AUSTRALIA F B RICE & CO Patent and Trade Mark Attorneys Patents Act 1990 JELD-WEN, INC COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Assembly of a cavity door pocket The following statement is a full description of this invention including the best method of performing it known to us:- 2 Cross-Reference to Related Applications The present application claims priority from Australian Provisional Patent Application No 2007905750 filed on 19 October 2007, the entire content of which is incorporated herein by reference. 5 Field of the Invention This invention relates, generally, to the manufacture of a cavity door pocket and, more particularly, to equipment for assembling a cavity door pocket. 10 Background to the Invention The use of sliding doors in a building is reasonably common, particularly where space is at a premium. Such sliding doors, when open, are received in a box-like frame built into the wall. The box-like frame is referred to as a "cavity door pocket" and shall be referred to as such in this patent specification. The cavity door pocket is 15 prefabricated for subsequent location in the wall. A cavity door pocket comprises a pair of spaced frames interconnected by a spacer, referred to as a backpost, to define a slot in which the door is received, when in an open condition, in use. Each frame of the cavity door pocket is constituted by a vertical, operatively front member, referred to as a split stop with a plurality of beams 20 arranged at spaced intervals on the split stop and connecting the split stop to the backpost. Each beam is referred to as a spreader. The spreaders are secured to their associated split stop by a metal carrier of angle section. Known cavity door pockets are assembled in a substantially manual operation. This is time-consuming and labour-intensive. 25 Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim 30 of this application. Summary of the Invention Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated 35 element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps. 700204_1.doc 3 According to the invention, there is provided equipment for assembling a cavity door pocket, the equipment comprising: a support structure; a receiving zone arranged on the support structure for receiving first 5 components of the cavity door pocket; a fastener dispenser for dispensing fasteners; a plurality of fastener drivers associated with the receiving zone and arranged at spaced intervals, the fastener drivers being in communication with the fastener dispenser for fastening the first components together into at least one sub-assembly in a 10 substantially automated manner; a storage unit for storing a plurality of further components, at least one of the further components being accessible; a securing arrangement for securing one of the accessible further components and the at least one sub-assembly together in a substantially automated manner once the 15 accessible further component has been placed in an operative position. In this specification, the term "substantially automated" means, unless the context clearly indicates otherwise, that the components are fastened or secured together or the components or sub-assemblies is/are moved using devices that operate without being handled by a person during the fastening, securing or moving operation. 20 A picker unit is preferably provided for picking the accessible further component from the storage unit and for placing the accessible further component in the operative position. The picker unit preferably comprises a picker arm assembly. The picker arm assembly preferably comprises a plurality of longitudinally spaced arms. The arms are preferably rotatable, together, from a first position at which they 25 remove the accessible further component from the storage unit to a second, operative position at which the accessible further component is secured, by the securing arrangement, to the at least one sub-assembly. Each of the arms preferably includes a clamp at a free end thereof for clamping the accessible further component located in the storage unit, removing the accessible further component from the storage unit and 30 manoeuvring the accessible further component into its operative position. The receiving zone, the fastener dispenser and the fastener drivers are preferably located in a first station. The storage unit, the picker unit and the securing arrangement are preferably located in a second station located downstream of the first station. A carriage is preferably provided for conveying the at least one sub-assembly 35 from the first station to the second station. The first station is preferably configured to form two of the sub-assemblies simultaneously. The securing arrangement preferably 700204_1.doc 4 connects the two sub-assemblies to opposite sides of the accessible further component to form a frame of the cavity door pocket. The first components preferably comprise an elongate member, having a longitudinal axis, and an associated bracket. The first components preferably further 5 comprise a plurality of bracing members each having one end for attachment to the elongate member, such that the bracing members extend transversely to the longitudinal axis in longitudinally spaced apart relationship. The receiving zone preferably includes a holder for holding the elongate members. The holder is preferably rotatable about the longitudinal axis through a 10 predetermined angle to facilitate, in an initial fastening operation, securing the bracket to a surface of its associated elongate member and, in a second fastening operation, after the elongate member has been rotated through the predetermined angle, fastening of the plurality of bracing members to the bracket. The predetermined angle is preferably approximately 90*. 15 The receiving zone preferably further includes one or more positioning elements for facilitating positioning of the bracket relative to the elongate member. The positioning elements preferably also facilitate positioning of the bracing members with respect to the bracket after the holder has been rotated through the predetermined angle. In an embodiment, these positioning elements may be in the form of guide blocks 20 arranged operatively outwardly of the holder and in a fixed orientation relative to the holder. It will, however, be appreciated that other forms of positioning elements could be provided such as, for example, channels, or the like. The accessible further component is preferably a stud and the securing arrangement is preferably adapted to attach the stud to a free end of the at least one sub 25 assembly to form an assembled cavity door pocket. A displacing mechanism is preferably provided for displacing the at least one sub-assembly from a first orientation to a second orientation in which the at least one sub-assembly abuts the accessible further component in its operative position. The displacing mechanism preferably comprises at least one ram for displacing the at least 30 one sub-assembly to the second orientation. An indexing mechanism is preferably provided for indexing the at least one sub-assembly relative to the securing arrangement to facilitate securing of the accessible further component to a plurality of positions on the at least one sub assembly. 35 In an embodiment, the fastener dispenser may comprise a plurality of spaced hoppers. Each hopper may receive the fasteners therein. The fastening devices may 700204_1.doc 5 communicate via fluid lines with the hoppers so that fasteners are dispensed in an automated manner from the hoppers to the fastening devices in a substantially simultaneously operation with respect to each holder. In an embodiment, the fastener dispenser may comprise two hoppers. Each 5 hopper may feed a plurality of the fastening devices. For example, in embodiments providing for simultaneous assembly of two sub-assemblies, one hopper may feed the fastening devices associated with a first holder with the other hopper feeding the fastening devices associated with a second holder. The fasteners may be screws and, therefore, the fastening devices may be fluid 10 operable screwdrivers. More particularly, the screwdrivers may be pneumatically operable screwdrivers. The carriage may be a wheeled carriage which runs on rails extending beneath the first station and the second station. As indicated above, each sub-assembly of an elongate member with its attached 15 bracket and bracing members may be conveyed in a first orientation from the first station to the second station by the carriage. The storage unit may be a magazine. In an embodiment, the magazine may be arranged in an elevated location relative to the support structure and offset with respect to a centre line of the support structure. 20 The securing arrangement may comprise a plurality of longitudinally spaced, opposed pairs of fluid operable guns for driving securing elements, such as nails or staples, into the bracing members to secure the bracing members to the elongate member. Thus, it will be appreciated that there is a gun associated with each bracing member. The guns may be displaceable between a first, inoperative position and a 25 second, operative position. While the cavity door pocket is being indexed by the indexing mechanism, the guns may be in their first, inoperative positions. The equipment may include a control unit for controlling operation of various components. The control unit may be a programmable logic controller (PLC). In addition, the equipment is, largely, fluid operable and may be connectable to a source 30 of the fluid such as, for example, compressed air. Limits of movement of the various parts of the equipment may be controlled by microswitches. Brief Description of the Drawings 35 Fig. I shows a side view of an embodiment of equipment for assembling a cavity door pocket; 700204_1.doc 6 Fig. 2 shows a plan view of the equipment. Fig. 3 shows an end view, from a first end, of the equipment; Fig. 4 shows an end view, from an opposed end, of the equipment; and Fig. 5 shows -a side view of a cavity door assembly including a cavity door 5 pocket. Detailed Description of Exemplary Embodiment In Fig. 5 of the drawings, reference numeral 10 generally designates a cavity door assembly. The cavity door assembly 10 comprises a sliding door 12, slidably 10 received in a cavity door pocket 14. In use, the cavity door pocket is built into a wall (not shown) of a structure. The cavity door 12 slides on a rail 16 extending from an upper end of the cavity door pocket 14. The cavity door pocket 14 comprises a pair of spaced frames, one of which is shown at 18 in Fig. 5 of the drawings. The frames 18 are identical and are spaced from 15 each other to define a slot in which the sliding door 12 is received. Each frame 18 comprises an elongate face member in the form of a split stop 20, having a longitudinal axis 21. The split stop 20 is a timber element. A metal bracket in the form of a length of angle section 22 is secured to that surface of the split stop 20 which is not visible and which extends transversely to a plane of sliding of the door 12. 20 Each length of angle section 22 supports a plurality of longitudinally spaced timber bracing members or spreaders 24. The spreaders 24 are secured to a timber back stop stud 26, transversely to the longitudinal axis 21, to support the frames 18 in spaced relationship. This disclosure relates to equipment 30 (Figs. 1-4) for assembling the cavity 25 door pocket 14. Thus, referring to Figs. 1-4 of the drawings, the equipment 30 is described in greater detail. The equipment 30 comprises a support structure 32. A first station 34 is arranged on the support structure 32 and a second station 36 is arranged downstream of the first station 34 and is supported on the support structure 32. The equipment 30 further includes a carriage 37 slidably displaceable on a rail 30 arrangement 38 (Figs. 3 & 4) between the first station 34 and the second station 36. It is to be noted that in Figs. 1-4 of the drawings, different parts of the equipment 30 are omitted from different drawings for the sake of clarity. However, those skilled in the art will readily understand how to put the equipment 30 together into a working configuration based on this description when read in conjunction with 35 the drawings. 700204_1.doc 7 The first station 34 is used for assembling each frame 18 of the door pocket 14. Each frame 18, once assembled, constitutes a sub-assembly of the cavity door pocket 14. As illustrated more clearly in Fig. 3 of the drawings, the first station 34 5 comprises a receiving zone including a pair of transversely spaced holders 40, each for simultaneously assembling a respective frame 18. The holders 40 are arranged on the carriage 37 on opposed sides of a central axis 42 of the support structure 32 of the equipment 30. Further, each holder 40 is rotatably supported on the carriage 37. The holders 40 are rotatable about the longitudinal axis of the split stop 20 in opposite 10 directions. Thus, the holder 40 on a right hand side of the central axis 42, as viewed in Fig. 3 of the drawings, is rotatable in a clockwise direction with the holder 40 on the left hand side of the axis 42 being rotatable in a counter-clockwise direction. The holders 40 are rotatable through a predetermined angle, more particularly, an angle of approximately 900 as will be described in greater detail below. 15 The first station 34 further includes a fastener dispenser in the form of a pair of hoppers 44. Each hopper 44 is connected via feed lines (not shown) to a set of fastener drivers in the form of pneumatically operated screwdrivers 46. It will therefore be appreciated that one hopper 44 feeds the screwdrivers 46 associated with one of the holders 40 with the other hopper 44 feeding the screwdrivers 46 associated with the 20 other holder 40, the screwdrivers 46 being fed with screws from the hoppers 44 in an automated manner. In the first station 34, as an initial step, each holder 40 is loaded with a split stop 20. The split stop 20 is inserted into its holder 40 with its surface to which the angle section 22 is to be secured facing upwardly. The angle section 22 is then positioned on 25 that surface. Each holder 40 includes a positioning member, in the form of a stop member 48, for locating the angle section 22 with respect to its associated split stop 20. While loading the split stops 20 and the angle sections 22 in the holders 40, the screwdrivers 46 are held in an elevated position relative to the holders 40. Once the holders 40 have been loaded with their associated split stops 20 and angle sections 22, 30 the screwdrivers 46 are lowered and screws are driven into the angle section 22 and the split stop 20 to secure the angle section 22 to its associated split stop 20. The screwdrivers 46 are then raised, allowing the holders 40 to rotate through 90" to expose a planar surface of the angle sections 22 to the screwdrivers for attachment of the spreaders 24. 700204_ .doc 8 The spreaders 24 are then mounted in position relative to the holders 40. In this regard, a support plate 48 is arranged outwardly of each holder 40 to support the spreaders 24. Still further, to position the spreaders 24 orthogonally with respect to the holders 5 40, and thereby with respect to the longitudinal axis of the split stops 20 and associated angle sections, a plurality of positioning elements in the form of guide blocks 50 are supported on each support plate 48 in longitudinally spaced relationship. Each spreader 24 is positioned relative to its associated angle section 22 by being placed in abutment against the relevant guide block 50. 10 Once the spreaders 24 have been positioned such that ends of the spreaders 24 are received in their associated lengths of angle section 22, on the exposed planar surface, the screwdrivers 46 are again lowered and screws are driven into the angle sections 22 and the spreaders 24 for securing the spreaders 24 to the angle sections 22. This forms each sub-assembly or frame 18 of the cavity door pocket 14. 15 With the spreaders 24 of each frame 18 arranged substantially horizontally, the carriage 37 is displaced from the first station 34 into the second station 36. The section station 36 comprises a cage structure 52 mounted on the support structure 32. The cage structure 52 carries safety elements (not shown) such as, for example, sheets of transparent impact resistant material so that the interior of the 20 second station 36 is still visible. The second station 36 has a storage unit in the form of a magazine 54 arranged to one side of the central axis 42. The storage unit 54 supports a plurality of backstop studs 26 for the cavity door pocket. At least one of the backstop studs 26 is accessible from the storage unit 54. 25 The second station 36 further includes a picker unit 56. The picker unit 56 comprises a picker arm assembly having a plurality of spaced, pivotable arms 58. The arms 58 move in unison and are arranged on the same side of the central axis 42 as the magazine 54. A free end of each arm 58 carries a clamp 60 which clamps an accessible 30 backstop stud 26 for transportation of a backstop stud 26 from the magazine 54 to an operative position, as will be described in greater detail below, in which the backstop stud 26 is suspended above the carriage 37 on the longitudinal axis 42. Thus, the arms 58 move through an arc as illustrated by line 62 in Fig. 4 of the drawings. Still further, the second station 36 includes a securing arrangement 64 for 35 securing the backstop stud 26 to the frames 18 of the cavity door pocket 14. 700204_1.doc 9 The securing arrangement 64 comprises a plurality of longitudinally spaced pairs of nail guns or staple guns 66, with each spreader 24 having an associated gun 66. The guns 66 are supported on rotatable beams 68 to be rotatable between an inoperative position, as shown at 66.1 in Figs. 3 & 4 of the drawings, and an operative position as 5 shown at 66.2 in Fig. 4 of the drawings. It will be appreciated that the guns 66 will all be in their inoperative positions or their operative positions simultaneously. The illustration of the guns in Figs. 3 & 4, with the guns 66 on one side of the axis 42 being in their inoperative position and the guns 66 on the opposed side of the axis being in their operative position, is purely for explanatory purposes. 10 The second station 36 also includes an indexing mechanism 70 (Fig. 1) for indexing the carriage 37 a predetermined amount in the direction of arrow 72, as will be described in greater detail below. In use, as described above, the carriage 37 delivers the frames 18 of the cavity door pocket 14 to the second station 36 with the spreaders 24 lying substantially 15 horizontally. The carriage 37 may be displaced manually or it may move in a substantially automated manner. The picker unit 56 picks a backstop stud 26 from the magazine 54 and the arms 58 are rotated through the arc 62 to support the picker unit 56 in an elevated position above the carriage 37 on the central axis 42 of the support structure 32. 20 The second station 36 includes a displacing mechanism 74 for displacing each of the two frames 18 from their first orientation, in which the spreaders 24 lie substantially horizontally, to a second position, through an arc 76 (Fig. 4) of approximately 900, in which free ends of the spreaders 24 abut the suspended backstop stud 26 and sandwich the stud 26 therebetween. The displacing mechanism 74 25 comprises a plurality of spaced rams 78 associated with each holder 40. The rams 78, when extended, rotate the spreaders 24 to their second, substantially vertical orientation. While the rams 78 are operating, all the guns 66 of the securing arrangement 64 are in the position shown at 66.1. Once the spreaders 24 abut the backstop stud 26, the 30 guns 66 are displaced to the position as shown at 66.2 and are operated to insert a first securing element, such as a staple or nail, through the spreaders 24 into the backstop stud 26. The cavity door pocket 14 so formed is then indexed in the direction of arrow 72 by the indexing mechanism 70 to allow for at least one further securing element to be driven home in a second location. 35 To cater for different depths of door pocket, the equipment 30 includes an adjustment mechanism in the form of a rotatable wheel 80 (Fig. 3) and a scale 82 with 700204_1.doc 10 gradations 84 to enable the backstop stud 26 to be positioned at the desired elevation above the carriage 37. As indicated above, the various components of the equipment 30 are, in general, fluid operated and, more particularly, pneumatically operated. Thus, the equipment is 5 connectable to a source of compressed air (not shown). In addition, limits of movement of the various moveable components are controlled by microswitches under the operation of a controller 86 in the form of a programmable logic controller. Hence, it is an advantage of the preferred embodiment that equipment 30 is provided for fabricating a cavity door pocket 14 in a substantially automated manner. 10 This results in considerable time saving and reduction in labour intensity. Also, improved safety results from the use of the substantially automated equipment 30. It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the scope of the invention as broadly described. 15 The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. 700204_1.doc