AU2006236100A1 - Jamb and finishing assemblies - Google Patents

Description

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AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION NAME OF APPLICANT(S):: Bevan Sallaway ADDRESS FOR SERVICE: DAVIES COLLISON CAVE Patent Attorneys 255 Elizabeth Street, Sydney, New South Wales, Australia, 2000 INVENTION TITLE: Jamb and finishing assemblies The following statement is a full description of this invention, including the best method of performing it known to me/us:- 5102 P:\WPDOCS\LNM\Spcc\12728791 Jamib&FillishingA.itsblic_AU complet doe-16 1/06 -1-D 4 JAMB AND FINISHING ASSEMBLIES

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Field of the Invention The present invention relates generally to door assemblies and structures, such as jambs, as IN well as trim assemblies such as skirting boards, architraves, plinths, finishing and edging items, in particular those used in domestic buildings.

Background to the Invention The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that that prior art forms part of the common general knowledge in Australia.

Known door assemblies generally include jambs, lock assemblies and recesses, door element, hinge hardware, handles and architraves to finish. Jambs generally are in the form of what is known as timber mouldings, in which the required rebates, and other contours are cut or otherwise formed in a surface of the jamb.

Attachments to the jambs such as architraves and skirting boards, plinths and the like, are generally adhered to a broad, flat area of the jamb, and are adhered to, and generally positioned after wall panels are fitted in place and adjacent the jamb.

Trim pieces also are generally adhered to the wall panels, after the wall panel is fixed in position on wall studs. To remove the trim items, generally destroys the wall panel, which is normally made from plasterboard. These items are heavy, require a high degree of skill to finish properly, and are expensive.

The present invention seeks to ameliorate one or more of the abovementioned F \WPDOCSLN.M\SMp\1272879 I jwi,,b&intsi SAlbeiaAU~cwipr e do 111/06

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-2- Z disadvantages.

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Summary of the Invention

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Cc According to one aspect of the present invention there is provided a door jamb assembly INO including: Oa jamb element which includes a main body; the main body including one or more recesses for receiving respective door edges thereagainst when the door is in a closed position; two or more mounting regions spaced-apart from one another and suitable for mounting to a structural member of a dwelling or other shelter.

According to another aspect of the invention there is provided a finishing member including: a trim element having a profiled main body and at least one finish surface thereon which includes finish patterns, textures, and/or profiles; and at least two spaced apart mounting regions for mounting to a support.

Preferably at least one of the two mounting regions include projections which in use insert into apertures disposed on the support. In one form the projections are adapted to be bent once they have passed through the aperture, which assists retention and also renders the finishing member removable if desired.

One of the mounting regions may include an abutment region for abutting against the support, and adapted to be adhered or through-fastened to the support by a piercing fastener such as a screw or nail or rivet or bolt.

The finishing member may be in the form of a plinth, architrave, skirting board, reveal, or like members.

PAWDGCS\LN.M\Spcc\ 272879I J)mb&fit~inMigAssliaAUCopIl1e dm-16/1110O

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-3z In one form the finishing member is a metal or plastic section, roll-formed, pressed or IND extruded as appropriate, formed into decorative styles. Preferably the mounting regions are disposed at outer edges of the finish surface.

It is also contemplated that the finish members may include recesses or rebates for Cc, receiving finish panels such as plasterboard. In one form, an external corner trim is IND provided so that mitred edges are not required to be cut into the plasterboard edges, or at Sleast provide an alternative to a perforated angle which is known and used to finish external corners.

A similar solution for internal corners is contemplated, wherein the finish surface traverses the corner, and the plasterboard panels abut an edge of the finish surface. These corners, external and internal, are stronger and simpler to finish than currently known solutions.

Preferably the finishing members mount on the above described door jamb element, to form a preferred form of the doorjamb assembly.

In one form, the doorjamb element includes apertures for receiving, in use, the projections on the finishing members. Preferably, the jamb element is a sheet of metal or plastic, formed by rolling, extrusion or pressing, so that the apertures are through apertures, allowing access to a rear side of the jamb element, so that tabs/projections may be folded or unfolded as required.

Preferably the mounting regions of the jamb element include flanges for fastening to the structural member or stud. The flanges may be adhered or fastened to the stud with bolts, screws, nails or rivets as required.

Seal elements for smoke/draft minimising may be provided in recesses or other appropriate surfaces of the jamb element.

According to another aspect of the present invention there is provided a method of p:\WPDOCS\LjpNM\pcc\1272 E791 lbFinish h litmAU plidoc-I 111/06 -4- 0 Z finishing a wall in a dwelling, the method including the steps of: installing two spaced- IND apart finishing panel-retaining members on structural members of the dwelling; setting a finishing panel in the panel-retaining members.

Preferably the finishing panel-retaining members include channels so that the finishing Cc panel may be sprung or slid in from an end of the channels.

Preferably the method includes provision of a channel member which includes internal and/or external corner treatments as described above and below in preferred embodiments.

Preferably the method includes the step of installing skirting boards having board-retaining means so that retention along a base edge is also effected.

Preferably the channel members are incorporated within architrave members.

According to yet another aspect of the present invention there is provided a door element constructed from compressed or aerated particulate or fibrous material for resisting the passage of heat or fire from one side of the door to the other.

Preferably the material is inorganic. In one embodiment the inorganic material is concrete, but it may be aerated autoclaved concrete.

Preferably a fire inhibiting chemical may be added to the particulate or fibrous material before processing or pressing into a door parcel.

A skin may be provided to retain the particulate matter into a door panel or door plane.

The skin may by printed onto the particulate material often pressing into a door panel slope, or the skin may be wrapped around the door panel, or the skin may form a formwork or cast into which the particulate matter may be poured and then pressed into a selected shape having, for example, architectural embossing, panels, surface textures, etc.

The skin may be a fire damping chemical, or plastic or steel formed sheet.

P:\WPDOCSLNM\Spct\12728791_)J b&FiishigAtIbliaAU_ompltc.do-611 /106 0 IN Reinforcing elements may be added to a mould or into a Batt of the particulate material before pressing. These may be fibrous matting or steel lattice or the like.

Preferably the door element is less than 35mm thickness, and having locks, or latches, Cc and/or adjustable pivot fixings moulded into the door element.

Preferably the door element is combined with jambs and/or architraves as described above.

As described above, the finishing members may be in the form of a reveal for placing adjacent a window frame.

The reveals may be fashioned with impressed wood grain, or other patterns knurled into the section, so as to increase strength.

The reveals may be fixed into position adjacent window frames by rivets or self tapping screws. As described above the reveals may be fitted with slots or perforations to connect to metal architraves. Vertical stiles may have tags which connect to corresponding apertures in heads and sills. The tags may then be bent to retain the assembly. Joints may be sealed.

The reveals may be roll formed.

Just as for doors described above, a fire resistant wall or ceiling cladding panel is to be provided as yet another aspect of the present invention, which includes a metal sheet; a layer of particulate fire resistant matter attached thereto; and embossed or pressed otherwise formed for increased strength.

Preferably the sheet is coated with fire resistant material, in one form being porcelain enamel.

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-6- 0 z In one form, tiles are embossed on the sheet in order to provide strength and attractive IDappearance.

Preferably the panels include connecting means for connecting to adjacent frames, architraves, jambs, and the like, in the form of tags for insertion in corresponding apertures Sin, for example, frames.

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SThe panels may be adapted to accommodate toughened glass inserts, by forming an edge recess to receive the glass pane.

Wall and ceiling panels may be manufactured in a knockdown kit and a room may be assembled on site, the tags into the apertures of adjacent panels. The assembly would be akin to tilt-up construction, as there is some rigidity in the panels.

The panels may include a formwork box, so that fire-resistant filler may be injected, poured or otherwise filled between skins.

Brief Description of the Drawings In order to enable a clearer understanding of the present invention, a preferred embodiment will hereinafter be described with reference to the attached drawing, and in that drawing: Figure 1 is ajamb assembly in plan view; Figure 2 is ajamb element in isometric view; Figure 3 is another embodiment ofjamb element in isometric view; Figure 4 is a plan view of external corner trim/finishing elements in plan view; P:\WPDOCS\LNM\Sp\1 2728791 _Junb&Finish ilgAs bl iAU comple d -16/11/06

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S-7- 0 Z Figure 5 is another embodiment of external comer finish assembly shown in plan view;

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Figure 6 is yet another embodiment of external corner finish assembly shown in plan view; Figure 7 is an embodiment of internal comer finish assembly shown in plan view; IND Figure 8 is a jamb assembly incorporating plinth, and skirting board, shown in isometric Sview; Figure 9 is an upper comer trim element in side elevation view; Figure 10 is a side elevation view of a plinth element and jamb element, shown in situ on a wall with plasterboard panels also assembled thereto; Figure 11 is a comer trim element shown in front elevation; Figure 12 is a plinth integrated with jamb element shown in isometric view; Figures 13-16 are side elevation views of skirting boards; Figures 17-21 are plan views of jamb elements; Figure 22 is a front elevation view of a door assembly including jambs; Figure 23 is a plan view of the door of Figure 22; Figure 24 is a plan view of a jamb assembly; Figure 25 is a front elevation view of a jamb element; and Figure 26 is a side elevation view of a skirting element.

PA\WPLXCS\LNWMSp/I 272879 1 j.o1&FniftgAos/bbAUiconipIa I 106

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N-8- INO Figure 27 is an isometric view of fire-resistant wall panels according to a preferred embodiment of the present invention.

Figure 28-32 are front elevation views of preferred wall panels having different decorative Cc and structural features; SFigure 33-34 are isometric views of preferred arrangements of fire resistant wall panels; Figure 35 is a detail view of a preferred arrangement of Fig 38 and 39; Figure 36 is a side elevation view of a fire resistant door according to a preferred embodiment of the present invention; Figure 37 is a front elevation view of a fire resistant door according to a preferred embodiment of the present invention; Figure 38 is a plan view of a fire resistant door according to a preferred embodiment of the present invention; Figure 39 is a detail plan view of Figure 38; Figure 40 is a section view in plan of a fire resistant door according to a preferred embodiment of the present invention; Figure 41 is a section view in plan of a window frame assembly showing rolled formed or extruded window reveals and associated finishing structure; Figure 42 shows several views of interconnecting fire resistant walls according to a preferred embodiment of the present invention which may be assembled to form a bathroom; P %WPDOCS\LM\Spa1279 l Finldc m. 16/11106 Q)-9- IDFigure 43 is a detail view of joint between the walls of the room shown in figure 42.

Description of Preferred Embodiments SReferring to Figures 1 and 2 at least, there is shown a jamb assembly, generally indicated Sat 10, including a jamb element 12, having a main body 14. The main body 14 includes one or more recesses 16, 17 for receiving edges of a door 18 (Figures 22, 23) there against when the door 18 is in a closed position. Sealing elements 20 may be provided to reduce drafts and smoke if present, as well as reduce noise, also upon closing the door.

Two or more mounting regions 24 are provided on the jamb 12 so that the jamb element 12 may be mounted to a structural member 22 (or stud). The mounting regions 24 are spaced apart from one another, being 26 and 28 in this embodiment. The mounting regions 26 are fastened by through fasteners while 28 is glued. Other fastening arrangements are of course possible, such as rivets, bolts, screws, integral nails or tabs. Cavity 30 may be filled with noise or fire damping substance (not shown), in the form of vermiculite or like substance.

Finishing members 32 are affixed to the jamb element in the form of architrave 34, plinth 36. Skirting board 38 may be applied to structural members as shown in Figures 13-16 or to plinth 36 as is required.

Various jamb sections are contemplated and shown in Figures 17-21. Preferred embodiments ofjambs and finishing members are constructed from metal sheet or plastic extrusion. Steel is a preferred metal, and it may be rollformed, pressed or extruded to form jamb 12.

Architraves are contemplated in many shapes and sections, as with skirting boards, shown in other Figures such as Figures 4, 13-16, 26. Architraves may be made easily installed PAWPDOCS\LNMWSpc\I 272879 1 j-b&Finj6isanbl mALucoppnc dm. 16/11 06

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0 Z and somewhat removable by a second mounting region. The second mounting region 40 is IDa plurality of recesses 42 and corresponding projections 44 which, in use, engage with each other.

Recesses 45 or abutting forces 46 are provided so that plasterboard or other cladding such Cc as plywood, villaboard, or timber sheeting 48 may be quickly installed or "sprung" (,i IDbetween finish members. The faces of recess 45 assists in retaining the cladding 48, Sspeeding assembly time and reducing fastenings required.

(,i A new method of assembly walls and jambs and finishing pieces is thereby described.

That is, affix doorjambs 12 to studs; insert projections 44 into recesses (through holes) 42, so that architrave 34 is attached to jamb 12. Recesses 45 are provided, in which plasterboard panels 48 are mounted. Internal and external comers are more easily dealt with, as corner treatments are provided in steel (or plastic) and the only kind of joints required to be finished are butt joints. These joints may be up to 10mm and filled, or have a fillet slipped in the joint so less filler is required.

Recesses 47 are also provided on skirtings (Figure 26) allowing cladding panels to be dropped in and retained rather than using many fixings. Flush joints are more easily struck. Surfaces of skirtings, architraves, jambs may be fashioned, impressed or embossed or otherwise treated with woodgrain or other textures, by rolling, knurling, or other roll forming, to add some texture and strength.

Referring to Figure 27 it can be seen that projections 44 insert into through holes 42 in order that a panel 50 may be connected to panel 51, panel 50 is impressed or embossed for additional rigidity, the embossing shown at 52.

Panels 50 and 51 include voids (not shown) defined in part by stand-off 54 and panel and 51 subsequently attached to frame element 55 by fasteners through flanges 56. Void may be filled with suitable fire resistant material, in this embodiment being vermiculite.

Panel 51 is improved in strength by embossed tiles 58 and resistance to corrosion is P:\WPDOCS\LNMSpc\I272791_Iwb&FnishinA bimAUcmplacdo-161I1106

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O -11- 0 Z provided by a vitreous enamel coating 59.

Various fire retardant panels are shown at Figures 28-32 and 33, and 34 standard wall panels being shown at Figures 28 and 29 with various architectural embossings for rigidity and aesthetic appeal, Figure 30 showing an aperture and window mounting at item 60. An Cc aperture for a door is shown at item 62 of Figure 31. Door apertures are also shown at 63 INDand 64 of Figure 32. Figures 33 and 34 show isometric views of panels shown in Figures S28-32, wherein the depth of the panels are shown so as to partially define a void 66 within which fire retardant particulate material may be inserted, pressure injected, or otherwise included. Connection means are provided via tags 44 and apertures 42 which interconnect.

Flanges 56 accommodate through fasteners 57 in order to attach to framing. Figures 35-40 show various views of fire resistant door panels which include an outer skin 62 having a pressure filled fire retardant powder and a pivot cam adjustor 69 integral with the door panel. Doors panels, just as with wall panels above described, may be imprinted for embossed or additional structural rigidity, the embossing shown at 71 in Figure Figure 41 shows a window assembly including window reveals in the form of a stile 73 which in this embodiment is rollformed and attached by flanges 75 and through fasteners 77 and 79 to framing. Tags 144 and apertures 142 connect finishing structures 81 to the reveal stile 73.

Other finishing structures 83 may be formed in different profiles as shown.

Figure 42 shows that a knock down kit formed into a room, in this case a bathroom. A room such as that shown in figure 42 may be constructed on site from preferred embodiments of the present invention, wherein fire resistant walls 85, 86, 87 and 88 may be transported to a site, preferably having facilities installed upon their faces such as sink 89 toilet 90 window 91, so that bayonet hose connections may be merely pressed on to make the bathrooms functionally complete.

Wall panels 85-88 are similarly provisioned as those panels above described, having metal P:\WPDOCS\LNM\Spcc\2728791 Jlnlb&FinishingAsscmblics AU _omplletdoc-16I /06 a -12-

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Sskins embossed with tile patterns for strength and finished in vitreous enamel for corrosion ND protection. Each panel may be connected to an adjacent panel by tags and corresponding apertures, and a room made thus be quickly formed in a prefabricated manner.

0 As mentioned bayonet plumbing or similar electrical connections may be merely press Sfitted to outside of the wall cladding, reducing labour and expense.

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SFinally, it is to be understood that various alterations, modifications and/or additions may be incorporated into the various constructions and arrangements of parts without departing from the spirit or ambit of the invention.

Claims (34)

1. A doorjamb assembly including: a jamb element which includes a main body; the main body including one or more recesses for receiving respective door edges CI thereagainst when the door is in a closed position; two or more mounting regions spaced-apart from one another and suitable for CI mounting to a structural member of a dwelling or other shelter.

2. A finishing member including: a trim element having a profiled main body and at least one finish surface thereon which includes finish patterns, textures, and/or profiles; and at least two spaced apart mounting regions for mounting to a support.

3. A door jamb assembly or a finishing member in accordance with claim 1 or 2 respectively wherein at least one of the two mounting regions include projections which in use insert into apertures disposed on the support.

4. A door jamb assembly in accordance with claim 3 wherein the projections are adapted to be bent once they have passed through the aperture, which assists retention and also renders the finishing member removable if desired.

A finishing member in accordance with claim 2, 3 or 4 wherein the finishing member may be in the form of a plinth, architrave, skirting board, or reveal.

6. A door jamb assembly or a finishing member in accordance with any respective previous claim wherein the jamb element or finishing member is a decorative member which has been roll-formed, pressed or extruded section constructed from metal or plastic.

7. A finishing member in accordance with any one of claims 2 6 wherein finishing PA\WPDoCs\LNWppa\127297 I _JltM&Finishin&AcblioAr__vmipnlp dx 1/06 \O -14- 0 z members include recesses or rebates for receiving finish panels such as plasterboard.

8. A finishing member in accordance with any one of claims 2 7 wherein external or internal corner formations are provided, which each includes recesses for receiving and mounting mutually perpendicular plasterboard panels. IND IND

9. A jamb assembly in accordance with claim 1 wherein one or more finishing members in Saccordance with claim 2 are mounted on the doorjamb element.

10. A jamb assembly in accordance with any one of claims 1, 3, 4 or 9 wherein the door jamb element includes apertures for receiving corresponding projections mounted on a finishing members.

11. A jamb assembly in accordance with any one of claims 1, 3, 4, 6 9 or 10 wherein the mounting regions of the jamb element include flanges for fastening to the structural member or stud.

12. A jamb assembly in accordance with any one of claims 1, 3, 4, 6 9, 10 or 11 wherein seal elements for minimising smoke or draft may be provided in recesses or on other appropriate surfaces of the jamb element.

13. A method of finishing a wall in a dwelling, the method including the steps of: installing two spaced-apart finishing panel-retaining recesses on structural members of the dwelling; setting a finishing panel at least partially in the panel-retaining members.

14. The method according to claim 13 wherein the finishing panel-retaining recesses are closed to form channels disposed so that their open faces oppose one another, so that the finishing panel may be sprung or slid into a space between the channels from an end of the channels.

The method in accordance with claim 14 or 15 wherein the method includes the step P.\WPDOCSUNM\Sp\2728791 Imb&Finishi b A i do-I&I V% \O INDS Z of: installing skirting boards which include board-retaining means so that retention IND along a base edge is also effected.

16. The method in accordance with claim 14 or 15 wherein the channel members are incorporated within architrave members. IND

17. A door element constructed from compressed or aerated particulate or fibrous material Sfor resisting the passage of heat or fire from one side of the door to the other.

18. A door element in accordance with claim 17 wherein the compressed or aerated particular door material is an inorganic material.

19. A door element in accordance with claim 18 wherein the inorganic material is concrete.

20. A door element in accordance with claim 17, 18 or 19 wherein the door element includes a fire inhibiting chemical

21. A door element in accordance with any one of claims 17 20 wherein a skin is provided which, when connected to the particulate matter, substantially envelops the particulate matter.

22. A door element in accordance with claim 21 wherein the skin is a fire damping chemical, or plastic or steel sheet.

23. A door element in accordance with any one of claims 17 22 wherein a reinforcing means is provided so as to connect to the particulate material so as to maintain an even distribution of the particulate material throughout the door panel.

24. A door element in accordance with claim 24 wherein the reinforcing means is in the form of fibrous matting or steel lattice. P.\WPDOCSLNM\Spcc\12728791 mb&FinishinblgA cmblic_AU complcdoc. 16 /06 ID 0 -16- Z

25. A finishing member in accordance with any one of claims 2, 5, 7 or 8 wherein the a IND textured or contoured surface is applied to the finishing element so as to increase strength.

26. A fire resistant wall or ceiling cladding panel which includes a metal sheet; a layer of Cc particulate fire resistant matter attached thereto; wherein the metal sheet is textured or IND contoured for increased strength.

27. A fire resistant wall or ceiling panel in accordance with claim 26 wherein the wall is suitable for forming a bathroom wall, the wall panel including tile shapes formed on the metal sheet and suitable for attachment to finishing elements in accordance with any one of claims 2, 5, 7 or 8.

28. A fire resistant wall or ceiling panel in accordance with claim 26 or 27 wherein the panels include connecting means for connecting to adjacent frames, architraves, jambs, and the like, the connecting means in the form of tags for insertion into corresponding apertures in frames or jambs or architraves.

29. A fire resistant wall or ceiling panel in accordance with claim 26, 27 or 28 wherein the panels include an edge recess to accommodate windows in the form of toughened glass inserts.

A kit suitable for constructing and/or finishing a bathroom or kitchen which includes: fire resistant wall and ceiling panels which include connecting tags for insertion into panel mounting apertures of adjacent panels or architraves or jambs or skirting boards or plinths.

31. A kit in accordance with claim 30 wherein a formwork box is provided, attached to each panel, which are configured to receive a fire-resistant filler.

32. A jamb assembly substantially as hereinbefore described with reference to the attached P.%WPDOCS\LNM\Spm\l 2729791_J~ullbBfinishng ngAm blic Ucw do. 16/11/06 -17- O Z drawings. ID

33. A finishing member substantially as hereinbefore described with reference to the 0 attached drawings. mC

34. A fire resistant wall or ceiling panel substantially as hereinbefore described with I0 reference to the attached drawings. A kit substantially as hereinbefore described with reference to the attached drawings.