shown, the fastener 56 is moved in a direction D.sub.2 through the
spacer portion 54 and into the rough opening 6 to secure the jamb
assembly 5 to the rough opening. In certain embodiments, the head
of the fastener 56 contacts the spacer portion 54 such that the
jamb assembly 5 is prohibited from moving away from the rough
opening 6. Further, in certain embodiments, the interior surface of
the spacer portion 54 is threaded and configured to mate with a
threaded portion of a fastener to prohibit movement of the jamb
assembly 5 relative to the rough opening 6.
[0060] The guide portion 52 may be attached to the jamb assembly 5
in a variety of different ways. For example, the guide portion 52
may be secured within an opening of the jamb assembly 5 or to a
face of the jamb assembly. Fasteners, such as screws or nails, may
be used to secure the guide portion 52 to the jamb assembly 5. In
certain embodiments, the guide portion 52 is press fit into an
opening of the jamb assembly 5. Further, the guide portion 52 may
comprise features that prohibit the guide portion from moving
relative to the jamb assembly 5. For example, the outer surface of
the guide portion 52 may be threaded or the comprise features, such
as ridges or barbs, that prohibit movement of the guide portion
within an opening of the jamb assembly 5. The guide portion 52 may
also be shaped such that it does not rotate with an opening of the
guide portion. For example, the cross sectional shape of the guide
portion 52 may be non-circular, e.g., square, triangle, pentagon,
etc., such that the guide portion does not rotate within an opening
of the jamb assembly 5.
[0061] The installation device 50 may be configured in a variety of
ways to permit selective movement of the spacer portion 54 relative
to the guide portion 52. For example, the portions 52 and 54 may
comprise features that permit selective movement of the spacer
portion relative to the guide portion. These features may include,
for example, a track and guide, ridges and grooves, rack and
pinion, detents, threads, friction fit, or the like. In certain
embodiments, the installation device 50 comprises a threaded guide
portion 52 and a spacer portion 54 configured to selectively move
relative to the threaded guide portion to adjust the jamb assembly
5 relative to the rough opening 6. The threaded guide portion 52
has a hollow open ended cylinder with a threaded inner surface or
inner diameter. The spacer portion 54 has a hollow open ended
cylinder with a threaded outer surface or outer diameter adapted to
engage the threaded inner surface of the threaded guide portion 52
when extended therethrough.
[0062] FIG. 2 shows a portion of the jamb assembly 5 positioned
proximate to a portion of rough opening 6. The rough opening 6
includes framing members 7 and paneling 8. Further, brick molding 9
and/or other trim is positioned on one side of the opening,
obscuring one side of the gap 10 between the rough opening 6 and
the jamb assembly 5. As illustrated in FIG. 2, when utilizing a
device of the present application, the jamb assembly 5 is
positioned in the rough opening 6 and, in certain embodiments, a
clearance hole 11 is provided in the jamb assembly.
[0063] FIGS. 3-8 illustrate a device 100 for installing jamb
assemblies and like structures within a rough opening according to
an embodiment of the present application. By the use of the device
100, a door jamb can be adjusted until it is in square, plumb, and
aligned with a structural opening. As illustrated in FIGS. 3-8, a
threaded guide 110 of the device 100 is placed in the clearance
hole 11. In certain embodiments, the threaded guide 110 is an
open-ended hollow cylinder with a threaded inner diameter. Once the
jamb assembly 5 is positioned within the rough opening 6, a spacer
111 of the device 100 is inserted through the clearance hole 11 and
extends into the threaded guide 110. In certain embodiments, the
spacer 111 has a threaded outer diameter and threadably engages
with the threaded inner diameter of the threaded guide 110. In such
embodiments, the outer diameter of the guide 110 has a profile that
resists rotation within the clearance hole 11, allowing the spacer
111 to be positioned without displacing the threaded guide within
the clearance hole.
[0064] As illustrated in FIGS. 4-8, the spacer 111 is threaded
through the guide 110 and into contact with a framing member 7. In
certain embodiments, the spacer 111 is an open-ended hollow
cylinder with an inner diameter adapted to allow a portion of a
fastener (e.g., a screw or nail) to pass through. The spacer 111
may be configured to prohibit the entire length of the fastener
from passing through the spacer. In certain embodiments, an end of
the spacer 111 is adapted to prevent an entire length of a fastener
from extending through the inner diameter of the spacer. For
example, the end of the spacer 111 that remains within the
clearance hole 11 after the spacer is adjusted into contact with
the framing member 7 may have a diameter that is less than the head
of the fastener. The process of threading the spacer 111 through
the threaded guide 110 is repeated for each device utilized,
generally for the four regions shown in FIG. 1A, until the jamb
assembly 5 is aligned and plumb within the rough opening 6.
[0065] As illustrated in FIGS. 5-8, once the jamb assembly 5 is
satisfactorily aligned, a fastener 199 is utilized to secure the
jamb assembly 5 in position. FIG. 5 is a cross-sectional view
showing the fastener 199 (here a woodscrew) positioned for securing
the jamb assembly 5 to the framing member 7 after the spacer 111
has engaged the framing member. FIG. 6 shows another
cross-sectional view of the fastener 199 in position for securing
the jamb assembly 5. FIG. 7 shows a top cross-sectional view,
wherein the jamb assembly 5 is substantially aligned and plumb
within the rough opening 6 and secured in place with the fastener
199. The fastener 199 extends through the spacer 111 and into the
framing member 7. FIG. 8 shows another cross-sectional view of the
jamb assembly 5 secured to the framing member 7 by the fastener 199
that extends through the spacer 111 and into the framing member
7.
[0066] FIG. 9 is a perspective view of a back-to-back jamb assembly
for use when, for example, the assembly includes double doors
(e.g., French doors) that are attached together, or doors with a
sidelight attached. In such embodiments, the gap 10 that is
adjusted is between jambs 5 and 15, rather than between a jamb and
a rough opening. In FIG. 9, a clearance hole 11 has been made in
the jamb assembly 5 for aligning it with the secondary jamb
assembly 15. Further, a mull cap 12 is positioned at either end of
the gap 10 between the jambs 5 and 15.
[0067] FIGS. 10-13 illustrate a device 200 for installing and
adjusting back-to-back jamb assemblies. FIG. 10 shows a top view of
a cross-section of the back-to-back jamb assemblies shown in FIG.
9. As shown, a threaded guide 210 of the device 200 is positioned
within the clearance hole 11 and a spacer 211 is extended through
the inner diameter of the threaded guide. In certain embodiments,
the threaded guide 210 is an open-ended hollow cylinder with a
threaded inner diameter. The outer diameter of the threaded guide
210 may have a cross-sectional profile such that it is resistant to
rotation once it is positioned within the clearance hole 11.
[0068] In certain embodiments, the spacer 211 of the device 200 is
an open-ended hollow cylinder with a threaded outer diameter and an
inner diameter adapted to allow a portion of a fastener (e.g., a
screw or nail) to pass through. The spacer 211 may be configured to
prohibit the entire length of the fastener from passing through the
spacer. In certain embodiments, an end of the spacer 211 may be
adapted to prevent an entire length of a fastener from extending
through the inner diameter of the spacer. For example, the end of
the spacer 211 that remains within the clearance hole 11 after the
spacer is adjusted into contact with the secondary jamb assembly 15
may have a diameter that is less than the head of the fastener.
[0069] When the spacer 211 has a threaded outer diameter, the
spacer threadably engages with the inner diameter of threaded guide
210 when extended therethrough. FIG. 11 shows an embodiment where
the spacer 211 is extended through the threaded guide 210 and into
contact with the secondary jamb 15. The process of extending the
spacer 211 through the respective threaded guides 210 is repeated
for each device utilized to align the jamb and the secondary jamb
assembly. FIGS. 12 and 13 shows the device with a fastener 199
extended through the threaded guide 210 and the spacer 211 and
securing the jamb assembly 5 to the secondary jamb assembly 15.
[0070] FIG. 1C schematically illustrates a top cross sectional view
of an installation device 60 according to an embodiment of the
present application. Similar to the installation device 50 shown in
FIG. 1B, the installation device 60 comprises a first adjustment
portion 62 that facilitates movement of the jamb assembly 5 in a
direction D.sub.1 relative to the rough opening 6. The first
adjustment portion 62 comprises a guide 64 that is attached to the
jamb assembly 5 and a spacer 66 that is operatively connected to
the guide and configured to selectively move relative to the guide
in a direction D.sub.1. The spacer 66 extends from the installation
device 60 to contact the rough opening 6 and move the jamb assembly
5 in a direction D.sub.1 relative to the rough opening.
[0071] Further, the installation device 60 comprises a second
adjustment portion 68 that facilitates movement of the jamb
assembly 5 in a direction D.sub.3 relative to the rough opening 6.
As shown, the second adjustment portion 68 comprises a guide 70
that engages a member 72 extending from the jamb assembly 5 to move
the jamb assembly in a direction D.sub.3 relative to the rough
opening 6 while still permitting movement of the jamb assembly in
the direction D.sub.1 relative to the rough opening. Further, the
second adjustment portion 68 comprises an adjustment member 74
attached to the rough opening 6 that is operatively connected to
the guide 70 and configured to selectively move the guide in a
direction D.sub.3 relative to the rough opening. As such, movement
of the guide 70 relative to the adjustment member 74 moves the jamb
assembly 5 in a direction D.sub.3 relative to the rough opening 6.
Thus, the installation device 60 provides adjustment of the outside
facing surface of the jamb assembly 5 in a direction toward or away
from the rough opening 6 and also provides adjustment of the
outside facing surface of the jamb assembly in a direction parallel
to the rough opening (i.e., in and out of the rough opening).
[0072] The guide 70 of the second adjustment portion 68 may be
configured to engage the member 72 extending from the jamb assembly
5 in a variety of different ways. For example, the guide 70 may
comprise an extension that mates with or is received in an
aperture, such as a slot, of the member 72 such that the member
moves in the direction D.sub.3 when the guide is selectively moved
relative to the adjustment member 74. Further, an extension of the
guide 70 may comprise an opening, such as a slot, that engages the
member 72 extending from the jamb assembly 5 such that the member
moves in the direction D.sub.3 when the guide is selectively moved
relative to the adjustment member 74.
[0073] The second adjustment portion 68 may be configured in a
variety of ways to permit selective movement of the guide 70
relative to the adjustment member 74. For example, the adjustment
member 74 and guide 70 may comprise features that permit selective
movement of the guide relative to the adjustment member. These
features may include, for example, a track and guide, ridges and
grooves, rack and pinion, detents, threads, friction fit, or the
like. In certain embodiments, the installation device 60 comprises
a jamb bracket attached to the jamb assembly and a frame bracket
attached to the rough opening. The jamb bracket comprises a mating
element and the frame bracket comprises a base member, a threaded
adjustment member, at least one threaded adjustment member retainer
extending from the base member, a traversing guide member having a
threaded inner diameter adapted to threadably engage the threaded
adjustment member, and a mating tab extending from the traversing
guide member and adapted for mating with the mating element of the
jamb bracket. Movement of the traversing guide member relative to
the threaded adjustment member in the direction D.sub.3 moves the
mating element and, in turn, the jamb assembly in the direction
D.sub.3.
[0074] Once the jamb assembly 5 is satisfactorily positioned
relative to the rough opening 6, a fastener 78 may be used with the
device 60 to secure the jamb assembly to the rough opening. As
shown in FIG. 1C, the fastener 78 is moved in a direction D.sub.2
through the spacer 66 and into the rough opening 6 to secure the
jamb assembly 5 to the rough opening. In certain embodiments, the
head of the fastener 78 contacts the spacer 66 such that the jamb
assembly 5 is prohibited from moving away from the rough opening 6.
Further, in certain embodiments, the interior surface of the spacer
66 is threaded and configured to mate with a threaded portion of a
fastener to prohibit movement of the jamb assembly 5 relative to
the rough opening 6.
[0075] FIG. 1D is a top cross sectional view schematically
illustrating another embodiment of an installation device 80
similar to installation device 60. The first adjustment portion of
the device 80 is the same as the first adjustment portion 62 of the
device 60. However, the second adjustment portion 82 of the device
80 comprises a guide 84 that engages a portion of the rough opening
6 such that it is prohibited from moving in a direction D.sub.3
relative to the rough opening but still permits movement of the
jamb assembly 5 in directions D.sub.1 and D.sub.3 relative to the
rough opening. Further, the second adjustment portion 82 comprises
an adjustment member 86 attached to the jamb assembly 5 that is
operatively connected to the guide 84 and configured to selectively
move relative to the guide in a direction D.sub.3. As such,
movement of the adjustment member 86 relative to the guide 84 moves
the jamb assembly 5 in a direction D.sub.3 relative to the rough
opening 6.
[0076] FIG. 14 shows a perspective view of a portion of a jamb
assembly 5, with a clearance hole 11 extending therethrough. FIG.
15 shows a similar portion of a jamb assembly 5 from another
viewpoint, with a jamb bracket 305 according to an exemplary
installation device 300. The jamb bracket 305 comprises a threaded
guide 310, a jamb contact member 315 (here secured to the jamb by
fasteners) and a mating element 316. Here the guide 310 is shown
integral to the jamb bracket 305 on a portion of the jamb contact
member 315. The mating element 316 is shown extending from the jamb
contact member 315.
[0077] FIG. 16 shows another view of the installation device 300
shown in FIG. 15 further including a spacer 311 extending through
the threaded guide 310. In certain embodiments, the spacer 311 is
an open-ended hollow cylinder with a threaded outer surface or
diameter and an inner surface or diameter adapted to allow a
portion of a fastener such as a woodscrew to pass through, but not
the entire length of the fastener, e.g., an end of the spacer may
be adapted to prevent an entire length of the fastener from
extending through the inner diameter of the spacer. When the spacer
311 has a threaded outer diameter, the spacer threadably engages
with the inner surface or diameter of the threaded guide when
extended therethrough.
[0078] FIG. 17 shows a frame bracket 320 of the device 300 for
aligning and securing the jamb assembly 5 shown in FIGS. 14-16. As
shown, the frame bracket 320 engages a framing member 7 of a rough
opening. FIG. 18 is a closer view of the frame bracket 320 shown in
FIG. 17. The frame bracket 320 comprises a base member 321 (shown
here in contact with a framing member of the rough opening), an
optional frame alignment flange 322 extending away from the base
member and engaging a surface of a panel (shown here extending from
the base member at substantially a right angle), a first threaded
member retainer 323, and a second threaded member retainer 324. In
certain embodiments, such as that shown in FIG. 18, the threaded
member retainers 323 and 324 extend from the base member 321 at
substantially right angles. The distance or axis between the first
threaded member retainer 323 and the second threaded member
retainer 324 defines a traversing member path 350. As shown in FIG.
18, the longitudinal axes of the openings in the first threaded
member retainer 323 and the second threaded member retainer form
the traversing member path 350. The frame bracket 320 further
includes a threaded member 325 extending between and retained by
the first and second threaded member retainers 323 and 324. The
threaded member 325 comprises a threaded outer surface or diameter
along the traversing member path 350. As the arrow R indicates, the
threaded member 325 may rotate within the first and second threaded
member retainers 323 and 324.
[0079] The frame bracket 320 also comprises a traversing member
326. In certain embodiments, the traversing member 326 has a
threaded inner surface or diameter. In such embodiments, the
traversing member 326 is threadably engaged with the threaded
member 325, such that rotation of the threaded member causes the
traversing member 326 to traverse along the traversing member path
350 in the direction D.sub.4. The traversing member 326 further
comprises a mating tab 327 extending from an outer surface of the
traversing member, the mating tab adapted to operationally engage
with the mating element 316 of the jamb bracket 305.
[0080] FIG. 19 shows a section of a jamb assembly 5 during
positioning within a rough opening 6. The arrow D.sub.5 indicates
the general direction of positioning, bringing the jamb bracket 305
and the frame bracket 320 of the device 300 into proximity with one
another. FIG. 20 shows another view of the jamb assembly 5 being
positioned within the rough opening 6. FIG. 21 shows the jamb
assembly 5 positioned within the rough opening 6, allowing for the
mating tab 327 of the frame bracket 320 and the mating element 316
of the jamb bracket 305 to operationally engage.
[0081] FIG. 22 is a closer view of the device 300 for aligning and
securing a jamb assembly, wherein the mating tab 327 is
operationally engaged with the mating element 316. As previously
mentioned, rotation of the threaded member 325 causes the
traversing member 326 to traverse along the traversing member path
350. Once the brackets 320 and 305 of the device 300 are
operationally engaged, as shown in FIG. 22, the rotation of the
threaded member 325 causes not only the traversing member 326 to
move, but also the jamb bracket, and correspondingly the jamb
assembly 5 relative to the rough opening 6. Thereby, a user can
adjust the position of the jamb assembly 5 by rotation of the
threaded member 325 once operationally engaged with the mating
element 316 of the jamb bracket 305. Thus, if a user utilizes a
device 300 at each of the corners of a rough opening 6, a jamb
assembly 5 can be adjusted into planar alignment with the rough
opening by adjustment of each threaded member 325.
[0082] FIG. 23 shows another view of the device 300 for aligning
and securing a jamb assembly, wherein the two brackets 305 and 320
are operationally engaged and the threaded guide 310 and the spacer
311 are shown. The arrow D.sub.6 indicates the direction of
movement of the spacer 311 through the threaded guide 310 and into
contact with the framing member 7. The other arrow D.sub.4
indicates the direction of movement of the traversing member 326
along the length of the threaded member 325 caused by the rotation
of the threaded member. These adjustments may be made iteratively
until the jamb assembly 5 is satisfactorily positioned relative to
the rough opening 6.
[0083] FIG. 24 shows the device 300 with the spacer 311 extended
through the threaded guide 310 and into contact with the framing
member 7. Once satisfactorily aligned, the jamb assembly 5 may be
secured to the framing member 7 by a fastener 199. FIG. 25 shows
another view wherein the fastener 199 has been extended through the
spacer 311 and into the framing member 7 to secure the jamb
assembly 5 in alignment with the rough opening 6. As can be seen
from the drawings, in certain embodiments, an end of the spacer 311
is adapted to prevent an entire length of the fastener 199 from
extending through the inner diameter of the spacer.
[0084] FIG. 26 illustrates an installation device 400 for aligning
and securing a jamb assembly. As shown, the installation device 400
is positioned in the gap 10 between a rough opening 6 and a jamb
assembly 5. FIG. 27 shows a portion of a jamb assembly 5 with a
jamb bracket 405 of the device 400 attached thereto. The jamb
bracket 405 comprises a threaded guide 410 with a spacer 411
extending therethrough, a jamb contact member 415 (here secured to
the jamb by fasteners) and a mating element 416. Here the threaded
guide 410 is shown integral to the jamb bracket 405 and on a
portion of the jamb contact member 415.
[0085] FIG. 28 is a close-up view of the jamb bracket 405 shown in
FIG. 27. The jamb bracket 405 comprises a jamb contact member 415,
a mating element 416, and a threaded guide 410 with a spacer 411
extending at least partially therethrough. As shown, the spacer 411
comprises a hollow portion 417 and the mating element 416 comprises
a channel with parallel walls extending outward from the jamb
contact member 415.
[0086] FIG. 29 shows a frame bracket 420 of the installation device
400, the frame bracket engaging a framing member 7 of a rough
opening 6. The frame bracket 420 comprises a base member 421 (shown
here in contact with a framing member 7 of the rough opening 6) and
an optional frame alignment flange 422 extending away from the base
member and engaging a surface of a panel 8 (shown here extending
from the base member at substantially a right angle). FIG. 30 is a
close-up view of a frame bracket 420 shown in FIG. 29. The frame
bracket 420 comprises a first threaded member retainer 423
extending from the base member and a second threaded member
retainer 424 (FIG. 32) opposite the first threaded member retainer.
In certain embodiments, such as that shown in FIG. 30, the first
and second threaded member retainers 423 and 424 extend from base
member 421 at substantially right angles. The distance or axis
between the first threaded member retainer 423 and the second
threaded member retainer 424 define a traversing member path 450.
As shown in FIG. 32, the longitudinal axes of the openings in the
first threaded member retainer 423 and the second threaded member
retainer 424 form the traversing member path 450. The frame bracket
further includes a threaded member 425 extending between and
retained by the first and second threaded member retainers 423 and
424. The threaded member comprising a threaded outer diameter along
the traversing member path. The threaded member 425 comprises a
threaded outer surface or diameter along the traversing member path
450. As the arrow R in FIG. 30 indicates, the threaded member 425
may rotate within the first and second threaded member retainers
423 and 424.
[0087] Further, the frame bracket 420 comprises a traversing member
426. In certain embodiments, the traversing member 426 has a
threaded inner diameter or surface. In such embodiments, the
traversing member 426 is threadably engaged with the threaded
member 425 such that rotation of the threaded member causes the
traversing member 426 to traverse along the traversing member path
450 as shown by the arrow D.sub.6 in FIGS. 30 and 32. The
traversing member 426 further comprises a mating tab 427 extending
from an outer diameter or surface of the traversing member, the
mating tab adapted to operationally engage with the mating element
416 of the jamb bracket 405.
[0088] FIG. 31 shows a perspective view of the frame bracket 420 of
the installation device 400. In FIG. 31, the arrow D.sub.7
indicates that the mating tab 427 may be selectively rotated into,
or out of, an optional mating tab retaining slot 428 in the base
member 421. This rotation may help to facilitate insertion of the
mating tab 427 into the mating element 416 or slot.
[0089] FIG. 32 shows a rear view of the frame bracket 420 of the
installation device 400. The frame bracket 420 comprises a threaded
member retainer 423 and a second threaded member retainer 424. As
shown, the threaded member 425 is disposed between the two threaded
member retainers 423 and 424 with the traversing member 426
threadably engaged with the threaded member. The arrow D.sub.6
indicates the direction of movement of the traversing member 426
along the traversing member path 450 as the threaded member is
rotated between the two threaded member retainers 423 and 424.
[0090] FIGS. 33 and 34 show the jamb assembly 5 in proximity to a
rough opening 6, thereby bringing the mating element 416 of the
jamb bracket 405 into operational engagement with the mating tab
427 of the frame bracket 420. FIG. 35 shows the jamb assembly 5
positioned into the rough opening 6 such that the mating tab 427 is
operationally engaged (mated) with the mating element 416.
[0091] FIG. 36 shows the installation device 400 wherein the jamb
bracket 405 and the frame bracket 420 are positioned in operational
engagement and the rough opening and jamb assembly removed for ease
of viewing. As can be seen from the Figure, the mating tab 427 is
operationally engaged with the mating element 416 and the spacer
411 is also shown extending into a threaded guide (not shown), the
spacer comprising a hollow portion 417 for extension of a fastener
therethrough.
[0092] FIG. 37 shows the jamb assembly 5 positioned within the
rough opening 6 and the jamb bracket 405 and the frame bracket 420
of the device 400 are engaged. The spacer 411 is positioned within
the clearance hole 11. The spacer 411 may be extended through the
threaded guide 410 to align the jamb assembly 5 relative to the
rough opening 6. FIG. 38 shows the spacer 411 extended through the
threaded guide 410 and into contact with the framing member 7. FIG.
39 shows the jamb assembly 5 aligned within the rough opening 6
with a fastener 199 extended through the spacer 411 and into the
framing member 7 of the rough opening. As shown in FIG. 39, the
fastener 199 need not be extended into the clearance hole 11 and
into contact with the end of the spacer 411 to secure the jamb
assembly 5 to the framing member 7.
[0093] The present application discloses exemplary embodiments of
devices for aligning and securing a jamb assembly in a rough
opening. Any of the assemblies, components, or features of the
devices for aligning and securing a jamb assembly in a rough
opening can be reversed. That is, any of the assemblies,
components, or features shown on the rough opening can be moved to
the jamb and any of the assemblies, components, or features shown
on the jamb can be moved to the rough opening.
[0094] The following exemplary method for aligning a jamb assembly
within a rough opening utilizes installations devices such as those
discussed herein. In certain embodiments, four separate individual
devices are positioned on a vertical portion of a jamb assembly and
near separate corners of the jamb assembly. However, it should be
understood that the installation devices may be installed at any
location around the jamb assembly.
[0095] A user may begin the installation and alignment process by
providing a clearance hole in a portion of the jamb assembly where
the installation device is to be used if one does not already
exist, e.g., near each of the four corners. This clearance hole
will later receive an installation device such as those disclosed
herein. Some of the installation devices disclosed herein
facilitate spacing of the door jamb from the rough opening and take
the place of traditional shims. These installation devices
generally only provide adjustment of the outside facing surface of
the jamb assembly in a direction toward or away from the rough
opening (see, e.g., FIGS. 1B and 2-13). Other installation devices
disclosed herein facilitate adjustment of the location of the door
jamb assembly with respect to a vertical plane, in addition to
facilitating spacing of the door jamb from the rough opening. Thus,
these installation devices provide adjustment of the outside facing
surface of the jamb assembly in a direction toward or away from the
rough opening and also provide adjustment of the outside facing
surface of the jamb assembly in a direction parallel to the rough
opening (i.e., in and out of the rough opening) (see, e.g., FIGS.
1C, 1D, and 14-39).
[0096] In regards to the installation devices that permit
adjustment of the door jamb assembly with respect to the vertical
plane (i.e., in and out of the rough opening), the user positions a
jamb bracket on the rough opening side of the jamb assembly about
the clearance hole and aligns the threaded aperture of the jamb
bracket with the clearance hole. The jamb bracket is generally
fastened to the jamb assembly with a fastener. A frame bracket is
positioned on the rough opening, generally using an optional frame
alignment tab, in a location that permits connection of the mating
element and the mating tab of a traversing member when the jamb
assembly is later positioned within the rough opening. The user
generally fastens the frame bracket to the rough opening with a
fastener or the like. This process is repeated until the requisite
number of devices are positioned (e.g., two, three, four, five,
six, etc.). The jamb assembly is positioned within the rough
opening and is rotated until the mating elements and mating tabs of
the respective brackets engage. If necessary, the user may
reposition one or more of the frame brackets or jamb brackets to
facilitate engagement of all of the brackets. The user then plumbs
the jamb assembly within the rough opening by adjusting each
threaded member appropriately (and thus moving the traversing
member and the corresponding jamb member).
[0097] Once adjusted to lie satisfactorily within the vertical
plane of the rough opening, the user will then adjust the gap
between rough opening and the rough opening-facing surface of the
jamb assembly. This is accomplished by extending a spacer through
each clearance hole (and operationally engaging each respective
threaded aperture) until the jamb assembly is aligned vertically
within the rough opening. Once the jamb assembly is aligned, a
fastener is then driven through the hollow portion of each spacer
and into, for example, a framing member of the rough opening to
secure the jamb assembly within the rough opening.
[0098] Although the methods disclosed herein have been described
with a particular order of steps, any one or more of the steps may
be omitted and/or the order of the steps may be changed without
departing from the spirit and the scope of the disclosed methods.
Moreover, any one or more of the steps may be carried out manually
or via an automated process utilizing various equipment known to
those of skill in the art.
[0099] It should be understood that the embodiments discussed above
are representative of aspects of the invention and are provided as
examples and not an exhaustive description of implementations of an
aspect of the invention. As used in the description of the
invention and the appended claims, the singular forms "a," "an,"
and "the" are intended to include the plural forms as well, unless
the context clearly indicates otherwise. In addition, the
recitations of numerical ranges by endpoints include all numbers
subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75,
3, 3.80, 4, 5, etc.).
[0100] To the extent that the term "includes" or "including" is
used in the specification or the claims, it is intended to be
inclusive in a manner similar to the term "comprising" as that term
is interpreted when employed as a transitional word in a claim.
Furthermore, to the extent that the term "or" is employed (e.g., A
or B) it is intended to mean "A or B or both." When the applicants
intend to indicate "only A or B but not both" then the term "only A
or B but not both" will be employed. Thus, use of the term "or"
herein is the inclusive, and not the exclusive use. See Bryan A.
Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995).
Also, to the extent that the terms "in" or "into" are used in the
specification or the claims, it is intended to additionally mean
"on" or "onto."
[0101] As described herein, when one or more components are
described as being connected, joined, affixed, coupled, attached,
or otherwise interconnected, such interconnection may be direct as
between the components or may be indirect such as through the use
of one or more intermediary components. Also as described herein,
reference to a "member," "component," or "portion" shall not be
limited to a single structural member, component, or element but
can include an assembly of components, members or elements.
[0102] While the present invention has been illustrated by the
description of embodiments thereof, and while the embodiments have
been described in considerable detail, it is not the intention of
the applicants to restrict or in any way limit the scope of the
invention to such details. Additional advantages and modifications
will readily appear to those skilled in the art. For example, where
components are releasably or removably connected or attached
together, any type of releasable connection may be suitable
including for example, locking connections, fastened connections,
tongue and groove connections, etc. Still further, component
geometries, shapes, and dimensions can be modified without changing
the overall role or function of the components. Therefore, the
inventive concept, in its broader aspects, is not limited to the
specific details, the representative apparatus, and illustrative
examples shown and described. Accordingly, departures may be made
from such details without departing from the spirit or scope of the
applicant's general inventive concept.
[0103] While various inventive aspects, concepts and features of
the inventions may be described and illustrated herein as embodied
in combination in the exemplary embodiments, these various aspects,
concepts and features may be used in many alternative embodiments,
either individually or in various combinations and sub-combinations
thereof. Unless expressly excluded herein all such combinations and
sub-combinations are intended to be within the scope of the present
inventions. Still further, while various alternative embodiments as
to the various aspects, concepts and features of the
inventions--such as alternative materials, structures,
configurations, methods, devices and components, alternatives as to
form, fit and function, and so on--may be described herein, such
descriptions are not intended to be a complete or exhaustive list
of available alternative embodiments, whether presently known or
later developed. Those skilled in the art may readily adopt one or
more of the inventive aspects, concepts or features into additional
embodiments and uses within the scope of the present inventions
even if such embodiments are not expressly disclosed herein.
Additionally, even though some features, concepts or aspects of the
inventions may be described herein as being a preferred arrangement
or method, such description is not intended to suggest that such
feature is required or necessary unless expressly so stated. Still
further, exemplary or representative values and ranges may be
included to assist in understanding the present disclosure,
however, such values and ranges are not to be construed in a
limiting sense and are intended to be critical values or ranges
only if so expressly stated. Moreover, while various aspects,
features and concepts may be expressly identified herein as being
inventive or forming part of an invention, such identification is
not intended to be exclusive, but rather there may be inventive
aspects, concepts and features that are fully described herein
without being expressly identified as such or as part of a specific
invention, the inventions instead being set forth in the appended
claims. Descriptions of exemplary methods or processes are not
limited to inclusion of all steps as being required in all cases,
nor is the order that the steps are presented to be construed as
required or necessary unless expressly so stated. The words used in
the claims have their full ordinary meanings and are not limited in
any way by the description of the embodiments in the
specification.
* * * * *