AU686700B2 - Door frame and components therefor - Google Patents

Description

Regulaiion 32

AUSTRALIA

Patents Act 1952 COMPLETE SPECIFICATION FOR A STANDARD PATENT

(ORIGINAL)

Name of Applicant: A L WINDOWS PTY. LTD.

•20 Apollo Drive Hallam 3803 Victoria, Australia Actual Inventor: Arion Reeves PIERSON Address for Service: DAVIES COLLISON CAVE, Patent Attorneys, 1 Little Collins Street, Melbourne, 3000.

Invention Title: Door Frame and Components Therefor Details of Associated Provisional Application No.: PM3505/94 Filed 25 January, 1994 The following statement is a full description of this invention, including the best method of performing it known to us: -1is-,Pof itY.Aqi72213 3)11W -2- DOOR FRAME AND COMPONENTS THEREFOR This invention relates to a door frame and components therefor.

The object of the invention is to provide a novel door frame which is made from extruded components, the frame being simple and relatively inexpensive to make.

According to the present invention there is provided an extrusion for use as a jamb in a door frame, said extrusion including a central web portion which stands proud of first and second end flange portions and is joined thereto by first and secono shoulders, the first shoulder constituting a door stop and wherein at least one of said first and second end flange portions includes mutually opposed channel members for receipt of a fixing strip for covering fixing and/or adjusting fasteners.

0 0 15 The invention also provides an extrusion of the above type for use as a jamb in a door frame, said extrusion in combination with a fixing bracket, said extrusion and fixing bracket including interlocking members which permit relative rotation, the arrangement being such that the bracket can be rotated adjacent to a framework and fixed thereto to thereby fix the jamb in the framework.

9:9':i The invention also provides an extrusion of the above type for use as a jamb in a door frame, said extrusion including at least one lug fixing flange to which fixing lugs can be coupled, the arrangement being such that the fixing lugs can be fixed in brickwork and then coupled to the fixing lug or lugs to thereby fix the jamb relative to the brickwork.

In preferred embodiments of the invention, the jamb extrusions can be made to fully span the wall section therefore avoiding the use of reveals or other materials to p!fvide finishing details.

-3- The projecting flanges permit adjustability for fixing of the door frame to the framework or brickwork of a dwelling.

Preferably further, the extrusions can be provided with one or more channels for receipt of weather seals or the like.

Preferably further, the door frame can have an attractive visual appearance which is consistent with traditional timber products but the frame can be made without using natural timber products which are becoming increasingly scarce. The door frame and components therefore are of comparable cost to timber products.

The invention will now be further described with reference to the accompanying drawings, in which: Figure 1 is a fragmentary perspective view of part of a door frame of the 15 invention; Figure 2 is a cross-sectional view through a header extrusion of the invention; Figure 3 is a side view of the header; Figure 4 is a sectional view through a sill extrusion of the invention; Figure 5 is a side view of the sill; Figure 6 shows the upper ends of jamb extrusions; Figure 7 is a cross-sectional view through the jamb extrusion of the invention; :Figure 8 is a more detailed view of part of the jamb extrusion; Figure 9 is a fragmentary view of part of the jamb extrusion; Figure 10 is a horizontal section through a door frame constructed in accordance 25 with the invention; Figure 11 is a vertical section through a doorway constructed in accordance with the invention; Figure 12 schematically illustrates a side light adjacent to a door frame of the invention; Figure 13 is a schematic view of a mounting bracket; and Figure 14 is a fragmentary view of a door installation.

95o125,popcr\gcp,&LWINDxcap,3 -4- Figure 1 diagrammatically illustrates a door frame 2 constructed in accordance with the invention. It is made from a door header 4, sill 6, a left hand jamb 8 and a right hand jamb 9. The header 4, sill 6 and jambs 8 and 9 are made from extruded material such as aluminium. The right hanci jamb 9 can comprise the same extrusion as that which is used for the left hand jamb 8 but is reversed in its orientation relative to the header and sill.

Figure 2 illustrates the header extrusion 10 which is used to form the door header 4 and Figure 11 diagrammatically illustrates the header 4 in the assembled door frame.

The header extrusion 10 includes a central web portion 12 having an external face 14 which is generally planar. The inner face of the web portion 12 is provided with two screw flutes 16 and 18. The central web 12 has an external end flange 20 which is normally located towards the exterior of a dwelling. The flange 20 is at right angles to the central web 12 and terminates with a weather seal channel 22 for receipt of a weather .oo.

15 seal (not shown) which can be made to sealingly engage an adjacent surface of an eave 24 (or brickwork or other structural component). The inner end of the central web 12 is defined by a door stop portion 26 which includes a sealing strip channel 28. A sealing eoeoo strip 30 (see Figure 11) can be located in the channel 28 so as to form a seal with a door *mounted in the door frame. The extrusion 10 further includes an inner web portion 32 20 which terminates with an inner finishing flange 34. The inside face of the web 32 is provided with a screw flute 36. A fixing fin 38 projects inwardly from the web 32 from a point near the door stop 26. The fixing fin 38 can be used for connecting the header 4 to timber framework by nailing or for cooperation with mounting brackets or lugs (not shown) for further fixing of the header 4 if that is necessary. The central web 12 S 25 includes an external stop flange 40 which can be used to provide a door stop for a flyscreen or security screen for the door frame.

Figure 4 illustrates an extrusion 42 which is used to make the sill 6. The extrusion 42 includes a central web portion 44 which is provided with an external support flange 46 and a central support flange 48. The inner end of the central web 44 is defined by a door stop 50 including a weather seal channel 52 for receipt of a weather seal 53, as shown in Figure 11. The extrusion 42 includes an inner web 54 which terminates in 950125,pAopetcpA&LW1ND.caP.4 an inner stepped support flange 56. The flangcs 48 and 56 are provided with feet 58 and and the flalige 46 is provided with a weather seal channel 62 for receipt of a weather seal 64, as shown in Figure 11. The feet 58 and 60 and weather seal channel 62 are generally coplanar so that they can cooperate with structural elements of the dwelling.

As seen in Figure 11, the feet 58 and 60 engage packing pieces 66 which are placed on floor joists 68 (or a floor slab) to give the sill the correct height relative to the floor surface 67.

As best seen in Figure 11, the inner flange 56 and inner web 54 are generally perpendicular to one another so that these components are vertical and horizontal respectively in the assembled doorway. The central web 44 is, however, downwardly inclined so as to provide drainage to the exterior of the door frame. The flange 48 is perpendicular to the central web 44 so as to provide better support for the central part of that web. The upper face of the central web 44 may be provided with ribs or projections 70 to provide a non-slip tread surface for the sill 6. The underside of the web 44 is provided with a flashing mounting channel 72 for receipt of flashing material 74.

o I S"Figure 7 shows an extrusion 76 which is used for the door jambs 8 and 9. The extrusion 76 comprises a central web portion 78 which at one end terminates with a door 20 stop 80 provided with a weather seal recess 82. The weather seal recess 82 may receive the same sealing strip 30 which is used in the door header 4. The extrusion 76 includes an inner web portion 81 which includes a first portion which includes decorative ribs 83 and a second portion which is generally rebated and includes a screw flute 84. The rebated portion is bounded by ribs 86 for receipt of a finishing strip 88 (see Figures 9 and 25 12) which can be made from decorative material such as extruded PVC or the like. The inner web portion 81 terminates in a finishing flange 90. The inside face of the inner web 81 is provided with a stepped nailing fin 92 and a fixing flange 94 which is generally adjacent to the door stop 80. A screw flute 96 is provided adjacent to the flange 94 for additional fixing at this point if required. The inner face of the central web 78 is provided with three screw flutes 98, 100 and 102 which are located side by side, as seen in Figure 7. The outer end of the central web 78 is defined by an external door stop 104. An external web 106 extends from the stop 104 and terminates in an outer 950125,p:\ApefcpA&LWIND-cap4S -6facing flange 108 which has an inturned leg 110 provided with a weather seal recess 112.

The recess 112 receives a weather seal 113 which forms a seal with brickwork 114 (see Figure 14) or adjacent structural components. The inside face of the external web 106 includes a screw flute 116 and a fixing flange 118.

The door frame 2 may be provided in kit form comprising the header 4, sill 6, jambs 8 and 9 which have been predrilled for fixing them together. It is preferred that the frame is provided in its assembled form including hinges 120 for mounting the door (not shown).

As indicated previously, the door header 4 is made from the extrusion 10 and is provided with rebates 122 and 124 at either end, as shown in Figure 3. The rebates 122 and 124 receive the central webs 78 of the jambs 8 and 9, as diagrammatically illustrated in Figure 1.

As best seen in Figures 1 and 6, the upper ends of the jambs 8 and 9 are each •provided with three screw holes 126, 128 and 130 for receipt of mounting screws 132.

As best seen in Figure 1, the holes 126 and 130 pass through the flutes 84 and 116 respectively. The hole 128 simply passes through the central web portion 78. The holes 20 126, 128 and 130 correspond in position to the screw flutes 36, 16 and 18 respectively of the header 4 so that the mounting screws 132 are securely anchored in the header.

As best seen in Figures 1 and 5, the ends of the sill 6 are each provided with four holes 134, 136, 138 and 140 for receipt of mounting screws 142. The holes are 25 positioned so that they will be aligned in use with the screw flutes of the jambs 8 and 9.

More particularly, the hole 134 is aligned with the flute 84, the hole 136 is aligned with the flute 96, the hole 140 is aligned with the flute 116 and the hole 138 is aligned with one of the flutes 98, 100 or 102. In this way the moui screws 142 are anchored in the flutes for secure mounting of the jambs 8 and 9 to the sill 6.

Figure 8 shows the lower end 144 of the jamb 8 having a profile which is shaped so as to be generally complementary to the shape of the sill. More particularly, the lower 9SO125,p\opcr\gcpA&LWIND.cap,6 -7end includes an inclined portion 146 which has the same inclination as the central web 44 of the sill. The lower end also includes a horizontal portion 148 which corresponds to the inner web 54 of the sill. The right hand jamb 9 has a corresponding shape at its lower end.

The door frame is normally supplied to builders as a complete assembly, that is to say with the mounting screws 132 and 142 in position so that the header and sill are securely coupled to the jambs. Installation of the frame is effected by inserting the assembled frame into the door opening defined by jamb studs 150, lintel 151, joists 68 and packing pieces 66. Preferably the hinge jamb is plumbed and nailed into place. This is effected by nailing through the nailing fin 92 into the inner face 151 of the jamb stud 150 by means of nails 152. This is preferably done at the top and bottom only so that final positioning of the frame can be done later. The framework should be checked to make sure that it is square and then the other jamb is nailed through its nailing fin 92 to 15 the jamb stud 150 at the other side of the doorway. The central web portions 44 of the-,; jambs may now be connected to the opposite faces 160 of the jamb studs 150. This is preferably effected by using a number of mounting brackets 154 of the type illustrated i in Figure 13. ach of these brackets includes a nailing flange 156 and a coupling hook portion-158. The brackets 154 are first coupled to the jambs by interlocking the hook 20 portion 158 with one or other of the screw flutes 98, 100 or 102 and rotating the brackets 154 into position so that their nailing flanges 156 lie adjacent to the outer faces 160 of the studs 150, as diagrammatically illustrated in Figures 10 and 14. The bracket is coupled to a selected flute 98, 100 or 102 on the basis of the size of the studs and preferably so that the flanges 156 are flush with the outer faces 160 of the studs. It is S. 25 preferred that three brackets 154 would be used for each of the jambs at spaced locations.

6 6 j For a brick veneer construction, the outer part of the jambs are coupled to the brickwork 114 by means of mounting lugs 162. The lugs 162 preferably have been set into the mortar during laying of the brickwork 114. The lugs 162 have recess- frmations 163 which receive and engage the fixing flanges 118 as shown in Figure 14. For a solid brick construction, lugs 162 would be used in both courses of the brickwork and the internal lugs would be coupled to the flanges 94 of the jambs.

950125p:\opigcp.A&LWVINDcap,7 -8- Once the frame has been securely connected to the doorway as described above, the weather seals can be mounted and the flashing material 74 on the underside of the sill can be unrolled.

The door may now be mounted to the hinges 120 which are already in position on the appropriate jamb. The doors are preferably hung by pulling out the hinge pins, positioning the door and replacing the hinge pins. After installing the door, final fixing of the door frame is effected by nailing through the fixing flange 92 to the jamb studs 150. During or after installation of the door, adjustments can be made to the position of the frame by removal of the finishing strip 88 and drilling through the flute 84 to insert screws which can be screwed into the jamb studs 150 so as to adjust the position of the jambs. After adjustment, the strips 88 can be repositioned.

Latch striker plates (not shown) can be fitted by marking and cutting the strip 88 with a chisel or knife. The rib 86 adjacent to the finishing flange 90 is also cut above and below the location of the striker plate so that the edge can be deformed inwardly into the rebated region of the inne.: web 81. Where a relatively wide striker plate is to be eo i S"used, both of the ribs 86 could be partially removed as well as the ribs 83 to accommodate the striker plate.

After mounting the door frame and door, plaster sheets 190 can then be fixed to •the studs as shown in Figures 10 and 11.

*Figure 12 diagrammatically illustrates the use of the frame with a side light 25 window 170. The side light window 170 comprises an extruded frame 172 and pane 174.

The frame 172 includes a first channel portion 176 which in use lies adjacent to the seal recess 112 of the adjacent jamb 8 or 9, as shown in Figure 12. The frame 172 includes a second channel 178 which in use receives a reveal panel 180 which can be made from timber or the like. The inner end of the reveal panel 180 is connected by means of screws 182 to the jambs. The screws 182 pass through the flute 84 and are concealed by the finishing strip 88. A bead or other finishing strip 184 can be mounted to cover the joint between the reveal panel 180 and the finishing flange 90 of the jambs. In this 95o125,p.\opcrgcp.A&LWIND.cap,8 -9use, the nailing fins 92 can be removed or bent so that they do not interfere with the inner faces of the reveal panels 180. The side light frame 172 is connected to the jamb 8 by means of a U-shaped connecting moulding 177 which has its oppFsed legs snugly received within the channel 176 of the side light frame and adjacent recess 112 of the jamb 8, as shown in Figure 12. The moulding 117 alsc veather seal between the jamb and the frame 172.

It will be appreciated by those skilled in the art that the door frame assembly and components therefor are relatively cheap and convenient to use and result in a very neat and attractive door frame for a dwelling.

Many modifications will be apparent to those skilled in the art without departing from the spirit and scope of the invention.

o* 0* 0 o 950125,pAopcgcpA&LW1NDCap,9

Claims (16)

1. An extrusion for use as a jamb in a door frame, said extrusion including a central web portion which stands proud of first and second end flange portions and is joined thereto by first and second shoulders, the first shoulder constituting a door stop and wherein at least one of said first and second end flange portions includes mutually opposed channel members for receipt of a fixing strip for covering fixing and/or adjusting fasteners.

2. An extrusion as claimed in claim 1 wherein the door stop is an external door stop m.nd the second shoulder is provided with a weather seal recess.

3. An extrusion as claimed in claim 1 or 2 wherein a screw flute is formed in the second end flange. 0 9

4. An extrusion as claimed in claim 3 wherein said channel members are formed in the 0 second end flange on opposite sides of said screw flute. An extrusion as claimed in any one of claims 1 to 4 including fixing flanges which project from the end web portions away from the central web portion.

6. An extrusion as claimed in claim 5 including a nailing flange projecting from the S second end web.

7. An extrusion as claimed in claim 5 or 6 including a first barbed fixing flange projecting from the second end web portion adjacent to the second shoulder.

8. An extrusion as claimed in any cne of claims 5, 6 or 7 including a second barbed flange projecting from the first end web portion adjacent to the first shoulder. S R11 Y> ,7- I' i2PERI.KAq721221' .(IA 12/5/1 -11

9. An extrusion as claimed in claim 7 or 8 in combination with a masonry fixing lug which can be coupled to the barbed fixing flange or flanges. An extrusion as claimed in any one of claims 1 to 9 including flutes projecting rearwardly from the central web portion.

11. An extrusion as claimed in claim to in combination with mounting brackets having formations which can interlock with the flutes projecting from the central web portion. 10 12. An extrusion as claimed in any one of claims 1 to 12 in combination with a finishing strip the width of which is such that, in use, its longitudinal edges are engaged by the opposed channel members and it generally overlies said second end web portion. t

13. An extrusion as claimed in any one of clair- 1 to 11 for use as a jamb in a door frame in combination with a fixing bracket, said extrusion and fixing bracket including interlocking members which permit relative rotation, the arrangement being such that the bracket can be rotated adjacent to a framework and fixed thereto to thereby fix the jamb in the framework.

14. An extrusion as claimed in any one of claims 1 to 11 for use as a jamb in a door frame, said extrusion including at least one lug fixing flange to which fixing lugs can be coupled, the arrangement being such that the fixing lugs can be fixed in brickwork and then coupled to the fixing flange or flanges to thereby fix the jamb rela''ve to the brickwork. 0 A method of installing a door frame including door jambs, wherein the jambs comprise extrusions as claimed in claim 6, said method including the steps of nailing through the nailing flanges to wall studs.

16. A method of installing a door frame including door jambs wherein the jambs comprise extrusions as claimed in claim 11, said method including the step of interlocking the 1 R A \30 formations of the mounting brackets with the flutes which project from the central web I'\IIHT llWtf21220 LA 12151 -12- portions, rotating the brackets so that flange portions thereof lie adjacent to studs and nailing the flange portions to the studs.

17. A method of installing a door frame in a brick veneer structure, the door frame including door jambs as claimed in claim 9 wherein said method includes the step of setting said masonry fixing lugs in mortar and coupling the projecting ends of the masonry fixing lugs to said second barbed flanges.

18. An extrusion substantially as hereinbefore described with reference to Figure 2, 4 or 10 7.

19. A door frame substantially as hereinbefore described with reference to the accompanying drawings.

20. A method of installing a door frame substantially as hereinbefore described with reference to the accompanying drawings. em em. Cr cop es C C.. C C o 0 6 C DATED this 12th day of May, 1997 A L WINDOWS PTY. LTD. By DAVIES COLLISON CAVE Patent Attorneys for the Applicant ABSTRACT An extrusion (10) for use as a jamb in a door frame. The extrusion includes opposed channolI members (86) for receipt of a fixing strip (88) for covering fixing and/or adjusting fasteners. 950125,p. opcr\gcp,A&LWIND.cap,13