Adjustable Door Or Window Frame

Abstract

For use in a door or window opening, an expansible, frame element, frame and corner joint, in which the frame includes pre-assembled U-shaped members which include assembly plates forming sockets receiving a face panel for width adjustments; jamb elements are secured over fastening elements securing the face plates together; the face plates include notches and holes accommodating fasteners after width adjustments have been made; and a corner connector having transverse, triangular ribs extending over mitered corners and into which flanges are deformed to stake the elements and draw them together at the corners; and in which the jamb element includes on one side a lateral undercut slot for receiving a silencer strip therein. The era of "do it yourself" prefabricated building structures has enabled relatively unskilled labor to effect installations previously requiring skilled carpenters, mechanics, etc. In recent years, many procedures in erecting a residence or building have been improved, i.e., pouring concrete floors; prefabricated stair wells; curtain walls, etc. Many attempts have been made to provide adjustable window and door frames; however, structure to achieve the wide range of adjustments met in the field have not been readily afforded, and, specifically, when means are provided for the width adjustment, the means to effect this adjustment are generally perceptible. Primary objects of the present invention are: to provide a novel, expansible frame element; to provide a novel, expansible of width-adjustment frame; to provide a novel, staked corner joint drawing mitered corners together. It is also an object to provide a novel, expansible frame element from which a novel frame is assembled in which one face element forms a lateral socket with an assembly plate, and another face element includes a portion adjustably plane in the lateral socket and fasteners secure the face elements in adjusted relation, and jamb elements are secured in laterally extending relation from the inner surface of the face elements and overlying the fasteners. It is another object of this invention to provide in the frame elements as set forth above, hinge-plate recesses overlying the assembly plate to permit flush mounting of hinge leafs. It is another object of this invention to provide novel notches and holes on respective face plates whereby width adjustments still provide a through aperture at the intersection of the slots for receiving a fastener therethrough. It is a general object of this invention to provide an improved, prefabricated frame structure which is simple in construction, adapted to be readily shipped in a pre-assembled condition or in a knocked down version and which is adapted to be quickly and readily installed and adjusted at a job to fit a wide range of conditions and with a minimum amount of skill being necessary on the part of the workmen involved.

Description

These, together with other objects and advantages which will become apparent from a consideration of the following description of exemplary embodiments when taken in conjunction with the drawings forming a part thereof:

FIG. 1 is an elevational view of a door opening incorporating a frame of the invention; directed foot

FIG. 2 is an enlarged, fragmentary perspective view looking into the upper right-hand corner of the frame of FIG. 1.

FIG. 3 is a further enlarged, horizontal section taken on the plane of line 3--3 of FIG. 1,

FIG. 4 is a further enlarged, fragmentary elevation view looking generally at the area shown at line 4--4 of FIG. 2;

FIG. 5 is a top, further enlarged fragmentary perspective view looking down into the area shown at line 5--5 of FIG. 2.

FIG. 6 is a view similar to FIG. 3 and showing an alternate means for assembling the adjustable frame; and

FIG. 7 is a fragmentary section taken on the plane of line 7--7 of FIG. 6.

Referring to FIG. 1, a door opening in wall 10 has secured therein a frame 12 in which a door 14 is hung. It will be understood that the building opening, whether for a door or window, will be final-finished, i.e., the walls will be plastered, dry-walled, etc., and exposed portions at the building opening will be generally wooden, masonry and, or metallic terminal elements 16, see FIG. 3.

The frame 12 will be adjustable in width, and, accordingly, will embrace exposed edges of the opening, at both sides, (see FIG. 3) and preferably can be of prefinished, anodized aluminum, for example, so that when the frames are installed, no further finishing will be required. The frame 12 will generally be described as an inverted, U-shaped member comprising a header and jambs, that is, vertical legs 18 and 20 connected to a transverse header 22. The door can be hung on either the right or left side of the frame opening, i.e., on either of the jambs, leg members 18 or 20. The legs and header are constructed from frame elements most clearly seen in FIG. 3, and this will be first described, next the expansible frame elements 18 and 20 will be described, and then the corner joint of FIG. 5 will be described.

Referring to FIG. 3, each of the legs 18 and 20 include a first face-panel element 24 which includes a face panel portion 26 in the opening, which includes at one marginal edge a side panel 28 in a plane parallel to the plane of closure and having an inwardly directed return or foot flange 30 abuttingly engageable with the outer surface of the wall 10 at the margin of the opening. The face plate 26 includes an inwardly directed, slightly offset plate 32 which includes spaced, parallel, slightly resilient or displacable jamb-mounting flange means comprising flanges 34 and 36; the former extending generally from the juncture of portion 26 and plate 32, and the latter extending from the marginal edge of plate 32 (in the exemplary embodiment). The flanges 34 and 36 respectively include relieved outer edges 38 and 40 which function to assist in mounting a jamb-cap or stop 42 thereon; as will be described. Flange 36 has formed on the outer surface thereof hook or lips 44 and 46 and flange 34 includes a lip 48. The jamb-cap includes a face 50 into the building opening and generally mutually parallel flanges 52 and 54 having formed on the inner surfaces thereof lock lip portions substantially permanently mounting the jamb-cap 42 illustrated in FIGS. 2 and 3.

The side panel 28 has extending inwardly in spaced, parallel relation from the inner surface of face panel 26 a rib 56 defining with panel 26 an inwardly directed groove 58, and in spaced, parallel relation and depending from plate 26 is a T-shaped rib 60 forming an inwardly opening second groove 62.

Disposed in the inner surface of the face panel element 24 is a plurality of assembly plates indicated generally at 64, one of which will be disposed beneath each hinge as shown by dotted lines in FIG. 2, and serve as mounting plates for said hinges on the hinge side 20, as shown in FIG. 1, in a manner to be described hereinafter. Two, three or more of the assembly plates 64 are also spaced along the vertical leg 18 and one or more may also be spaced along the transverse header 22 if necessary. Generally, however, the assembly plates are not necessary along the header except possibly to provide added rigidity for wide span door openings.

Each assembly plate 64 is preferably in the order of 3 in. to 6 in. long and includes flanges 66 and 68 respectively received in the grooves 58 and 62 and will be shimmed out by wedge-like shims 70, 72 from the frame elements 16. Each assembly plate 64 includes a projecting plate portion 74 which is disposed in spaced, parallel relation from plate 32 and forms an elongated, thin socket 76. The plate portion has extending toward the plate 32 anti-rattle ribs 78 spaced inwardly from the edge. Each assembly plate 64 includes in its outer face parallel grooves 80, preferably having a V-shaped cross section and serving to accommodate a drill bit when drilling holes 82 for the leaf of a hinge assembly when used on the hinge side 20 of the door frame.

A second face panel element 84 includes a face panel 86 having at its outer edge a side wall panel 88 (similar to side wall panel 28) and having an inwardly directed foot flange 90. The face panel 86 is adjustably received in socket 76 and the outer surface will be coplanar with the outer surface of face panel portion 26.

All that is required to adjustably install the elements of FIG. 3 on the wall 16 is a screwdriver, drill-and-bit and mallet. Initially, a plurality of assembly plates 64 are mounted in a spaced relationship in the grooves 58 and 62 of the first face-panel elements 24 on both of the legs 18 and 20 as described. On the hinge leg 20, the plates 64 are spaced to correspond to the hinge locations as illustrated in FIG. 2 and two or more plates 64 are spaced along the leg 18, preferably in the same number and general locations as on the hinge side. The portion of the frame 12 consisting of face panel elements 24 of the legs 26 and the header 22, in assembly with the door mounted thereon, are mounted in the door opening and shimmed to a plumb condition as described and installation screws 94 are driven loosely into the position illustrated in FIG. 3 through pre-punched holes to hold said portion of the frame and door in said plumb position in the door opening. Next, the face panel portions 86 of the panel elements 84 of the legs 18 and 20 and the header 22, in assembly, are inserted in the sockets 76 formed by the assembly plates 64 and the leg portions 90 are snugged against the wall as shown in FIG. 3. The installation screws 94 are then tightened to hold the entire assembly in place. Suitable holes are then drilled through overlying portions of plate 32, face panel 86 and plate portion 74 of each assembly plate 64 for the reception of screws 92.

As best illustrated in FIG. 4, a cutout portion 95 is provided in the face panel portions 86 to correspond to the position of each installation screw 94 to provide for a maximum amount of adjustment of said face portions into the pockets 76 after the installation screws 94 are driven loosely into position. The positions for the reception of assembly screws 94 may be pre-marked in any convenient manner to correspond to the positions of the cutout portions 95. The screws 92 and 94 are located between the flanges 34, 36, and after the parts are installed as described the jamb-caps 42 are snapped onto flanges 34, 36 by using a mallet or the palm of one's hand.

The jamb-cap 42 includes in one side thereof a laterally-opening, undercut groove 96 which receives therein a correspondingly formed portion of a sealing (weather seal) strip 98 which will engage at the peripheral margin of the door 14.

As seen in FIGS. 2 AND 3, the face panel 26 of member 20 will have a rectangular recess 100 cut therefrom and the hinge leaf of the hinge assemblies 102 will be flush with the outer surface of panel 26. Note an assembly plate 64 will be disposed beneath each recess 100 and the holes 82 can be readily drilled in grooves 80, and countersunk screws 104 can be readily installed.

The upper ends of the header 22 and legs 18 and 20 are mitered as seen at 106 and are assembled by stabilizing brackets indicated generally at 108 and 110. The brackets 108 comprise flat, angular elements having legs received in opposed tracks formed by flanges 112 and 114 on the inner surface of side panels 28 and 88.

The bracket 110 is a right angular element having one edge disposed beneath the flange 114 and the opposite edge beneath a deformable rib or flange 116. The bracket 110 includes a generally flat base 118 having extending transversely thereacross triangular element or ribs 120 which are spaced therealong. The bracket is installed with the brackets 108 and, thereafter, the flanges 116 are deformed at 121 into the grooves 122 formed by adjacent ribs 120, deformation starting at the groove most remote from the mitered corner. This deforming or staking results in stretching or drawing the corner into close assembled relation.

Before referring to FIGS. 6 and 7, it will be understood that the frame 12 will be substantially pre-assembled, i.e., the U-shaped frame as seen in FIG. 1 will have the legs and headers of one side of the frame assembled at its corners by means of a bracket 108 and the bracket 110. The other side of the frame which includes two leg portions and a header will be assembled with a bracket 108 at its corners. The side wall panels 86 will be loosely disposed in sockets 76 of the co-operating frame. The cap-jambs 42 will not have been installed and the screws 92 and 94 will not have been installed; however, the assembly plates 64 will be mounted on the one U-shaped frame to form the sockets 76.

The two U-shaped frame portions will be installed on opposite sides of a building opening spanning the side and top edges. Convenient foot brackets 124 (FIG. 2) are provided to assist in stabilizing initial and final installation. Holes for screws 94 will be drilled after the wedge shims 70 have been installed to properly orient the legs of the frame. Thereafter, screws 92 are installed, and the cap-jambs 42 are installed over the screws.

Prior to this complete frame installation, when convenient, the hinge-leaf recesses 100 will have been cut, preferably at the factory. The weather seals 96 are installed, the hinge assembles 102 are installed on the frame and doors, and the doors 14 are hung.

Referring to FIGS. 6 and 7, the legs 18' and 20' of a frame function in substantially the same manner as the previously described adjustable frame 12 and only structural differences will be described. In this embodiment, the retention screws 92 are eliminated. The screws 94' are used in this embodiment; as in that previously described, however, as seen in FIG. 7, the overlying portions 86' and 32' at the socket 76 have angularly related slots indicated generally at 95'. Extending substantially the width of plate 32' is a through-slot 97' disposed at substantially 45 degrees to the longitudinal axis of face panel element 24' and through-slot 99' is formed in plate portion 86' at 180 degrees with respect to slot 97'; slots 97' and 99' intersect over substantially the width of adjustment of the overlying members. When the members 24' and 28' are moved toward or away from each other, the intersection between slots 97' and 99' continues to provide a square, through-aperture and a hole is drilled in the plate portion 74' at the point of intersection through which the assembly screws 94 will project into the door frame side and top frame members to maintain the frame 12 in adjusted and installed relation as has been previously described in detail with respect to FIGS. 1-5.

Claims

What is claimed is:

1. An adjustable frame for a doorway comprising a first face plate element, a second face plate element, assembly plate means and cap-jamb means, said first face plate element comprising a face panel and a side panel extending laterally from one edge thereof, said first face plate element further including assembly plate mounting means on the inner surface thereof, said face panel including plate means, cap-jamb mounting flange means extending laterally out from said plate means, said assembly plate means underlying the inner surface of said face panel element and being mounted thereon, said assembly plate means including a plate portion spaced from the inner surface of said plate means and extending parallel thereto, thereby defining a laterally opening socket with said plate means, said socket underlying said cap-jamb mounting flange means, said second face plate element having a face panel and a side panel extending laterally from one edge thereof, said second face panel being slidably received in said socket, fastening means extending through said first and second face panels and said plate portion of said assembly plate means at said socket for retaining said face panels and said side panels at an adjusted width, said assembly plate mounting means comprising laterally opening grooves beneath said first face panel, and opening in a direction common to that of said socket, said assembly plate means including spaced, laterally disposed ribs respectively engaged in said laterally opening grooves, said cap-jamb means engaged on said cap-jamb mounting flange means and overlying said fastening means, said cap-jamb mounting flange means comprising flanges including camming portions at the upper edges thereof facilitating mounting of said cap-jamb means and lower lateral lip portions, and said cap-jamb means comprising inwardly directed lock-lips engaged beneath said lateral lip portions.

2. The frame of claim 1 in which said first face panel includes a hinge-leaf recess extending therethrough, said assembly plate means underlying and extending beyond opposite ends of said recess, whereby a hinge-leaf can be installed on said assembly plate and substantially flush with said face panel.

3. The frame of claim 2 in which said assembly plate means includes groove portions exposed at said recess for orienting a drill bit to form holes for fasteners for a hinge-leaf.

4. The frame of claim 1 in which said plate portion of said assembly plate means and said second face panel include orienting ribs engaged and maintaining the outer surface of said second face panel substantially co-planar with the corresponding surface of said first face panel.

5. The frame of claim 1 in which said cap-jamb means includes at least one laterally opening, undercut groove removably receiving a resilient weather strip element having a lock rib corresponding in cross section to said undercut groove.

6. The frame of claim 1 in which said cap-jamb mounting flange means comprises flanges at the terminal edge and an intermediate portion of said first face panel.

7. The frame of claim 1 in which said first and second face panels include overlying, reversely-angled slots which have a through opening when the face panels are adjusted to width for receiving said fastening means therethrough.

8. The frame of claim 1 in which the frame includes a pair of vertical spaced parallel leg portions and a header in spanning relation to the upper ends thereof, each of said leg portions and said header including said first and second face plate elements and said cap-jamb means, said assembly plate means comprising a plurality of relatively short socket defining members in a spaced relationship along said two legs.