Adjustable Door Frame Assembly

Abstract

The present invention comprises an adjustable door frame assembly in which the weight of the door is carried by hidden support means rather than the door facing. The support means are enclosed by overlapping L-shaped jamb members which are telescopically adjustable to accommodate walls of varying thicknesses. The interfaces between the adjustable pieces, as well as the attachment means for attaching said pieces together, are hidden so as to enhance the beauty of the door frame.

Description

BACKGROUND OF THE INVENTION

The present invention relates to adjustable frame assemblies and particularly adjustable door frames.

Applicant's prior U.S. Pat. No. 3,676,966 discloses a door frame in which the weight of the door is borne by hidden support means and ultimately by the wall. The facings, i.e. the door jambs and casings, are attached to the support means by hidden attachment means, and the frame is vertically adjustable to door openings of varying heights. To the extent that the features of applicant's prior door frame can be incorporated into frames according to the present invention, the disclosure of U.S. Pat. No. 3,676,966 is herein expressly incorporated by reference.

It frequently happens that when a wall is provided with a door opening, variations in thickness of the wall occur around the opening. Accordingly, door frame assemblies made to conform to a standard thickness wall will not fit as desired and consequently the aesthetic appearance not only of the door frame assembly but of the entire room is diminished. Also, it not infrequently happens that in large office buildings and commercial structures wherein there is frequent remodeling, to accommodate various floor plans, doors in an existing wall structure will be utilized in the remodeled structure. Obviously, if the thickness of the walls in the remodeled floor plan is different from that of the original floor plan, new door frame assemblies must be purchased.

U.S. Pat., No. 3,324,599 to Brost, shows a door frame assembly which is adjustable; however, the door frame is relatively complicated, being composed of many parts. Thus it is more difficult and expensive to manufacture, assemble and disassemble. Furthermore the arrangement shown in the Brost patent places the weight of the door directly on the visible facing or jamb.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a simple door frame assembly, adjustable to various wall thickness.

It is another object of the invention to provide an adjustable door frame assembly in which the weight of the door is borne by hidden support means.

Another object of the invention is to provide an adjustable door frame assembly having a minimum number of parts.

Still another object of the invention is to provide an adjustable door frame assembly requiring minimum time for assembly and disassembly.

Yet another object of the invention is to provide an adjustable door frame assembly with hidden adjustment means.

Applicant's present invention comprises an improvement in door frames such as those shown in his prior patent whereby the frame is adjustable to accommodate walls of varying thicknesses.

The door frame assembly herein is comprised of side frame sections, each of which includes a pair of overlapping or telescoping L-shaped jamb members. At least one of the side frame sections is superimposed over support means secured to the wall. Jamb legs of the jamb members extend into the door opening and overlap while casing legs extend away from the opening on opposite sides of the wall. The overlapping jamb members are movable relative to each other in a direction to vary the distance between the two casing legs and thus accommodate various wall thicknesses.

One of the side jamb legs of the frame section which encases the support means has a hinge aperture therein to expose a portion of the support means, whereby a hinge leaf can be attached directly to the support member and thus allow the weight of the door to be borne by the hidden support means, and ultimately by the wall itself, rather than by the jamb members.

A header frame section mounted between the side frame sections at the top of the opening also comprises a pair of L-shaped jamb members having overlapping jamb legs and opposed casing legs. The header jamb members are adjustable in essentially the same manner as the side jamb members.

Means are provided for attaching the overlapping pairs of jamb legs together and for securing all parts of the frame assembly in the door opening.

The above and other features, objects and advantages of the invention will be made apparent by the following detailed description of a preferred embodiment, by the drawings and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the hinge side and header of a door frame assembly according to the invention, with parts broken away.

FIG. 2 is a perspective view of the support means of the hinge side of the door frame assembly.

FIG. 3 is a perspective view of the support means of the strike side of the door frame assembly.

FIG. 4 is a cross-sectional view taken along the lines 4--4 of FIG. 1.

FIG. 5 is a cross-sectional view similar to that of FIG. 4 but at a lower level and showing the invention adapted for use with a solid concrete wall .

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and particularly FIGS. 1-4, the door frame assembly comprises a side frame section F and a header frame H. The assembly further includes side support means 2 for mounting on the hinge side of a door opening. The frame preferably also includes side support means 4 (FIG. 3) for mounting on the strike side of the door opening, although, as will be apparent, where a free swinging door is to be used, side support means 4 may be omitted.

In a dry wall construction, such as is shown in detail in FIG. 4, support means 2 and 4 are secured to channel-shaped studs 6, 8 respectively. Studs 6 and 8 comprise webs 10 and 12 and wings 14, 16, 18 and 20 extending perpendicularly from the edges of the webs 10 and 12. Support means 2 and 4 are secured to the webs 10 and 12 as by screws 22. Studs 6 and 8 are disposed between the parallel spaced-apart sections 24 and 24a of the wall adjacent the sides of the door opening. Wings 14, 16, 18 and 20 are then secured to wall sections 24 and 24a by screws 25 so that studs 6 and 8 become part of the wall.

Superimposed over side support means 2 is a first side frame section F, it being understood that a similar side frame section (not shown) is superimposed over side support means 4 is the latter is employed.

As shown, the support means 2 and 4 comprise elongated wooden planks extending generally from the level of the header frame section H along the entire length of the side frame section F. However it will be readily appreciated that support means 2 and 4 could be formed of any strong rigid material, such as steel, and that they could take other forms, such as small, appropriately placed plates (see applicant's prior U.S. Pat. No. 3,676,966). Preferably, side support means 2 and 4 are slightly wider than the thickness of the wall and have inner surfaces 30 and 32 facing the door opening, outer surfaces 34, 36 facing away from the door opening and opposite side surfaces 38, 40 and 42, 44.

Side frame section F comprises first and second L-shaped side jamb members 46 and 48. The term "L-shaped" as used herein, refers to a configuration which, in cross section, generally includes two angularly depending legs which may be perpendicular, slightly acute or slightly obtuse. The first side jamb member 46 has a side jamb leg 50 extending into the door opening along and in contact with inner surface 30 of support means 2. First side jamb member 46 further has a side casing leg 52 extending away from the door opening along one side of wall section 24a. Second side jamb member 48 also has a side jamb leg 54 extending into the door opening and partially overlapping side jamb leg 50, leg 54 lying along inner surface 30 but spaced from surface 30 by projections 58 integral with side jamb leg 54 and extending toward surface 30. Projections 58 are of substantially the same thickness as side jamb leg 50. Second side jamb member 48 also has a side casing leg 56, opposite casing leg 52, and extending away from the door opening along the surface of section 24.

A door-stop 60 is formed along the edge of side jamb leg 54 of second side jamb member 48. Door-stop 60 has a channel 62 facing the door and a second channel 66 facing the door opening. A flexible insert or sealing member 64 is disposed in channel 62. A bolt 68 in the bottom of channel 66 attaches the overlapped portions of the side jamb legs 54 and 50 together by securing them to support means 2. Several such bolts are preferably included along the length of channel 66. Bolts 68 are hidden from view by a flexible insert 70 which may be snapped into channel 66 and locked into place by projections 71 which fit into grooves 73 in the sides of channel 66. The location of door stop 60 at the edge of side jamb leg 54 enhances the appearance of the frame by hiding the interface between the two side jamb members 46 and 48. Thus, although the side frame section is formed in two parts so as to be adjustable to various wall thicknesses, it retains the unbroken lines and pleasing appearance of a one-piece assembly.

Side jamb members 46 and 48 are laterally extensible, i.e. relatively movable in a direction to vary the distance between side casing legs 52 and 56, and thus accommodate walls of various thicknesses. In a preferred form, the side support means 2 is formed of two pieces which are scarfed as at 72 along their lengths. Thus the support means 2 itself is laterally extensible to vary the distance between side surfaces 38 and 48, and the side jamb members 46 and 48 can move with the individual pieces of support means 2 (see phantom lines in FIG. 5). Other variations are possible. For example, the support means could be made in one piece, with adjustments being made by moving the side jamb members relative thereto; or if desired, the support means can be extensible and the side jamb members also extensible relative to the support means. In any event, suitable openings such as horizontal slots or horizontally spaced holes must be provided in side jamb legs 50 and 54 for screws 68.

To enable the weight of the door to be placed directly on the support means, rather than the side jamb members, the side jamb leg 54 of second side jamb member 48 has a mortised hinge aperture 74 exposing a portion 76 of inner surface 30 of support means 2. Thus one leaf of a hinge 78 is secured directly to support means 2 and the other leaf attached to the door so that the weight of the door is placed on support means 2 and ultimately borne by the wall. For this reason the side jamb members can be made of lightweight material such as aluminum or plastic.

Small flanges 80 on side casing legs 52 and 56 are directed inwardly toward the surfaces of the wall and lie against outer surface 34 of support means 2. The flanges 80 cooperate with projection 59 on the rear surface of side jamb leg 54 and the rear surface 50a of side jamb leg 50 to form support raceways 51 and 53, respectively, for side support means 2. Side support means 2 is chamfered on its inner surface 30 as shown to accommodate projection 57. Support means 2 is preferably wider than the thickness of the wall thus providing an important feature of the present invention. It will be readily appreciated that in the case of walls which are relatively thick, requiring relatively wide jamb legs and when a lightweight material such as aluminum is employed in the manufacture of the door frame, the jamb members 46 and 48 can pivot or flex around the generally vertical line determined by screws 68. Accordingly, should either of the jamb members be struck with a heavy object, as for example when furniture was being moved through the door opening, the possibility exists that the jamb member would be bent inwardly towards the door opening. However, when support means 2 is made wide enough such that opposing sides extend into the raceways 51 and 53, the jamb members 46 and 48 are effectively "locked" into place and cannot be moved inwardly towards the door opening, i.e. they cannot be made to pivot or flex about the line defined by attachment screws 68. Thus, the door frame, though being of two-piece construction, possesses the strength and rigidity of a single piece, non-adjustable door frame. It is not necessary that the flanges 80 extend the entire length of side casing legs 52 and 56, i.e. it is not necessary to form raceways 51 and 53 to effect the above locking of the jamb members. For example, vertically spaced projections along side casing legs 52 and 56 and directed inwardly towards the opposing surfaces of the wall would serve as well. Since the adjustable door frames herein are most conveniently manufactured by extrusion, in the preferred form, longitudinally extending flanges 80 are employed. As a practical matter, it is only necessary that some means be provided on casing legs 52 and 56 which will engage support means 2, substantially locking the jamb members 46 and 48 in position and preventing pivoting or flexing of the jamb members about the line determined by fastening screw 68. For example the opposing side surfaces 38, 40 could be provided with longitudinally extending grooves which could be engaged by flanges such as 80 or projections extending inwardly towards the wall surfaces. Another advantage of the scarfed support means thus resides in the assurance that the support means can be adjusted to the proper width to utilize support raceways 51 and 53. Other flanges 82 at the edges of side casing legs 52 and 56 face inwardly toward the outer surfaces of the wall section 24 and 24a but extend beyond flanges 80 to abut the wall surfaces.

The second side frame section (not shown), for attachment to support means 4, would be constructed in the same fashion as side frame section 26 with the exclusion of hinge aperture 74. If a strike plate is to be used, the second side frame section would have an aperture in one of its side jamb legs to expose at least a portion of support means 4, the latter having cutout portion 86 in one of its sides adjacent plate 84 to accommodate a strike box assembly (FIG. 3).

The header frame section H is substantially identical to side frame section F but may be used with or without a header support means such as 95 (FIG. 1). Header frame section H includes a first header jamb member 88 having a header jamb leg 90 extending into the door opening and a header casing leg 92 extending away from the door opening on one side of the wall. A second header jamb member 94 has a header jamb leg 96 extending into the door opening and partially overlapping header jamb leg 90, and a header casing leg 98 extending away from the door opening on the other side of the wall opposite header casing leg 92.

The header jamb members are relatively movable in a direction to vary the distance between header casing legs 92 and 98. After adjustment to the wall thickness, header jamb members 88 and 94 are secured together by bolts which pass through their overlapped portions and which may be hidden in a door-stop 100 similar to stop 60 and which is preferably at the edge of header jamb leg 96.

Flanges 80' and 82', similar to flanges 80 and 82, are formed on header casing legs 92 and 98. Flanges 80' cooperate with projection 59' on header jamb leg 96 and the rear surface 90a of header jamb leg 90 to form header support raceways 89 and 89a respectively. The ends of header frame section H and the adjoining upper end of the side frame section F have mating mitered edges 102, 104. If a header support means such 95 is used, it may be joined to the side support means such as by a dado joint, butt joint or the like. The mitered ends 102, 104 of the side and header frame sections are secured together by L-shaped clips 106 which are held in clip raceways 103 and 105 formed on the side casing legs 56 and 52 of the side frame section and clip raceways 107 and 109 in the header frame section. The clip raceways 103 and 105 in the side frame sections are on the side casing legs 56 and 52 behind the projections 59 and 57 and the enlarged ends of flanges 80. The clip raceways 107 and 109 in the header frame section are on the header casing legs 92 and 98 behind the projections 57' and 59' and the enlarged ends of flanges 80'.

FIG. 5 shows the invention as used with a solid wall such as concrete or the like which does not include studs such as 6 but which does have a plane edge surface 108 along the side of the door opening. In this type of application the support means 2 is "shot" directly to the surface 108 by nails 110 before the side jamb members are superimposed over the support means.

Claims

I claim:

1. An adjustable door frame assembly for an opening in a wall comprising:

side support means secured to said wall on at least one side of said opening, said side support means having an inner surface facing said opening;

first and second side frame sections mounted on opposite sides of said opening, said first side frame section being superimposed over said support means, each of said side frame sections including a first L-shaped side jamb member having a side jamb leg extending into said opening and a side casing leg extending away from said opening along one side of said wall, a second L-shaped side jamb member having a side jamb leg extending into said opening and partially overlapping the side jamb leg of said first side jamb member and a side casing leg extending away from said opening along the other side of said wall, said first and second side jamb members being relatively movable in a direction to vary the distance between said side casing legs, said first side frame section having at least one hinge aperture in the side jamb leg of one of its side jamb members exposing a portion of the inner surface of said side support means, the side jamb leg of the first side jamb member of said first side frame section having a substantially planar rear surface lying against said inner surface, and the side jamb leg of the second side jamb member of said first side frame section being spaced from said inner surface by spacing members located therebetween and having substantially the same thickness as the side jamb leg of the first side jamb member of said first frame section;

a header frame section extending between said side frame sections, said header frame section including a first L-shaped header jamb member having a header jamb leg extending into said opening and a header casing leg extending away from said opening on said one side of said wall, a second L-shaped header jamb member having a header jamb leg extending into said opening and partially overlapping the header jamb leg of said first header jamb member and a header casing leg extending away from said opening on said other side of said wall, said first and second header jamb members being relatively movable in a direction to vary the distance between said header casing legs;

header attachment means for securing said first and second side jamb members together;

means for securing said side jamb members in said opening; and

means for securing said header jamb members in said opening.

2. A door frame assembly according to claim 1 including two such side support means located on opposite sides of said opening adjacent respective ones of said side frame sections.

3. A door frame assembly according to claim 2 wherein the side jamb leg of the first side jamb member of said second side frame section lies against the adjacent inner surface and the side jamb leg of the second side jamb member of said second side frame section is spaced from said inner surfaces by spacing members located therebetween and having substantially the same thickness as the side jamb leg of the first side jamb member of said second side frame section.

4. A door frame assembly according to claim 1 wherein the side jamb leg of one of the side jamb members of each side frame section and the header jamb leg of one of said header jamb members include door-stop means.

5. A door frame assembly according to claim 2 wherein said side support means each have opposite side surfaces lying along said side casing legs and are each comprised of two scarfed pieces laterally extensible in a direction to vary the distance between said side surfaces.

6. A door frame assembly according to claim 2 wherein said support means are slightly wider than the thickness of said wall and have opposite side surfaces which extend into support raceways formed in said side jamb members.

7. A door frame assembly according to claim 2, further comprising a header support means, said header frame section being superimposed over said header support means, and said header support means having an inner surface facing said door opening.

8. A door frame assembly according to claim 1 wherein said header frame section and said side frame sections have adjoining mitered ends connected by L-shaped clips disposed in clip raceways formed in the side and header casing legs at said mitered ends.

9. A door frame assembly according to claim 4 wherein said door-stop means are located along the edges of the side jamb legs of said second side jamb members and the side header leg of said second header jamb member, each of said door-stop means having a channel facing said door opening, wherein said header attachment means and said side attachment means are located in said channels, and wherein said door frame assembly further includes flexible strips in said channels covering said header attachment means and said side attachment means.

10. A door frame assembly according to claim 9 wherein said side attachment means and said means for securing said side jamb members in said opening are the same and are comprised of means securing the overlapped portions of said side jamb legs to said support means.

11. In combination with a wall having an opening therein, an adjustable door frame assembly comprising:

side support means secured to said wall on at least one side of said opening, said side support means having an inner surface facing said opening;

first and second side frame sections mounted on opposite sides of said opening, said first side frame section being superimposed over said side support means, each of said side frame sections including a first L-shaped side jamb member having a side jamb leg extending into said opening and a side casing leg extending away from said opening along one side of said wall, a second L-shaped side jamb member having a side jamb leg extending into said opening and partially overlapping the side jamb leg of said first side jamb member and a side casing leg extending away from said opening along the other side of said wall, said first and second side jamb members being relatively movable in a direction to vary the distance between said side casing legs, one of said side jamb members of said first side frame section having at least one hinge aperture in said side jamb leg exposing a portion of said inner surface of said side support means wherein said side support means extends along a major portion of the length of said first side frame section;

a header section extending between said side frame sections and mounted across the top of said door opening, said header section including a first L-shaped header jamb member having a header jamb leg extending into said opening and a header casing leg extending away from said opening on one side of said wall, a second L-shaped header jamb member having a header jamb leg extending into said opening and partially overlapping said header jamb leg of said first header jamb member and a header casing leg extending away from said opening on the other side of said wall, said first and second header jamb members being relatively movable in a direction to vary the distance between said header casing legs;

header attachment means for securing said first and second header jamb members of said header section together;

side attachment means for securing said first and second side jamb members together;

means for securing said side jamb members in said opening; and

means for securing said header jamb members in said opening.

12. The combination of claim 11 further comprising a door mounted in said door opening, and a hinge having a first leaf mounted in said hinge aperture and rigidly attached directly to said exposed portion of said inner surface of said side support means, and a second leaf rigidly attached to said door.

13. The combination of claim 11 wherein said wall includes a pair of substantially parallel spaced-apart sections connected by a channel-shaped stud having a web surface extending between said sections adjacent each side of said door opening, and wherein said side support means are rigidly attached to said webs.

14. The combination of claim 11 wherein said wall is solid and has plane edge surfaces along the sides of said door opening, and wherein said side support means are shot to said edge surfaces.

15. An adjustable door frame assembly for an opening in a wall comprising:

side support means secured to said wall on at least one side of said opening, said side support means having an inner surface facing said opening;

first and second side frame sections mounted on opposite sides of said opening, said first side frame section being superimposed over said support means, each of said side frame sections including a first L-shaped side jamb member having a side jamb leg extending into said opening and a side casing leg extending away from said opening along one side of said wall, a second L-shaped side jamb member having a side jamb leg extending into said opening and partially overlapping the side jamb leg of said first side jamb member and a side casing leg extending away from said opening along the other side of said wall, said first and second side jamb members being relatively movable in a direction to vary the distance between said side casing legs, one of the side jamb members of said first side frame section having at least one hinge aperture in said side jamb leg exposing a portion of the inner surface of said side support means wherein said side support means extends along a major portion of the length of said first side frame section;

a header frame section extending between said side frame sections, said header frame section including a first L-shaped header jamb member having a header jamb leg extending into said opening and a header casing leg extending away from said opening on said one side of said wall, a second L-shaped header jamb member having a header jamb leg extending into said opening and partially overlapping the header jamb leg of said first header jamb member and a header casing leg extending away from said opening on said other side of said wall, said first and second header jamb members being relatively movable in a direction to vary the distance between said header casing legs;

header attachment means for securing said first and second side jamb members together;

means for securing said side jamb members in said opening; and

means for securing said header jamb members in said opening.

16. A door frame assembly according to claim 15 wherein said side support means extends from below said hinge aperture upwardly to a level above a lower edge of said header frame section.

17. A door frame assembly according to claim 16 including two such side support means located on opposite sides of said opening.

18. A door frame assembly according to claim 17 further comprising a header support means, said header frame section being superimposed over said header support means, and said header support means having opposite ends abutting respective upper ends of said side support means.