U.S. patent number 3,690,037 [Application Number 05/002,737] was granted by the patent office on 1972-09-12 for prefabricated door and frame assembly.
This patent grant is currently assigned to Taylor Garage Doors, Inc.. Invention is credited to John J. Kempel.
United States Patent |
3,690,037 |
Kempel |
September 12, 1972 |
PREFABRICATED DOOR AND FRAME ASSEMBLY
Abstract
A preformed door, preferably of metal, with a frame, of wood,
fitted to it for side clearance, and with magnetic weather
stripping of special design engaged in saw kerfs in the header bar
and lock jamb, non-magnetic weather stripping at the hinge jamb, an
adjustable threshold member, and a floating hinge connection
allowing the door to be adjusted relative to a tilted lock jamb, as
and when necessary.
Inventors: |
Kempel; John J. (Pontiac,
MI) |
Assignee: |
Taylor Garage Doors, Inc.
(Detroit, MI)
|
Family
ID: |
21702245 |
Appl.
No.: |
05/002,737 |
Filed: |
January 14, 1970 |
Current U.S.
Class: |
49/380; 49/399;
49/468; 49/383; 49/498.1; 49/495.1; 49/489.1; 16/242 |
Current CPC
Class: |
E06B
7/2316 (20130101); E06B 7/2312 (20130101); E06B
1/70 (20130101); Y10T 16/5324 (20150115) |
Current International
Class: |
E06B
1/70 (20060101); E06B 7/23 (20060101); E06B
7/22 (20060101); E06b 001/70 (); E05d 007/04 ();
E06b 003/32 () |
Field of
Search: |
;49/380,468,478,501,503,504,399,400 ;16/129,130-133 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Williamowsky; David J.
Assistant Examiner: Kannan; Philip C.
Claims
I claim:
1. A hinging arrangement for pivotally securing and supporting the
vertical edge surface of a swingable door member to the vertically
extending side frame member of a related door frame assembly,
comprising a clamping plate secured to and carried internally of
one of said members, said clamping plate being relatively elongated
and connected to a vertically extending wall portion of said one of
said members by a plurality of retainers extending through said
wall portion, a plurality of first clearance apertures formed
through said wall portion for the respective reception therethrough
of said retainers, said plurality of first clearance apertures
being of a size and configuration substantially larger than the
cross-sectional size and configuration of said retainers thereby
permitting freedom of translational movement of said retainers in
any of 360.degree. of direction within said apertures along with a
corresponding movement of said clamping plate, a plurality of
second clearance apertures formed through said wall portion of said
one of said members, said plurality of second clearance apertures
being vertically spaced from each other along said wall portion and
collectively located generally between said plurality of first
clearance apertures, a plurality of internally threaded apertures
carried by said clamping plate, said plurality of threaded
apertures being of a cross-sectional size substantially smaller
than the size of said plurality of second clearance apertures, said
plurality of threaded apertures being so located as to be
respectively accessible through said plurality of second clearance
apertures, a hinge member separate from both of said members and
having first and second hinge plates pivotally secured to each
other, for relative pivotal rotation about a pivotal axis, a
plurality of first fastener means for securing said first hinge
plate to the other of said members, and a plurality of second
threaded fastener means for passing through a plurality of
receiving apertures formed in said second hinge plate and passing
through said plurality of second clearance apertures and
respectively threadably engaging said plurality of threaded
apertures, said plurality of second threaded fastener means
comprising the only means for operatively connecting said second
hinge plate to said clamping plate, said clamping plate said
threaded fastener means and said retainers being capable of
relative translational movement within said first and second
clearance apertures whenever said threaded fastener means are
partially tightened thereby enabling the selective angular
positioning of said one member relative to said pivotal axis, and
said clamping plate and said second hinge plate disposed on
opposite sides of said vertically extending wall portion being
effective to frictionally engage and fixedly secure said wall
portion and said one of said members in a selected position
whenever said threaded fastener means are fully tightened against
said second hinge plate thereby drawing said second hinge plate and
said clamping plate toward each other and against opposite sides of
said wall portion.
2. A door frame assembly including a hinging arrangement for
pivotally securing and supporting the vertical edge surface of a
swingable door member to the vertically extending side frame member
of a related door frame assembly, comprising a clamping plate
secured to and carried internally of one of said members, said
clamping plate being relatively elongated and connected to a
vertically extending wall portion of said one of said members by a
plurality of retainers extending through said wall portion, a
plurality of first clearance apertures formed through said wall
portion for the respective reception therethrough of said
retainers, said plurality of first clearance apertures being of a
size and configuration substantially larger than the
cross-sectional size and configuration of said retainers thereby
permitting freedom of translational movement of said retainers in
any of 360.degree. of direction within said apertures along with a
corresponding movement of said clamping plate, a plurality of
second clearance apertures formed through said wall portion of said
one of said members, said plurality of second clearance apertures
being vertically spaced from each other along said wall portion and
collectively located generally between said plurality of first
clearance apertures, a plurality of internally threaded apertures
carried by said clamping plate, said plurality of threaded
apertures being of a cross-sectional size substantially smaller
than the size of said plurality of second clearance apertures, said
plurality of threaded apertures being so located as to be
respectively accessible through said plurality of second clearance
apertures, a hinge member separate from both of said members and
having first and second hinge plates pivotally secured to each
other, for relative pivotal rotation about a pivotal axis, a
plurality of first fastener means for securing said first hinge
plate to the other of said members, and a plurality of second
threaded fastener means for passing through a plurality of
receiving apertures formed in said second hinge plate and passing
through said plurality of second clearance apertures and
respectively threadably engaging said plurality of threaded
apertures, said plurality of second threaded fastener means
comprising the only means for operatively connecting said second
hinge plate to said clamping plate, said clamping plate said
threaded fastener means and said retainers being capable of
relative translational movement within said first and second
clearance apertures whenever said threaded fastener means are
partially tightened thereby enabling the selective angular
positioning of said one member relative to said pivotal axis, and
said clamping plate and said second hinge disposed on opposite
sides of said vertically extending wall portion being effective to
frictionally engage and fixedly secure said wall portion and said
one of said members in a selected position whenever said threaded
fastener means are fully tightened against said second hinge plate
thereby drawing said second hinge plate and said clamping plate
toward each other and against opposite sides of said wall portion,
wherein said one of said members comprises said swingable door
member, wherein said other of said members comprises said side
frame member, and wherein said plurality of second clearance
apertures are not only spaced from each other but also in staggered
relationship to each other.
3. The door frame assembly of claim 2, wherein said door member
comprises an outer metal covering, and wherein said vertically
extending wall portion comprises a portion of said metal
covering.
4. The door frame assembly of claim 3, including magnetic sealing
means secured thereto and effective for magnetically engaging a
generally peripheral portion of said metal covering to affect a
seal as between said member and said door frame assembly, said
magnetic sealing means comprising a door-contacting portion
including magnetic means carried thereby, an anchoring portion
secured in and carried by said door frame assembly, and an
elastomeric bellows connecting portion interconnecting said
anchoring portion to said door-contacting portion, said elastomeric
bellows connecting portion being effective to undergo resilient
deformation in order to enable said door-contacting portion to
achieve full face contact with said outer metal covering even when
a portion of said metal covering has been moved further away from
said anchoring portion by virtue of selective angular positioning
of said door member with respect to said pivotal axis.
Description
BACKGROUND OF THE INVENTION
Pre-cut and fitted door and frame assemblies are becoming
increasingly popular with builders because of the labor saving
advantages they offer.
Metal-clad doors with wooden frames are particularly appealing
because the frames can be handled as they always have been and the
metal-clad doors enable the use of magnetic weather stripping which
helps to further simplify installation problems.
Good quality control during factory production has enabled most of
the side clearance problems in these prefabrications to be
eliminated. However, it has required quite close tolerance
dimensioning, which is expensive and has increased the builders
product cost. In this respect, there are certain improvements due
in the use of magnetic weather stripping, and weather stripping in
general, to cut costs to avoid the necessity for such close
tolerance dimensioning in production.
Another problem area is that of threshold adjustment. Although
there are known weathertight threshold assemblies for use with
pre-cut and fitted door and frame assemblies, to close the free
swinging space at the bottom of a door, most of them involve a
trial-and-error adjustment that is very time consuming and
frustrating.
One other problem of note is the difficulty that arises due to a
tilted frame, at the lock jamb, because of a non-vertical wall. If
the lock jamb of the door frame is tilted either into or out of the
doorway, when it is being fastened to the wall, there will be gaps
at either the top or bottom of the door which weather stripping may
not be able to close. Although care in installation helps minimize
this problem, there is need for some way to make compensations when
this situation does occur.
SUMMARY OF THE PRESENT INVENTION
The present invention is directed to improvements in pre-cut and
fitted door assemblies and particularly to those with metal-clad
doors and magnetic weather stripping.
An overall combination involving a wooden door frame, a metal door,
special weather stripping, a new threshold member and a floating
hinge arrangement provides many advantages not heretofore
attainable.
The wooden door frame is pre-cut and fitted with the weather
stripping before receiving the door. Being of wood enables the
frame to be erected and installed, on the job, with such shims as
are needed, etc., just as has always been done. It also enables use
of conveniently disposed saw kerfs to receive and hold the weather
stripping while still enabling some adjustment thereof, if
needed.
Specially designed weather stripping, both magnetic and
non-magnetic enables having the most suitable for each intended
purpose and, in turn, somewhat less critical tolerance dimensioning
in factory production of the door and frame parts.
The threshold member, in combination with the weather stripping for
the bottom of the door, assures a good tight weather seal and, more
important, it is relatively easy to adjust and lock in place,
without being taken apart and put back together each time.
The new hinge arrangement enables a door to be hung with relative
ease and with every assurance that it will swing true, or as
otherwise desired. By means of a floating plate located at the
hinge position, the manufacture of the door, vertical as well as in
and out, adjustments of a door are easily obtained.
These and other objects and advantages attained in the practice of
this invention will be better appreciated in a reading of the
detailed description of the illustrated embodiment, which follows
hereinafter.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation of a left hand swinging door seen from
the outside, and including all the features of the present
invention.
FIG. 2 is an enlarged cross-sectional view taken through the top of
the door and its frame, as in the plane of line 2--2 in the first
drawing figure.
FIG. 3 is an enlarged and cross-sectional perspective view of the
magnetic weather stripping used.
FIG. 4 is an enlarged cross-sectional view of the threshold member
and weather stripping on the bottom of the door, as seen in the
plane of line 4--4 in the first drawing figure.
FIG. 5 is an enlarged and cross-sectional perspective view of the
weather stripping and protective wiper used on the bottom of the
door.
FIG. 6 is an enlarged cross-sectional view through both side
figures of the door assembly, as seen in the plane of line 6--6 in
the first drawing figure.
FIG. 7 is an enlarged and cross-sectional perspective view of the
non-magnetic weather stripping used at the hinge side of the
door.
FIG. 8 is an enlarged side plan view of the floating hinge plate in
the door, as seen in the plane of line 8--8 in the first drawing
figure, and looking in the direction of the arrows.
FIG. 9 is an enlarged perspective and partially exploded view of
the hinge side of the frame, showing the adjustable hinge
connection to an opened door.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT
The door and frame assembly 10 includes a metal-clad door 12, a
wooden frame 14 pre-cut and sized to fit about the door with a
known amount of side clearance, weather stripping that is both
magnetic and non-magnetic and which will be identified and
described later, a threshold member 16 for under the door, and a
floating hinge connection, also later identified, to hang the door
on the frame.
The door 12 includes side and end rails 18 and 20 of channel
section, as shown in FIGS. 2 and 6, with metal facing panels 22 and
24 to provide the front and back sides of the door. The side rails
have an inset carver 26 to receive turned edges 28 of the facing
panels, for a more finished appearance, and the door has a center
section 30 of hard setting plastic foam inserted during the
construction of the door or blown in afterwards.
The door frame 14 includes a header bar or rail 32 and side rails
34, 36, which serve as the lock and hinge jambs, respectively. A
shoulder stop 38 is formed on the header bar, and like stops 40 and
42 are formed on the side rails, to provide a stop for the door
within the frame. Suitable finish molding 44 is provided about the
edges of the frame, although shown in only a few of the drawing
figures, and is normally though not necessarily provided on at
least one side of the frame as a stop in locating the door and
frame assembly in a receptive opening in a wall.
Saw kerfs 46, 48, and 50 are provided at the base of each of the
door stop shoulders on the frame members 32, 34, and 36,
respectively, for the weather stripping, which is of both the
magnetic and non-magnetic types.
The magnetic weather stripping 52 is used in the header bar and
down the lock jamb. As best seen in FIG. 3, it is an extension of
vinyl plastic or other suitable material with a barbed leg 54 that
serves to anchor it in the saw kerfs 46, 48. A base flange 56
extends at a right angle and has a bellows shape 58 provided
thereover. The magnetic strip 60 is enclosed in a sheath 62
attached to the bellows part and is thereby afforded relative
freedom of lateral movement for the earliest and most effective
sealing engagement with a door edge placed in close proximity
thereto.
The base flange 56 of the magnetic weather stripping is not
fastened to the shoulder edge it rests against and so it may be
shimmed out to set the weather stripping further out, if ever
necessary. However, usually the advantage here is mostly in being
able to lift up the edge of the base flange when painting for a
more neat and finished appearance and to avoid any paint sealing
interference as regards flexibility and freedom of movement
intended.
The ends of the bellows part 58 are best left open to avoid any air
lock which might hold the door off from its latch plate. However,
where corner seals become important as on outside doors, the
bellows may be nipped at two or three places for the necessary air
bleed, without adversely affecting its other functions.
Referring now to FIGS. 6 and 7, the non-magnetic weather stripping
64 is shown as also having a barbed flange, identified as 66, for
anchoring engagement in the saw kerf 50 of the door frame's hinge
rail 36. It also includes a base section 68 that lies on the stop
shoulder, and can be lifted for painting, but which is relatively
square in shape, and has a center opening 70.
A closed tubular section 72 is provided on the base 68, in the
hinge corner, and a sealing flap 74 extends from the outer edge of
the weather stripping into relatively overlapping engagement with
the tubular part. The door is set in the frame for sealing
engagement with just the tubular part and the sealing flap, as
shown in FIG. 6. Any adjustment at the hinge, as later described,
has relatively little effect on the weather strip engagement since
it is so close to the hinge positions and because the non-magnetic
weather stripping is designed to provide a seal within the full
range of adjustment possible.
At the bottom of the door, where good sealing is often difficult,
the bellows part 58 of the magnetic weather stripping and the
tubular part 72 of the non-magnetic weather stripping may have
short lengths of a styrofoam material inserted in them to provide a
compression type seal that extends below the door edge.
The weather stripping on the bottom of the door is shown in FIGS. 4
and 5, and is identified as 76. It includes tubular sections 78 and
80 near each side edge and a wiper blade 82 at the center. Inturned
flanges 84 and 86 on its back side are received and held under
offset shoulder flanges 88 and 90 on a retaining strip 92
tack-welded to the bottom rail of the door.
The threshold member 16, under the door, is intended to cooperate
with the weather stripping 76, in the manner shown best in FIG.
4.
It includes two extended parts 94 and 96 cooperatively disposed
together. The larger part 94 is formed to provide a sill 98 with a
run-off incline and a plywood insert 100 to strengthen it. An
upturned channel section 102 at its other end receives the
downwardly extending flanges of the other threshold part 96, which
is also channel shaped.
Suitable screw bosses 104 and 106 are provided to fasten the ends
of the threshold part 94 to the frame rails which, while not
specifically shown, can be appreciated by reference to FIG. 9.
A center rib 108 in the upturned channel section 102, of the fixed
threshold part, is provided with suitable holes at spaced intervals
for adjustment screws 110 and lock screws 112, both with
self-tapping threads, to relatively locate and fix the position of
the threshold part 96 thereover. The adjustment screws 110 have an
oversized flange 114 that raises the channel part 96 as they are
elevated; which is obtained by means of a tool slot in their upper
ends that is through a receptive opening in the adjustable
part.
The adjustable part of the threshold assembly is fixed in its
adjusted position by having the heads of the lock screws 112
oversized and cone-seated for the holes they extend through. To
raise or lower the threshold channel, the lock screws are loosened
and the adjustment screws are turned up or down, as the case may
be. The channel will raise automatically but pressure should be
used to be sure the channel assumes a desired lower position.
Thereafter, the lock screws are tightened to keep the channel in
its newly adjuster position.
Further details of the threshold assembly are in my copending
application Ser. No. 183,665 which disclosure is made a part hereof
by reference.
FIGS. 8 and 9 show details of the hinge connection which enables
relative adjustment of the door 12 in its frame 14.
A standard type hinge 116 is used, with hinge leafs 118 and 120 for
attachment, respectively, to door and frame parts, as commonly
known. Within the door is a hinge plate 122 fastened by rivets 124
so that it has lateral freedom of movement. A floating connection
is obtained by oversized holes 125 for the rivet pins 124 so that
side and up and down movement is possible.
The hinge plate includes threaded screw holes for the hinge leaf
fasteners 126 and the door edge has oversized holes 128. This
enables the door to be moved relative to the hinge plate, if and as
needed. By loosening the hinge leaf fasteners slightly after the
door and frame is erected, the door may be adjusted at top or
bottom, in or out, to compensate for any frame twist which occurs.
The edge frame of the door is frictionally held between the hinge
leaf and hinge plate which the door is adjusted and is fixed
therebetween when the hinge leaf fasteners are finally tightened
down.
The weight of the door is of negligible effect applied, as it is,
so close to the culcrum afforded by the hinge. Moreover, three
hinges, as are normally employed, provide a most adequate
frictional facing to hold the most massive of doors.
FACTORY PRODUCTION
The metal-clad doors 12 are prefabricated by building up their
peripheral frame, attaching a metal facing to one side, adding the
center core material and then attaching a metal facing to the other
side. Relatively close tolerances are maintained by the factory
fixturing used and the usual range of door heights and widths is
easily attained.
The door frame 14 is built-up separate from the door 12 it will
later receive, but with a certain size door in mind. The side rails
and header bar of each frame are pre-cut to provide door stops,
rather than having separate stops added and in the course thereof,
the saw kerfs are provided for the weather stripping.
Magnetic weather stripping 52 is installed on the overhead and lock
jamb rails of the frame and non-magnetic weather stripping is used
on the hinge side.
The hinge leafs that attach to the door and to the frame are added,
as each is built up, and when they are finally brought together the
hinge pin is all that is needed to complete the assembly for
packaging and shipment.
The threshold member 16 may or may not be installed on the frame
during factory production. Since it is usually preferred to add it
after the door and its frame are up, it may be provided separately,
but it will always be to size and at a mid-point adjustment as to
height.
INSTALLATION
The door and frame, together, are centered in the rough opening
intended to receive them. The hinge jamb 36 is plumbed before it is
nailed in place. If the wall of the opening is not plumb, shims are
added behind the face molding on the frame. And, all hinge points
are backed with solid wood blocks and nailed after the face molding
is tacked in place, on the hinge side.
The use of solid wood blocks between the jamb and rough opening,
behind the hinges, assures a good solid anchoring of the frame at
the hinge side. By using a couple of long wood screws 130 in each
hinge leaf fastened to the frame, it also enables an anchoring of
the hinge through the frame to the wall.
After the door is hung on the frame, the lock jamb 34 is shimmed to
fit the door evenly from top to bottom and is then nailed in place.
Solid wood blocks are used behind the lock jamb, just as they are
behind the hinge jamb. No level is needed since the lock jamb is
preferably adjusted so that its weather stripping, which is
magnetic, has good even contact with the edge of the door.
If, for any reason the door and frame do not hang true, at the lock
jamb, after the frame is fastened in the wall opening, the door can
be shifted by loosening the screws 126 that fasten the hinge leaf
to the door just enough to move the door into position. Afterwards,
they are re-tightened to fix the door in its adjusted and better
fitting position.
The adjustable part 96 of the threshold member 16 should be set so
that the weather stripping 76 on the bottom of the door sweeps
evenly across it. If it is too low, the lock screws 112 should be
loosened so that the adjustment screws 110 can be turned up to
raise the inverted channel section. Then the lock screws should be
retightened. If it is too high, the reverse with the adjustment
screws turned down and the inverted channel pushed down when the
lock screws are reset.
* * * * *