AU2006200002B1

AU2006200002B1 - An Adjustable in-Wall Cavity Sliding Door Frame Assembly

Info

Publication number: AU2006200002B1
Application number: AU2006200002A
Authority: AU
Inventors: Anton Pilz
Original assignee: GAIL PILZ
Current assignee: Gangemi Glen; Gangemi Janita
Priority date: 2006-01-03
Filing date: 2006-01-03
Publication date: 2006-09-21
Anticipated expiration: 2026-01-03
Also published as: WO2007076569A1

Description

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o An Adjustable in-Wall Cavity Sliding Door Frame Assembly Field of the Invention.

cn oThis invention is directed to a sliding door (or possibly a sliding window or panel as well) which slides into a wall cavity, and where a frame assembly is positioned inside othe wall cavity and into which the door slides, and where this frame assembly is oadjustable in width in a simple manner.

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Background Art.

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c 10 It is quite well known to provide a sliding door which slides into a wall cavity. These types of arrangements are suitable where a swing door may present difficulties.

The sliding door typically comprises a wooden door, although for the purpose of the present invention, it is not considered that any particular limitation should be placed on the invention just by referring to a sliding door, and it is considered that the adjustable frame assembly could also be used for windows that slide within a wall cavity, or other types of sliding wings such as shutter doors etc.

The wall cavity needs to have an internal frame to accommodate the sliding door. The frame typically comprises vertical members and horizontal members which are interconnected to form a frame assembly, and a frame assembly is typically provided on each side of the wall cavity. The rear of the frame assembly is interconnected.

Each frame assembly can then be fastened to the internal wall of the wall cavity by screws, nails etc, this being quite conventional.

The vertical and horizontal members which form the frame are typically made of galvanised steel section. It is known to use a steel section which is called a "furring channel". These sections are also used to attach plasterboard to walls, ceilings and the like and sometimes, the sections are referred to as "top hat "sections.

One of the potential complications with the frame assembly is that the width of the frame assembly (by which is meant the distance between the front vertical member and the rear vertical member) needs to be adjusted depending on the size of the door.

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o Thus, larger doors need to have a wider frame assembly such that they can be fully retracted, and smaller doors need to have a smaller frame assembly.

o The rear end of the frame assembly usually contains a stop member and this limits further retraction of the door. Therefore, it is generally not a solution to simply have a overy wide frame assembly which can accommodate the smaller doors and the larger 0 odoors, as the smaller doors can then be inadvertently retracted all the way into the 0cavity and can then not be extended again. Put differently, it is generally necessary to o have the door flush or a small part of the door protruding from the cavity even when 0 N 10 fully retracted such that the door handle can be grasped to move the door.

In the past, it has been necessary to measure the door and the door cavity and then to cut the horizontal frame members to length such that the width of the frame assembly is correct. However, it is generally not desirable to have to cut the frame members to length on site.

Another consideration is that doors generally come in a relatively few width sizes.

Therefore, the corresponding width of the frame assembly also only requires relatively few adjustments to correspond to the door width. It would be advantageous if some 2 0 sort of width adjusting mechanism could be provided on the frame assembly which was relatively easy to use, did not require any cutting, punching, screwing etc and where the adjustment could be relatively restricted (as opposed to infinite) to make it easier to adjust to the width of the particular door.

It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

Object of the Invention.

It is an object of the invention to provide an adjustable frame assembly for use in a cavity door arrangement as described above and which can overcome at least some of the above-mentioned disadvantages or provide a useful or commercial choice.

In a broad form, the invention resides in an adjustable frame assembly for use in a cavity door arrangement, the assembly comprising a pair of spaced apart upright o (typically vertical) frame members, each frame member containing at least one extending typically horizontal) strut, the strut on one frame member adapted to at least partially overlap the strut on the other frame member, and means to enable the ostruts to be connected together at various different positions to enable the width of the 0frame assembly to be adjusted.

In a more particular form the invention resides in an adjustable frame assembly for use in a cavity door arrangement, the assembly comprising a pair of spaced apart vertical frame members, each frame member containing at least one substantially horizontal strut, the strut on one frame member adapted to at least partially overlap the strut on the other frame member, once said strut being provided with a plurality of spaced apart openings, and the other said strut being provided with a projection, the construction and arrangement being such that the struts can overlap and the projection can pass into one of said openings thereby enabling the width between the pair of spaced apart vertical frame members to be adjusted.

Suitably, each strut is provided with a plurality of said openings, and the projection, which means that it is possible for the struts to be attached together at two places.

This can provide greater strength.

The projection may comprise a lug or tongue which can pass through the hole and the tongue can then be crimped, bent, hammered or otherwise treated such that the struts a securely attached together. More than one projection may be provided.

In this manner, each strut can be provided with a particular number of spaced apart openings that ultimately will correspond to different door widths. An installer can 3 0 then select the correct spacing adjustment and attach the struts together such that the frame assembly is now of the correct width.

It is expected that a frame assembly, as described above, will be positioned in a wall 0 o cavity on each side, and the frame assemblies can be interconnected if desired. The rear of the frame assemblies can be provided with a doorstop or something similar.

o The vertical frame members may be made of any suitable material such as metal, plastics, wood, composite materials and the like. It is preferred that the frame omembers are made of galvanised steel and the frame members may comprise metal

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oangle.

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O The frame members may have any suitable length, but as the frame members will

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iN 10 form part of a cavity door arrangement, it is expected that the frame members will have a length which will be slightly longer than the height of the door and therefore a suitable length will be between 2-3 m.

Each upright frame member contains at least one substantially horizontal strut. The strut may be made from any suitable material such as metal, suitable plastics, composite materials, wood and the like. It is however preferred that the strut is made from galvanised steel. The strut may comprise a furring channel which is a channel having a "top hat" type design, an embodiment of which is illustrated in the accompanying illustrations. However, it is not considered that the invention should be limited to the strut comprising only a furring channel.

The length of the strut can vary depending ultimately on the width of the frame assembly. However, it is considered that a suitable length of the strut will be between 200-1000 mm, and a preferred length of the strut will be between 400-600 mm.

It is preferred that the strut is substantially straight. However, there may be instances, where there may be an advantage in having a strut which is curved, angled, or shaped other than substantially straight. In practice, it is most common for the metal members that form the strut to be straight and therefore it is considered most convenient for the strut to also comprise a substantially straight member.

The strut will usually extend in a manner which is substantially horizontal or substantially at right angles to the vertical frame member, as this is considered to be 0 o most convenient, although there may be circumstances where the strut can extend at an angle other than substantially at right angles to the vertical frame member.

o The strut can be attached to the vertical frame member by any convenient means which may include fasteners (screw, rivets, bolt etc), spot welds, crimping and the o like.

0 It is preferred that a plurality of struts is provided on each frame member. Thus, each o frame member may be provided between 2-10 struts, and typically between 4-6 struts.

ci 10 The struts may be evenly spaced apart or non-evenly spaced apart. Typically, the struts will be evenly spaced apart, and the spacing between adjacent struts may be between 200-600 mm.

It is especially preferred that the struts on one frame member are "aligned" with the struts on the other (for instance rear) frame member, so that when the frame members are bought together, the struts can overlap each other and be attached to each other.

Typically, at least one strut, and preferably each strut contains a plurality of spaced apart openings which can form part of the strut fastening system. These openings may be of any suitable size and shape. It is preferred that the openings are circular and have a diameter of between 3-10 mm, although the openings may be elongate, rectangular, have irregular shapes and the like. It is preferred that the spaced openings are spaced apart by regular distances, and this distance may be between 20-100 mm apart and preferably between 30-60 mm and most preferably about 50 mm. It is especially preferred that the openings are spaced apart by a distance which corresponds with the various commercial door width variations to make it quite easy to adjust the width of the frame assembly to suit the door.

The number of openings may vary. It is preferred that the number of openings is sufficient to cover the various commercial door width variations and therefore it is found that between 2-10 openings and particularly between 4-6 openings and most preferably 5 openings is sufficient.

0 O The openings may be spaced at any suitable place along each strut. It is preferred that the openings are spaced along a mid portion of the strut.

oThe strut on one frame member is adapted to at least partially overlap the strut on another frame member. It is preferred that the arrangement is such that the end of one strut can pass substantially into the end of the other strut. It is also preferred that the 0 ostruts substantially completely overlap, as this can provide strength to the 0 arrangement, although it is envisaged that there may be circumstances where the struts o only partially overlap.

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0 The struts can be attached to each other at a particular position to provide a particular width to the frame assembly. It is preferred that at least one strut contains some form of projection that can cooperate with an opening on the other strut, to connect the two together. The projection may comprise a tongue or tab or something else that extends from one strut, and it is preferred that the projection extends from the end of the one strut. It is especially preferred that each strut contains the plurality of openings and the projection which means that the struts are identical in shape and manufacture and each strut can be attached at two positions.

It is however envisaged that the invention may also comprise an arrangement where each strut is provided with some form of indicia to enable the width of the frame assembly to be readily calculated, and then some form of fastening means is used to connect to struts together. In this form of the invention, the fastening means may comprise a separate clamp, screws, rivets, attachment plate and the like.

Brief Description of the Drawings.

An embodiment of the invention will be described with reference to the following drawings in which:.

Figure 1. Illustrates the view of a frame assembly comprising a vertical member and a number of horizontal struts attached to the vertical member.

Figure 2. Illustrates the frame assembly in the assembled position.

Figure 3. Illustrates the head detail of the sliding door assembly.

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Figure 4. Illustrates a plan view of a door insider cavity and with the frame assembly on each side of the door.

Figure 5. Illustrated the mechanism of fastening two struts together.

Figure 6. Illustrates the manner by which the spacing between the frame assemblies can be adjusted.

Figure 7. Illustrates the spacing bracket.

Best Mode.

Referring to the drawings and initially to figure 1, there is illustrated one half of a frame assembly (that is figure 1 illustrates the frame assembly that sits on one side of the door cavity, and there will be another identical frame assembly that sits on the other side of the door cavity with the door sliding therebetween.

The frame assembly illustrated in figure 1 is made in two parts which can be adjustably connected together to provide various different widths. Specifically, the frame assembly illustrated in figure 1 comprises a pair of spaced apart vertical frame members 10, 11. In the particular embodiment, frame member 10 is the "front" frame member and frame member 11 is the "rear" frame member. Each frame member is made from galvanised metal angle, and has a height of slightly over 2 m (in the particular embodiment between 2 m-2.2 The front frame member 10 has a floor fixing bracket 12.

Each frame member 10, 11 contains a plurality (in the particular embodiment, five) horizontally extending struts 13, 14. The struts are also made of galvanised steel and in the particular embodiment, the struts are furring channels, having a particular profile, and the profile is illustrated in figure 3. Each strut has a length of between 500-600 mm.

Struts 13 and 14 are attached to the respective frame members 10, 11 in such a manner that the struts are aligned and can overlap each other when pushed together.

Figure 1 illustrates the "apart" position where the struts have not been overlapped, and figure 2 shows the "together" position where the struts have overlapped and been attached together.

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Each of the struts 13, 14 is provided with a plurality of spaced apart round openings oO 16, and in the particular embodiment, each strut is provided with five openings. The 0O

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0 o openings are spaced apart by 50 mmn, and the spacing between the first opening and the free end of each strut is 170 mm.

o Each of the struts 13, 14 is also provided with a forwardly extending projection, which in the particular embodiment comprises a small lug 15. Lug 15 is formed integrally o with the furring channel strut 13, 14) and has a length of between 3-10 mm. The o lug 15 is made in such a manner that it can be bent at 900 to pass through a respective 0 opening 16 and can then be hammered Or otherwise bent further to about 1800 to o securely lock the lug into the opening. Figure 5 illustrates this progressively and 0 Ni 10 shows lug 15 initially extending in a manner which is coplanar with the strut 14, and then able to be bent 90 to pass through opening 16, and then able to be hammiered to 180' to securely lock in place.

Figure 2 illustrates the frame assembly in the attached position. In this position, the struts 13, 14 have been bought together such that they overlie each other. The lugs on each strut are passed through a particular opening 16 in the manner illustrated in figure 5. Therefore, each pair of struts 13, 14 is attached in two spaced apart positions.

The width W" (see figure 2) of the frame assembly can be varied simply by changing the hole through which the lugs pass. As the holes are spaced apart by 50 mm, it is found that the width of the frame assembly can be adjusted in discrete amounts.

For instance, the smallest width of the frame assembly (that is where the lugs have passed into the furthermost hole (not illustrated)) provides for a 720 mm door, the next size up (where the lugs are in the second hole which is illustrated in figure 2) provides for a 770 mim door, the next size up provides for 820 mm door, the next size up provides for 870 mm door, and the last size (where the lugs are in the closest hole) provides for a 920 mm door. Thus, the amount of overlap between adjacent struts 13, 14 can be a maximum of 360 mm for the 720 mm door, and a minimum of 170 mm for the 920 mm door.

Figure 3 illustrates an end view of an upper part of the door cavity arrangement. The I9 figure particularly illustrates the inner and outer wall lining 17, an upper lintel 18, a sliding track fixing bracket 19, a standard sliding track 20, a door 21 which is attached to the sliding track 20 via a carriage 22 (the carriage typically comprising a pair of rollers mounted to a shaft which is attached to an upper part of the door, this being quite conventional). Figure 3 also illustrates the struts 13, 14.

Figure 4 is a plan view showing door 21, within a wall cavity defined by the outer ,I wall lining 17. Attached to the inside of wall lining 17 is a frame assembly 25 of the type illustrated in figure 2, and a frame assembly 25 is positioned on the inside of each wall lining 17. The inner end of each frame assembly is interconnected by a bracket 26 which contains a doorstop 27. A door jamb 28 is provided on the front of the cavity and is made neat with a suitable architrave 29. A floor bracket 30 is provided (with a similar ceiling fixing bracket also provided but not illustrated).

Figures 5-6 illustrate a mechanism to adjust the spacing between the frame assembly on one side of the door and the frame assembly 51 on the other side of the door. In figure 5, there is illustrated four exemplary spacings going from the smaller spacing at the top of the drawing to the largest spacing at the bottom of the drawing Figure 5 illustrates that each frame assembly has a rear fixing angle 52, 53 which is substantially L-shaped. Each fixing angle contains a number of slots 54. Referring now to figure 6, there is illustrated a spacing bracket 55. The spacing bracket can be of a single size and the slots in each rear fixing angle 52, 53 can be spaced in different positions such that bracket 55 can extend through the "outermost" slots (see A), through to the "innermost" slots (see to fix the spacing between frame assemblies 50 and 51. Again, spacing bracket 55 can contain a pair of lugs 56 which can be inserted into the respective slots and hammered over to lock the spacing bracket to each frame assembly. The spacing bracket 55 contains an opening 57 such that the spacing bracket can be screwed to a rear stud.

Throughout the specification and the claims (if present), unless the context requires otherwise, the term "comprise", or variations such as "comprises" or "comprising", will be understood to apply the inclusion of the stated integer or group of integers but not the exclusion of any other integer or group of integers.

S9a Throughout the specification and claims (if present), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to 00 c, the value for the range qualified by the terms.

It should be appreciated that various other changes and modifications can be made to Sany embodiment described without departing from the spirit and scope of the invention.

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Claims

2. The frame assembly as claimed in claim 1, wherein the projection comprises a lug which extends from one end of the strut and which is initially substantially coplanar with the strut, and which can be bent to pass through the opening in the other strut to connect the struts together.
3. The frame assembly as claimed in any one of claims 1-2, wherein each strut contains said opening and each strut contains said projection. 2 0 4. The frame assembly as claimed in any one of claims 1-3, wherein at least one strut contains a plurality of spaced apart openings. The frame assembly as claimed in claim 4, wherein the at least one strut contains between 2-10 openings.
6. The frame assembly as claimed in claim 4, or claim 5, wherein the spacing between adjacent openings is between 10-100 mm and preferably about mm. 3 0 7. The frame assembly as claimed in any one of the preceding claims, wherein each frame member contains between 2-10 struts. The frame assembly as claimed in any one of the preceding claims, wherein the or each strut has a length of between 20-100 cm.
9. The frame assembly as claimed in any one of the preceding claims wherein the, or each strut extends substantially at right angles to the frame member, and each strut is substantially in the same plane as each other strut. An in wall cavity sliding door frame arrangement comprising a pair of frame assemblies as claimed in any one of the preceding claims which are spaced apart such that a door can slide between the frame assemblies.
11. A frame assembly substantially as hereinbefore described with reference to only figures