AU785228B2

AU785228B2 - Modular door frame building system

Info

Publication number: AU785228B2
Application number: AU26167/02A
Authority: AU
Inventors: Guenter Quiskamp
Original assignee: Individual
Current assignee: Individual
Priority date: 2001-03-20
Filing date: 2002-03-19
Publication date: 2006-11-23
Anticipated expiration: 2022-03-19
Also published as: AU2616702A

Description

APPLICANT:

NUMBER:

FILING DATE: GUENTER QUISKAMP

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR THE INVENTION ENTITLED: "MODULAR DOOR FRAME BUILDING SYSTEM" The invention is described in the following statement:- 2 MODULAR DOOR FRAME BUILDING SYSTEM The present invention relates to a modular door frame building system and relates particularly, although not exclusively, to such a system that can be supplied in kit for the do-it-yourself (DIY) market.

In current building practices, when a residential home is being constructed, metal or wooden door frames must be installed by the builders during the construction phase.

The metal or wooden frame is typically prefabricated and must be bricked in or fastened to the frame of the wall in which the doorway is made. Wooden door frames are typically simply nailed directly onto the wall frame, and the holes filled with putty and lacquered over to produce a clean finish. One of the problems with such prior art door frames is that they have a tendency to come loose over time, particularly with doorways that are subject to heavy use. In addition, such door frames are commonly not provided 15 with architraves, and therefore the finish is aesthetically plain. Furthermore, such prior art door frames must be installed by a builder, and do not lend themselves to DIY *o installation.

The present invention was developed with a view to providing a modular door frame building system with architraves that is relatively simple to install.

"Throughout this specification the term "comprising" is used inclusively, in the sense that there may be other features and/or steps included in the invention not expressly defined or comprehended in the features or steps subsequently defined or described.

What such other features and/or steps may include will be apparent from the specification read as a whole.

According to one aspect of the present invention there is provided a modular door frame building system comprising: a pair of vertical frame members adapted to form each side of the door frame; a horizontal frame member adapted to form the top of the door frame; -3a first architrave adapted to be fitted to a front of the door frame; a second architrave adapted to be fitted to a back of the door frame using a tongue and groove join, wherein said second architrave is formed with a floating tongue that is received in a first groove in the back of said frame members, whereby, in use, the position of the second architrave relative to the first architrave can be adjusted, depending on the wall thickness, by moving said floating tongue in said first groove to achieve a flush fit of said first and second architraves against the respective front and back of the wall; and a pair of vertical jamb members and a horizontal jamb member adapted to be fastened to the inner faces of said door frame to form the door jamb, said frame members being formed with a rebate arranged to receive said jamb members in connection therewith, whereby, in use, when the door is closed against said door jamb the force is transmitted via the rebate to the door frame; wherein each said vertical frame member is fastened to the horizontal frame member by passing a bolt through one of the vertical or horizontal frame members and engaging the bolt with a nut disposed in a hole provided in the other of the vertical or horizontal frame members.

*iii: Preferably, said frame members and architraves are manufactured from a natural or synthetic wood material. Advantageously, said frame members and architraves are manufactured from a paper veneered medium density fibreboard (MDF). Typically said architraves are moulded in a classical style. Typically, said first architrave is fitted to the front of the door frame using a tongue and groove join. Preferably, said tongue and groove joins are fastened by means of a suitable adhesive.

Advantageously, said frame members, architraves and jamb members can be cut to standard lengths and supplied in a kit form to suit the DIY market. Preferably, said architraves each comprise a horizontal architrave member joined to two vertical architrave members by mitre joints, each mitre joint being held together by passing a bolt through one of the horizontal or vertical architrave members and engaging the bolt with a nut disposed in a hole provided in the other of the horizontal or vertical architrave members. Preferably, the bolt extends substantially perpendicular to the joining H:\jnelson\keep\speci\P45234 MODULAR DOOR FRAME BUILDING SYSTEM COMPLETE.doc 7/08/2006 4 surfaces at said mitre joint.

Additionally, the second architrave may be provided with a second groove adjacent the floating tongue, the second groove being arranged to receive an outer side wall of the first groove.

In accordance with an alternative aspect of the present invention, there is provided a kit of parts for a modular door frame, said kit of parts including: a pair of vertical frame members adapted to form each side of the door frame; a horizontal frame member adapted to form the top of the door frame; a first architrave adapted to be fitted to a front of the door frame; a second architrave adapted to be fitted to a back of the door frame using a tongue and groove join, wherein said second architrave is formed with a floating tongue that is received in a first groove in the back of said frame members, whereby, in use, the position of the second architrave relative to the first architrave can be adjusted, depending on the wall thickness, by moving said floating tongue in said first groove to achieve a flush fit of said first and second architraves against the respective front and back of the wall; and i a pair of vertical jamb members and a horizontal jamb member adapted to be fastened to the inner faces of said door frame to form the door jamb, said frame members being formed with a rebate arranged to receive said jamb members in connection therewith, whereby, in use, when the door is closed against said door jamb the force is transmitted via the rebate to the door frame; wherein each said frame member is fastened to the horizontal frame member during use by passing a bolt wherein each said vertical frame member is fastened to the S-horizontal frame member by passing a bolt through one of the vertical or horizontal frame members and engaging the bolt with a nut disposed in a hole provided in the other of the vertical or horizontal frame members.

In order to facilitate a more comprehensive understanding of the nature of the invention, a preferred embodiment of the modular door frame building system will now be described in detail, by way of example only, with reference to the accompanying H:\jnelson\keep\speci\P45234 MODULAR DOOR FRAME BUILDING SYSTEM COMPLETE.doc 7/08/2006 4a drawings, in which Figure 1 is a front perspective view of a corner of a door frame built according to a preferred embodiment of the modular building system of the present invention; Figure 2 is an exploded end view of the corner of the door frame illustrated in Figure 1; H:\jnelson\keep\speci\P45234 MODULAR DOOR FRAME BUILDING SYSTEM COMPLETE.doc 7/08/2006 5 Figure 3 is a rear perspective view of the comer of the door frame illustrated in Figure 1; and, Figure 4 is an exploded end view of the comer of the door frame illustrated in Figure 3.

The view of a preferred embodiment of the door frame 10 made in accordance with the modular building system of the present invention as illustrated in Figure 1, will for convenience of description be referred to as the font of the door frame, whereas the view illustrated in Figure 3 will be referred to as the rear of the door frame. However, it will be understood that the arrangement illustrated could be reversed without any change in the basic concepts of the invention.

The modular building system for constructing the door frame 10 as shown in the 15 drawings comprises a pair of vertical frame members 12 adapted to form each side of the door frame, and a horizontal frame member 14 adapted to form the top of the door frame. As only one corner of the door frame 10 illustrated in the drawings, it will be understood that the second vertical frame member would be parallel to and opposite the first vertical frame member 12, and joined to the horizontal frame member 14 at the other corner (not illustrated) of the door frame 10. A first architrave 16 is adapted to be fitted to the front of the door frame 10 as shown in Figure 1. In the illustrated embodiment, the first architrave 16 is attached to the frame members 12 and 14 of the door frame by means of a simple tongue and groove join. A tongue 18 formed on the frame members 12 and 14 is received in a groove 20 formed in a rear face 22 of the architrave 16. The rear face 22 is uniformly planar either side of the groove 20 as can be seen most clearly in Figure 2. The front face of the architrave 16 is moulded in a classical style.

The modular building system for the door frame 10 further comprises a second architrave 24 as shown in Figures 3 and 4 adapted to be fitted to the back of the door frame 10 using a tongue and groove join. The second architrave 24 is formed with a floating tongue 26 that is received in a groove 28 formed in the rear of the frame 6 members 12 and 14 as can be seen most clearly in Figure 4. A rear face 30 of the second architrave 24 is of stepped planar configuration with the tongue 26 protruding above the plain of the major portion of the rear face 30. The depth of the groove 28 is also larger compared to the depth of the groove 20 in the first architrave 16. This arrangement permits the extent to which the tongue 26 is received in the groove 28 to be varied without compromising the strength of the tongue and groove join. Preferably, a second groove 32 is formed adjacent to the floating tongue 26. An outer side wall 34 of groove 28 is received within the second groove 32 in a second tongue and groove fit.

The provision of floating tongue 26 means that during assembly of the modular door frame 10, the position of the second architrave 24 relative to the first architrave can be adjusted by moving the floating tongue 26 in the rear groove 28. In this way, the distance between the rear face 22 of the first architrave 16 and the rear face 30 of the second architrave 24 can be adjusted depending on the wall thickness to achieve a flush *i 15 fit of the architraves against the respective front and back of the wall. Hence, the same modular components can be used to assemble the modular door frame 10 in walls of a variety of thicknesses. The front face of the second architrave 24 is also moulded in the classical style.

In its final assembled condition, the tongue and groove joins on the front and back of the door frame are fastened to the frame members 12 and 14 by means of a suitable adhesive.

The frame members 12 and 14 and architraves 16 and 24 are manufactured from a suitably rigid material, preferably either a natural dressed timber, for example, solid oak or a synthetic wood material. In the illustrated embodiment the frame members and architraves are manufactured from a paper veneered medium density fibre board (MDF) that can be readily moulded and machined to the desired shape. Only the exposed, visible surfaces of the door frame 10 are covered with a suitable veneer.

The illustrated embodiment of the door frame building system is designed for a flush panel door and further comprises a pair of vertical jamb members 40 and a horizontal 7 jamb member 42 adapted to be fastened to the inner faces of the door frame to form the door jamb. As with the vertical frame members 12, only one of the vertical jamb members 40 is visible in the drawings. The jamb members 40 and 42 could be screwed or nailed onto the frame members 12 and 14. The frame members 12 and 14 are formed with a rebate 44, as can be seen most clearly in Figures 2 and 4, arranged to receive the jamb members 40 and 42 in connection therewith. For this purpose, a rear face of the jamb members 40 and 42 preferably has a stepped planar configuration designed to be received with a close fit within the rebate 44. In this way, in its assembled condition, when the door (not shown) is closed against the door jamb the force is transmitted via the rebate 44 to the door frame. This arrangement has the further advantage that the jamb members 40 and 42 can be fastened to the door frame using only a suitable adhesive, since the transverse forces applied to the door jamb are absorbed by the door frame via the rebate.

15 Each of the frame members 12 and 14, architraves 16 and 24 and jamb members 40 and 42 can be cut to standard lengths and supplied in a kit form to suit the DIY market. To that end, four different kits would typically be supplied to suit the following four standard door sizes: 620 x 2040mm, 720 x 2040mm, 770 x 2040mm and 820 x 2040mm. Of course, all of the components of the modular door frame building system 10 can be cut to suit other sized doors as required. A preferred method of assembling the modular door frame building system will now be described with reference to the drawings.

Assuming that all of the components have been supplied or cut to the correct size to suit the door, the first step involves fastening the vertical frame members to the horizontal frame member 14. Preferably each vertical frame member 12 is fastened to the horizontal frame member 14 using a pair of bolts 46 with an invisible nut arrangement 48 as shown in broken outline in Figure 2. Horizontal frame member 14 is formed with a rebate (not visible) at each end, sized to receive the top end of the respective vertical frame members 12 therein. The frame members are fastened by means of a pair of bolts 46 that are received in pre-drilled bores 50 provided transversally through the horizontal frame member 14 and longitudinally into the ends of the vertical frame members 12.

8 Near the inner ends of the bores 50, a transverse hole 52 is drilled into the vertical frame member 12 from the outer surface thereof so as to intersect with the end of the bore but not pass through to the inner surface of the vertical frame member 12. A nylon plug 54 is slidabably received within the hole 52 and is provided with the nut 48 therein.

Plug 54 can be rotated within the hole 52 so as to align the aperture of the nut 48 with the bore 50, and a threaded portion of the bolt 46 can then be screwed therein. As bolt 46 is tightened, plug 54 is pulled against the inner surface of the hole 52 so as to apply a compressive force between the end of the vertical frame member 12 and the horizontal frame member 14. In this way, an extremely strong join can be formed at each comer of the door frame 10. If desired, a suitable adhesive can also be applied to the join prior to :i tightening of the bolt and nut fasteners. Preferably, a relatively small steel right angle bracket, (not shown) adapted to fit within the rear groove 28 of the frame members 12 15 and 14, is provided to ensure true perpendicular alignment at the comers of the door frame.

The frame members 12 and 14 in their assembled condition are then placed in the recess provided in the wall for the door frame. Prior to fixing the frame members 12 and 14 in the wall recess, the first architrave 16 is glued to the front and back of the door frame.

This is done in order to ensure that the frame members 12 and 14 are correctly positioned in the wall recess to enable the first and second architraves to fit flush against the respective front and back of the wall. The position of the frame members 12 and 14 is then adjusted until the rear face of the first architrave 16 sits flush against the wall surface surrounding the wall recess. It is normally not necessary to loosely fit the second architrave 24 at this stage, since its position relative to the first architrave 16 can be adjusted by means of the floating tongue arrangement described above.

When the frame members 12 and 14 are correctly positioned they can be fixed in place with suitable fasteners, for example, nails or masonry screws, extending through the frame members and countersunk in the region of the rebate 44. Hence, once the jamb members 40 and 42 are positioned in the rebate 44, these fasteners are no longer visible.

9 A polyurethane foam is then injected into any gaps between the door frame and the wall recess. The polyurethane foam adheres to both the masonry (or wooden frame) of the wall and the frame members 12 and 14, and once it sets acts as a strong adhesive to further lock the door frame in position. The polyurethane foam also seals any air gaps to prevent drafts between the door frame and the wall recess. Jamb members 40 and 42 are then adhered to the rebate 44 on the inner surfaces of the frame members 12 and 14.

Lastly, the second architrave is fitted and glued to the frame members 12 and 14 of the door frame. The first and second architraves 16 and 24 each comprise a horizontal architrave member joined to two vertical architrave members by precision mitre joints.

Advantageously both precision mitre joints are held together by an invisible nut and bolt fastener arrangement, similar to that employed for fastening the vertical frame members i 12 to the horizontal frame member 14 (see Figure The bolt and invisible nut arrangement employed at the comers of the architraves 16 and 24 extend substantially 15 perpendicularly to the joining surfaces at the mitre joints.

Now that a preferred embodiment of the modular door frame building system has been described in detail, it will be apparent that it provides a number of significant advantages, including the following: Being in modular form, it can be supplied in kit form and is well suited to the DIY market; Invisible joining used throughout the assembly of the door frame provides an aesthetically pleasing finish; The floating tongue arrangement on at least one of the architraves permits adjustment during assembly to fit various wall thicknesses; and It is easy to assemble and the finished product looks more professional than many conventional door frames constructed by builders.

10 Numerous variations and modifications will suggest themselves to persons skilled in carpentry and in the building construction arts, in addition to those already described, without departing from the basic inventive concepts. For example, both architraves could be provided with a floating tongue if desired to give greater flexibility.

Furthermore, whilst the illustrated embodiment of the door frame is designed for a flush panel door, it will be apparent that the same system may be applied to other types of door ways. All such variations and modifications are to be considered within the scope of the present invention, the nature of which is to be determined from the foregoing description.

o ft *r

Claims

1. A modular door frame building system comprising: a pair of vertical frame members adapted to form each side of the door frame; a horizontal frame member adapted to form the top of the door frame; a first architrave adapted to be fitted to a front of the door frame; a second architrave adapted to be fitted to a back of the door frame using a tongue and groove join, wherein said second architrave is formed with a floating tongue that is received in a first groove in the back of said frame members, whereby, in use, the position of the second architrave relative to the first architrave can be adjusted, depending on the wall thickness, by moving said floating tongue in said first groove to achieve a flush fit of said first and second architraves against the respective front and back of the wall; and a pair of vertical jamb members and a horizontal jamb member adapted to be fastened to the inner faces of said door frame to form the door jamb, said frame members being formed with a rebate arranged to receive said jamb members in connection therewith, whereby, in use, when the door is closed against said doorjamb the force is transmitted via the rebate to the door frame; wherein each said vertical frame member is fastened to the horizontal frame member by passing a bolt through one of the vertical or horizontal frame members and engaging the bolt with a nut disposed in a hole provided in the other of the vertical or horizontal frame members. 25

2. A system as claimed in claim 1, wherein said architraves each comprise a horizontal architrave member joined to two vertical architrave members by mitre joints, each mitre joint being held together by passing a bolt through one of the horizontal or vertical architrave members and engaging the bolt with a nut disposed in a hole provided in the other of the horizontal or vertical architrave members.

3. A system as claimed in claim 2, wherein the bolt extends substantially perpendicular to the joining surfaces at said mitre joint. H:\jnelson\keep\speci\P4 5234 MODULAR DOOR FRAME BUILDING SYSTEM COMPLETE.doc 7/08/2006 12

4. A system as claimed in any one of claims 1 to 3, wherein the second architrave is provided with a second groove adjacent the floating tongue, the second groove being arranged to receive an outer side wall of the first groove.

A system as claimed in any one of the preceding claims, wherein said first architrave is fitted to the front of the door frame using a tongue and groove join.

6. A system as claimed in any one of the preceding claims, wherein said tongue and groove joins are secured using adhesive.

7. A kit of parts for a modular door frame, said kit of parts including: a pair of vertical frame members adapted to form each side of the door frame; a horizontal frame member adapted to form the top of the door frame; a first architrave adapted to be fitted to a front of the door frame; a second architrave adapted to be fitted to a back of the door frame using a tongue and groove join, wherein said second architrave is formed with a floating tongue S•that is received in a first groove in the back of said frame members, whereby, in use, the :•'..position of the second architrave relative to the first architrave can be adjusted, oo•• 20 depending on the wall thickness, by moving said floating tongue in said first groove to S°achieve a flush fit of said first and second architraves against the respective front and back of the wall; and a pair of vertical jamb members and a horizontal jamb member adapted to be fastened to the inner faces of said door frame to form the door jamb, said frame 25 members being formed with a rebate arranged to receive said jamb members in connection therewith, whereby, in use, when the door is closed against said door jamb the force is transmitted via the rebate to the door frame; "wherein each said frame member is fastened to the horizontal frame member during use by passing a bolt; wherein each said vertical frame member is fastened to the horizontal frame member by passing a bolt through one of the vertical or horizontal frame members and engaging the bolt with a nut disposed in a hole provided in the other of the vertical or horizontal frame members. H:\jnelson\keep\speci\P45234 MODULAR DOOR FRAME BUILDING SYSTEM COMPLETE.doc 7/08/2006 13

8. A system substantially as hereinbefore described with reference to, and as shown in, the accompanying drawings. DATED this 8th day of August 2006 GUENTER QUISKAMP By His Patent Attorneys GRIFFITH HACK 0 Fellows Institute of Patent and Trade Mark Attorneys of Australia S S S S S H:\jnelaori\keep\speci\P45234 MODULAR DOOR FRAME BUILDING SYSTEM COMPLETE.dOC 7/08/2006