CA2835577A1 - Brick mold assembly, connector for same and kit for assembly of same - Google Patents
Brick mold assembly, connector for same and kit for assembly of same Download PDFInfo
- Publication number
- CA2835577A1 CA2835577A1 CA2835577A CA2835577A CA2835577A1 CA 2835577 A1 CA2835577 A1 CA 2835577A1 CA 2835577 A CA2835577 A CA 2835577A CA 2835577 A CA2835577 A CA 2835577A CA 2835577 A1 CA2835577 A1 CA 2835577A1
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- CA
- Canada
- Prior art keywords
- longitudinal
- clip member
- door jamb
- connector
- brick mold
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B1/00—Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
- E06B1/04—Frames for doors, windows, or the like to be fixed in openings
- E06B1/32—Frames composed of parts made of different materials
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- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B1/00—Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
- E06B1/04—Frames for doors, windows, or the like to be fixed in openings
- E06B1/26—Frames of plastics
-
- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B1/00—Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
- E06B1/04—Frames for doors, windows, or the like to be fixed in openings
- E06B1/34—Coverings, e.g. protecting against weather, for decorative purposes
-
- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
- E06B3/96—Corner joints or edge joints for windows, doors, or the like frames or wings
- E06B3/964—Corner joints or edge joints for windows, doors, or the like frames or wings using separate connection pieces, e.g. T-connection pieces
- E06B3/9641—Corner joints or edge joints for windows, doors, or the like frames or wings using separate connection pieces, e.g. T-connection pieces part of which remains visible
Abstract
A brick mold assembly for a door frame comprises a brick mold portion configured to be installed adjacent a door jamb portion, and a connector configured for connecting the brick mold portion to the door jamb portion. The connector comprises a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member. The second longitudinal clip member is oriented relative to the first longitudinal clip member so as to define an angle therebetween.
Description
BRICK MOLD ASSEMBLY, CONNECTOR FOR SAME AND KIT FOR
ASSEMBLY OF SAME
Field of the Invention [0001] The present invention relates generally to door jambs and in particular, to a brick mold assembly, and a connector for same and a kit for assembly of same.
Background of the Invention
ASSEMBLY OF SAME
Field of the Invention [0001] The present invention relates generally to door jambs and in particular, to a brick mold assembly, and a connector for same and a kit for assembly of same.
Background of the Invention
[0002] Door frames of dwellings and other buildings are often constructed by installing wooden side plates and a wooden top plate around a doorway opening.
Wooden casings are typically attached to the edges of the side and top plates.
Hinges and lock set recesses are then added to opposite side plates.
Wooden casings are typically attached to the edges of the side and top plates.
Hinges and lock set recesses are then added to opposite side plates.
[0003] As will be appreciated, this approach requires considerable handiwork and the exercise of some degree of skill. It also requires significant on site labour, and is typically time-consuming. Additionally, this approach also does not provide for weather proofing, and weather proofing typically needs to be improvised by attaching weather stripping around the edges of the doorway opening.
[0004] To facilitate door frame construction, it may be desirable and more cost-effective to utilize a pre-fabricated door jamb comprising inexpensive structural materials such as plastic. Door jambs comprising extruded plastic have been previously described. For example, U.S. Patent No. 6,557,309 to Johnson discloses a door jamb assembly having an interchangeable multi-component design allowing for the framing of doorways with different configurations by first selecting a main frame and a decorative trim that conforms with the doorway, and then securing a first end of the main frame, being attached to the decorative trim, onto a wall with the use of an attachment flange and securing a second end of the main frame to an interior jamb with the use of a fastener.
[0005] U.S. Patent No. 7,472,519 to Caren discloses a plastic door jamb member for forming a portion of a door jamb, the plastic member having a recess for receiving a wooden door jamb portion, and an interlocking attachment recess for interconnection with a metal reinforcement plate. The plastic door jamb member may be interengaged with the wooden door jamb portion, and further interengaged with the metal reinforcement plate, and installed in position as a combination door jamb assembly.
[0006] Brick mold systems for door frames have also been disclosed. For example, U.S. Patent Application Publication No. 2010/0263307 to Gilles et al.
discloses a method of manufacturing of a brick molding system for window frames and door frames that includes providing a frame member which is used to form a frame to accommodate a variety of styles of window or doors in accordance with customer requirements. The frame member has a female brick molding attachment receptacle. A plurality of brick molding variations is provided, all of which have a male coupling engageable with the female brick molding receptacle. An order is received from a customer for a selected style of frame with a selected style of brick molding. Lengths of the frame member are secured together to form the selected style of frame and in the process of forming the frame the male coupling of the selected style of brick molding is inserted into the female brick molding receptacle.
discloses a method of manufacturing of a brick molding system for window frames and door frames that includes providing a frame member which is used to form a frame to accommodate a variety of styles of window or doors in accordance with customer requirements. The frame member has a female brick molding attachment receptacle. A plurality of brick molding variations is provided, all of which have a male coupling engageable with the female brick molding receptacle. An order is received from a customer for a selected style of frame with a selected style of brick molding. Lengths of the frame member are secured together to form the selected style of frame and in the process of forming the frame the male coupling of the selected style of brick molding is inserted into the female brick molding receptacle.
[0007] Improvements are generally desired. It is therefore an object at least to provide a novel brick mold assembly, and a connector for the same and a kit for assembly of the same.
Summary of the Invention [0001] In one aspect, there is provided a brick mold assembly for a door frame, comprising: a brick mold portion configured to be installed adjacent a door jamb portion; and a connector configured for connecting the brick mold portion to the door jamb portion, the connector comprising a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.
[0002] The first longitudinal clip member may be configured to engage the brick mold portion. The brick mold portion may comprise at least one feature configured for receiving the first longitudinal clip member. The at least one feature may be a longitudinal channel comprising a longitudinal clip member configured to cooperate with the first longitudinal clip member. The connector may further comprise a longitudinal intermediate portion joining the first longitudinal clip member and the second longitudinal clip member. The intermediate portion may comprise a longitudinal channel for receiving the longitudinal clip member of the brick mold portion.
100031 The second longitudinal clip member may be configured to engage the door jamb portion. The door jamb portion may comprise at least one feature configured for receiving the second longitudinal clip member. The at least one feature is a longitudinal channel comprising a longitudinal clip member of the door jamb portion configured to cooperate with the second longitudinal clip member.
The connector may further comprise a longitudinal corner configured to abut a corresponding corner of the door jamb portion when the second longitudinal clip member engages the door jamb portion.
100041 The connector may further comprise a longitudinal channel configured to receive a feature of the door jamb portion. The feature of the door jamb portion may be a longitudinal rib shaped to engage the longitudinal channel. The longitudinal rib may define a first longitudinal outer corner and a second longitudinal outer corner.
The longitudinal rib may have a generally square-shaped profile. The connector may further comprise a bracket having a longitudinal flange, the longitudinal flange being spaced from the second longitudinal clip member to define the longitudinal channel therebetween.
100051 The angle defined by the first and second longitudinal clip members may be about 90 degrees.
100061 The connector may be extruded.
[0007] In another aspect, there is provided a kit for assembly of a brick mold assembly for a door frame, comprising: a brick mold portion configured to be installed adjacent a door jamb portion; and a connector configured for connecting the brick mold portion to the door jamb portion, the connector comprising a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.
Summary of the Invention [0001] In one aspect, there is provided a brick mold assembly for a door frame, comprising: a brick mold portion configured to be installed adjacent a door jamb portion; and a connector configured for connecting the brick mold portion to the door jamb portion, the connector comprising a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.
[0002] The first longitudinal clip member may be configured to engage the brick mold portion. The brick mold portion may comprise at least one feature configured for receiving the first longitudinal clip member. The at least one feature may be a longitudinal channel comprising a longitudinal clip member configured to cooperate with the first longitudinal clip member. The connector may further comprise a longitudinal intermediate portion joining the first longitudinal clip member and the second longitudinal clip member. The intermediate portion may comprise a longitudinal channel for receiving the longitudinal clip member of the brick mold portion.
100031 The second longitudinal clip member may be configured to engage the door jamb portion. The door jamb portion may comprise at least one feature configured for receiving the second longitudinal clip member. The at least one feature is a longitudinal channel comprising a longitudinal clip member of the door jamb portion configured to cooperate with the second longitudinal clip member.
The connector may further comprise a longitudinal corner configured to abut a corresponding corner of the door jamb portion when the second longitudinal clip member engages the door jamb portion.
100041 The connector may further comprise a longitudinal channel configured to receive a feature of the door jamb portion. The feature of the door jamb portion may be a longitudinal rib shaped to engage the longitudinal channel. The longitudinal rib may define a first longitudinal outer corner and a second longitudinal outer corner.
The longitudinal rib may have a generally square-shaped profile. The connector may further comprise a bracket having a longitudinal flange, the longitudinal flange being spaced from the second longitudinal clip member to define the longitudinal channel therebetween.
100051 The angle defined by the first and second longitudinal clip members may be about 90 degrees.
100061 The connector may be extruded.
[0007] In another aspect, there is provided a kit for assembly of a brick mold assembly for a door frame, comprising: a brick mold portion configured to be installed adjacent a door jamb portion; and a connector configured for connecting the brick mold portion to the door jamb portion, the connector comprising a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.
[0008] In another aspect, there is provided a connector for connecting a brick mold portion to a door frame, the connector comprising: a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.
Brief Description of the Drawings 100091 Embodiments will now be described more fully with reference to the accompanying drawings in which:
[00010] Figure I is a perspective view of a door jamb assembly;
[00011] Figures 2a and 2b are exploded sectional and sectional views, respectively, of a door jamb portion forming part of the door jamb assembly of Figure 1, and taken along the indicated section line;
[00012] Figure 3 is an exploded, upper perspective view of a portion of the door jamb assembly of Figure 1;
[00013] Figure 4 is an exploded, lower perspective view of the portion of the door jamb assembly of Figure 3;
[00014] Figure 5 is a lower perspective view of the portion of the door jamb assembly of Figure 3;
[00015] Figure 6 is a perspective view of the door jamb assembly of Figure 1, installed in a doorway opening;
[00016] Figure 7 is a sectional view of the door jamb portion of Figure 2b, installed in a doorway opening and having a brick mold fitted thereto;
[00017] Figure 8 is a perspective view of another embodiment of a door jamb assembly, installed in a doorway opening;
[00018] Figures 9a and 9b are exploded sectional and sectional views, respectively, of a door jamb portion, a brick mold portion and a connector forming part of the door jamb assembly of Figure 8;
[00019] Figure 10 is a sectional view of the connector of Figure 9a;
[00020] Figure 11 is an enlarged fragmentary view of a portion of the door jamb portion, the brick mold portion and the connector of Figure 9b, identified by reference numeral 11;
[00021] Figure 12 is a sectional view of the door jamb portion, the brick mold portion and the connector of Figure 9b, installed in the doorway opening;
[00022] Figures 13a and 13b are exploded sectional and sectional views, respectively, of a door jamb portion, a brick mold portion and a connector forming part of another embodiment of a door jamb assembly;
[00023] Figure 14 is a sectional view of the connector of Figure 13a; and [00024] Figure 15 is an enlarged fragmentary view of a portion of the door jamb portion, the brick mold portion and the connector of Figure 13b, identified by reference numeral 15.
Detailed Description of the Embodiments [00025] Turning now to Figure 1, a door jamb assembly is shown and is generally indicated by reference numeral 20. Door jamb assembly 20 is configured to be installed in a doorway opening (not shown) of a wall for accommodating a door (not shown). The door jamb assembly 20 comprises three (3) door jamb portions that are connected by two (2) corner keys 24.
[00026] The door jamb portion 22 may be better seen in Figures 2 to 5.
Each door jamb portion 22 comprises an extruded, longitudinal door jamb member 30 and a longitudinal frame member 32. In this embodiment, the door jamb member 30 is fabricated of polyvinyl chloride (PVC) "cap stock", and is formed by co-extrusion of recycled (or "regrind") PVC and new PVC so as to provide a body of recycled PVC
that is coated with layer of new PVC, as is known in the art. The door jamb member 30 comprises a plurality of longitudinal internal cavities, which extend the length of the door jamb member 30 and which are separated by longitudinal internal webs.
In the embodiment shown, the door jamb member 30 comprises a first internal cavity 34, a second internal cavity 36 and a third internal cavity 38.
[00027] The door jamb member 30 also comprises a plurality of longitudinal channels that extend the length of the door jamb member 30. In the embodiment shown, the door jamb member 30 comprises a rounded channel 40 that extends the length of the door jamb member 30, and which is configured to engage the frame member 32 as described below. The door jamb member 30 further comprises a biased, longitudinal clip member 42 disposed along a first side of the rounded channel 40, and a longitudinal rib 44 disposed along a second side of the rounded channel 40.
Additionally, the door jamb member 30 comprises a channel 46 that is sized and shaped for accommodating a longitudinal reinforcement member (not shown) having a corresponding profile. The door jamb member 30 further comprises a channel that is sized and configured to accommodate weather stripping, and a biased, longitudinal clip member 48 spaced from a longitudinal outer corner 49 which together define an external, longitudinal channel 51 therebetween. The channel 51 is configured to accommodate trim surrounding the exterior of the doorway opening, such as for example a brick mold portion.
[000281 In this embodiment, each frame member 32 is formed by machining a longitudinal wooden board. In the embodiment shown, the frame member 32 comprises a rounded longitudinal edge 50, a longitudinal groove 52 disposed along a first side of the rounded longitudinal edge 50, and a longitudinal notch 62 disposed along a second side of the rounded longitudinal edge 50.
[00029] The rounded longitudinal edge 50 of the frame member 32 and the rounded channel 40 of the door jamb member 30 are configured to matingly engage so as to form a "bullnose" joint therebetween. When engaged in this manner, the longitudinal rib 44 matingly engages the longitudinal notch 62, and maintains the door jamb member 30 and the frame member 32 in a parallel relationship.
Additionally, when engaged in this manner, the biased, longitudinal clip member 42 engages the longitudinal groove 52 so as to secure the frame member 32 and the door jamb member 30 to each other. In this embodiment, the frame member 32 and the door jamb member 30 are further secured to each other by glue disposed between the rounded longitudinal edge 50 and the rounded channel 40.
[00030] The corner key 24 may be better seen in Figures 3 and 4. Each corner key 24 is a discrete and separate part from the door jamb portion 22. In this embodiment, each corner key 24 is fabricated of glass-filled nylon by injection molding. Each corner key 24 is generally shaped to engage the internal cavities 34, 36 and 38 of two (2) door jamb members 30, so as to form a generally ninety (90) degree, or a generally "right-angled", joint between two (2) door jamb portions 22.
Each corner key 24 comprises a first panel 70 and a second panel 72 that are connected along a common edge, and which are oriented generally orthogonally to each other. The first and second panels 70 and 72 are supported in relation to each other by gussets 74, and by a first end panel 76 and a second end panel 78. A
set of pins extends outwardly from each of the first and second panels 70 and 72. In the embodiment shown, each set of pins comprises a first pin 82, a second pin 84 and a third pin 86 extending from each of the first and second panels 70 and 72, and which are sized and positioned to engage the first internal cavity 34, the second internal cavity 36 and the third internal cavity 38, respectively, of the door jamb member 30.
The corner key 24 further comprises a cap pin 88 extending from the first end panel 76, which is sized and positioned to cover the channels 54 and interior cavities 92, when the corner key 24 connects the two (2) door jamb portions 22.
[00031] In use, the door jamb assembly 20 is assembled by providing two (2) corner keys 24 and three (3) door jamb portions 22, and namely two (2) door jamb portions 22 having a first length and one (1) door jamb portion 22 having a second length, the first length being greater than the second length. In this embodiment, each door jamb portion 22 is provided with the door jamb member 30 already secured to the frame member 32. Each end of the door jamb portion 22 having the second length is then connected to a corresponding end of a door jamb portion 22 having the first length using a corner key 24. In particular, adjacent door jamb portions 22 are connected by inserting a first pin 82, a second pin 84 and a third pin 86 of the corner key 24 into the first internal cavity 34, the second internal cavity 36 and the third internal cavity 38, respectively, of each adjacent door jamb portion 22. Once assembled, the assembled door jamb assembly may then be installed in a suitably-sized doorway opening in a wall, such that the one (1) door jamb portion 22 having the second length is oriented generally horizontally as a "header" and the two (2) door jamb portions 22 having the first length are oriented generally vertically.
[00032] Figure 6 shows the door jamb assembly 20 installed in a doorway opening of a wall 92. Hinges (not shown) and lock set recesses (not shown) have been added to the frame members of the vertically-oriented door jamb portions 22 for accommodating a door D.
[00033] Figure 7 shows the door jamb portion 22 of the door jamb assembly installed in another embodiment of a doorway opening of an exterior wall of a building, such as for example a house. As may be seen, the door jamb member 30 and the frame member 32 are positioned generally adjacent an inner surface 93 of a frame 94 surrounding the doorway opening. As may be seen, trim in the form of a longitudinal brick mold portion 95 is accommodated by the longitudinal channel 51, for generally finishing the joint between the door jamb portion 22 and an exterior surface 96 of the doorway opening frame 94 and a surface of an exterior brick wall 97. Additionally, in the embodiment shown, a reinforcement member in the form of a bar 98 having a "C"-shaped cross-sectional profile is accommodated by the channel 46, for generally providing reinforcement to the door jamb portion 22.
[00034] As will be appreciated, the "bullnose" joint formed between the rounded longitudinal edge 50 of the frame member 32 and the rounded channel 40 of the door jamb member 30 is strong, and is simple in design and may advantageously be fabricated at a low cost. Moreover, the inherent strength of the "bullnose"
joint advantageously eliminates the need for additional fasteners between the door jamb member 30 and the frame member 32, such as for example screws. Additionally, the rounded longitudinal edge 50 can advantageously be formed in a facile manner, and without folining burrs or surface roughness that might otherwise occur during formation of non-rounded edges by machining. As will be understood, the absence of burrs or surface roughness advantageously ensures a secure fit between the rounded channel 40 and the rounded longitudinal edge 50. Additionally, and as will be understood, the rounded longitudinal edge 50 does not have longitudinal corners or edges that would otherwise be likely to tear or chip upon insertion into a receiving channel of a member fabricated of non-wooden material.
1000351 As will be appreciated, the corner key 24 is configured to join two (2) door jamb portions 22 without requiring the ends of the door jamb portions 22 to be cut to a specific angle, other than the 90 degree angle formed during manufacture of the door jamb member 30. As will be appreciated, this eliminates the need to modify the ends of the door jamb portions 22, such as for example by cutting an end to a 45 degree angle by miter saw, during on site assembly of the door jamb assembly 20.
This allows the door jamb assembly 20 to be assembled from "stock" or unmodified parts, which advantageously reduces the cost of assembly of the door jamb assembly 20, and which advantageously allows parts that may have been damaged during transport or during assembly to be easily replaced.
[00036] The brick mold is not limited to that described above, and in other embodiments, the other brick molds may be used. For example, Figure 8 shows
Brief Description of the Drawings 100091 Embodiments will now be described more fully with reference to the accompanying drawings in which:
[00010] Figure I is a perspective view of a door jamb assembly;
[00011] Figures 2a and 2b are exploded sectional and sectional views, respectively, of a door jamb portion forming part of the door jamb assembly of Figure 1, and taken along the indicated section line;
[00012] Figure 3 is an exploded, upper perspective view of a portion of the door jamb assembly of Figure 1;
[00013] Figure 4 is an exploded, lower perspective view of the portion of the door jamb assembly of Figure 3;
[00014] Figure 5 is a lower perspective view of the portion of the door jamb assembly of Figure 3;
[00015] Figure 6 is a perspective view of the door jamb assembly of Figure 1, installed in a doorway opening;
[00016] Figure 7 is a sectional view of the door jamb portion of Figure 2b, installed in a doorway opening and having a brick mold fitted thereto;
[00017] Figure 8 is a perspective view of another embodiment of a door jamb assembly, installed in a doorway opening;
[00018] Figures 9a and 9b are exploded sectional and sectional views, respectively, of a door jamb portion, a brick mold portion and a connector forming part of the door jamb assembly of Figure 8;
[00019] Figure 10 is a sectional view of the connector of Figure 9a;
[00020] Figure 11 is an enlarged fragmentary view of a portion of the door jamb portion, the brick mold portion and the connector of Figure 9b, identified by reference numeral 11;
[00021] Figure 12 is a sectional view of the door jamb portion, the brick mold portion and the connector of Figure 9b, installed in the doorway opening;
[00022] Figures 13a and 13b are exploded sectional and sectional views, respectively, of a door jamb portion, a brick mold portion and a connector forming part of another embodiment of a door jamb assembly;
[00023] Figure 14 is a sectional view of the connector of Figure 13a; and [00024] Figure 15 is an enlarged fragmentary view of a portion of the door jamb portion, the brick mold portion and the connector of Figure 13b, identified by reference numeral 15.
Detailed Description of the Embodiments [00025] Turning now to Figure 1, a door jamb assembly is shown and is generally indicated by reference numeral 20. Door jamb assembly 20 is configured to be installed in a doorway opening (not shown) of a wall for accommodating a door (not shown). The door jamb assembly 20 comprises three (3) door jamb portions that are connected by two (2) corner keys 24.
[00026] The door jamb portion 22 may be better seen in Figures 2 to 5.
Each door jamb portion 22 comprises an extruded, longitudinal door jamb member 30 and a longitudinal frame member 32. In this embodiment, the door jamb member 30 is fabricated of polyvinyl chloride (PVC) "cap stock", and is formed by co-extrusion of recycled (or "regrind") PVC and new PVC so as to provide a body of recycled PVC
that is coated with layer of new PVC, as is known in the art. The door jamb member 30 comprises a plurality of longitudinal internal cavities, which extend the length of the door jamb member 30 and which are separated by longitudinal internal webs.
In the embodiment shown, the door jamb member 30 comprises a first internal cavity 34, a second internal cavity 36 and a third internal cavity 38.
[00027] The door jamb member 30 also comprises a plurality of longitudinal channels that extend the length of the door jamb member 30. In the embodiment shown, the door jamb member 30 comprises a rounded channel 40 that extends the length of the door jamb member 30, and which is configured to engage the frame member 32 as described below. The door jamb member 30 further comprises a biased, longitudinal clip member 42 disposed along a first side of the rounded channel 40, and a longitudinal rib 44 disposed along a second side of the rounded channel 40.
Additionally, the door jamb member 30 comprises a channel 46 that is sized and shaped for accommodating a longitudinal reinforcement member (not shown) having a corresponding profile. The door jamb member 30 further comprises a channel that is sized and configured to accommodate weather stripping, and a biased, longitudinal clip member 48 spaced from a longitudinal outer corner 49 which together define an external, longitudinal channel 51 therebetween. The channel 51 is configured to accommodate trim surrounding the exterior of the doorway opening, such as for example a brick mold portion.
[000281 In this embodiment, each frame member 32 is formed by machining a longitudinal wooden board. In the embodiment shown, the frame member 32 comprises a rounded longitudinal edge 50, a longitudinal groove 52 disposed along a first side of the rounded longitudinal edge 50, and a longitudinal notch 62 disposed along a second side of the rounded longitudinal edge 50.
[00029] The rounded longitudinal edge 50 of the frame member 32 and the rounded channel 40 of the door jamb member 30 are configured to matingly engage so as to form a "bullnose" joint therebetween. When engaged in this manner, the longitudinal rib 44 matingly engages the longitudinal notch 62, and maintains the door jamb member 30 and the frame member 32 in a parallel relationship.
Additionally, when engaged in this manner, the biased, longitudinal clip member 42 engages the longitudinal groove 52 so as to secure the frame member 32 and the door jamb member 30 to each other. In this embodiment, the frame member 32 and the door jamb member 30 are further secured to each other by glue disposed between the rounded longitudinal edge 50 and the rounded channel 40.
[00030] The corner key 24 may be better seen in Figures 3 and 4. Each corner key 24 is a discrete and separate part from the door jamb portion 22. In this embodiment, each corner key 24 is fabricated of glass-filled nylon by injection molding. Each corner key 24 is generally shaped to engage the internal cavities 34, 36 and 38 of two (2) door jamb members 30, so as to form a generally ninety (90) degree, or a generally "right-angled", joint between two (2) door jamb portions 22.
Each corner key 24 comprises a first panel 70 and a second panel 72 that are connected along a common edge, and which are oriented generally orthogonally to each other. The first and second panels 70 and 72 are supported in relation to each other by gussets 74, and by a first end panel 76 and a second end panel 78. A
set of pins extends outwardly from each of the first and second panels 70 and 72. In the embodiment shown, each set of pins comprises a first pin 82, a second pin 84 and a third pin 86 extending from each of the first and second panels 70 and 72, and which are sized and positioned to engage the first internal cavity 34, the second internal cavity 36 and the third internal cavity 38, respectively, of the door jamb member 30.
The corner key 24 further comprises a cap pin 88 extending from the first end panel 76, which is sized and positioned to cover the channels 54 and interior cavities 92, when the corner key 24 connects the two (2) door jamb portions 22.
[00031] In use, the door jamb assembly 20 is assembled by providing two (2) corner keys 24 and three (3) door jamb portions 22, and namely two (2) door jamb portions 22 having a first length and one (1) door jamb portion 22 having a second length, the first length being greater than the second length. In this embodiment, each door jamb portion 22 is provided with the door jamb member 30 already secured to the frame member 32. Each end of the door jamb portion 22 having the second length is then connected to a corresponding end of a door jamb portion 22 having the first length using a corner key 24. In particular, adjacent door jamb portions 22 are connected by inserting a first pin 82, a second pin 84 and a third pin 86 of the corner key 24 into the first internal cavity 34, the second internal cavity 36 and the third internal cavity 38, respectively, of each adjacent door jamb portion 22. Once assembled, the assembled door jamb assembly may then be installed in a suitably-sized doorway opening in a wall, such that the one (1) door jamb portion 22 having the second length is oriented generally horizontally as a "header" and the two (2) door jamb portions 22 having the first length are oriented generally vertically.
[00032] Figure 6 shows the door jamb assembly 20 installed in a doorway opening of a wall 92. Hinges (not shown) and lock set recesses (not shown) have been added to the frame members of the vertically-oriented door jamb portions 22 for accommodating a door D.
[00033] Figure 7 shows the door jamb portion 22 of the door jamb assembly installed in another embodiment of a doorway opening of an exterior wall of a building, such as for example a house. As may be seen, the door jamb member 30 and the frame member 32 are positioned generally adjacent an inner surface 93 of a frame 94 surrounding the doorway opening. As may be seen, trim in the form of a longitudinal brick mold portion 95 is accommodated by the longitudinal channel 51, for generally finishing the joint between the door jamb portion 22 and an exterior surface 96 of the doorway opening frame 94 and a surface of an exterior brick wall 97. Additionally, in the embodiment shown, a reinforcement member in the form of a bar 98 having a "C"-shaped cross-sectional profile is accommodated by the channel 46, for generally providing reinforcement to the door jamb portion 22.
[00034] As will be appreciated, the "bullnose" joint formed between the rounded longitudinal edge 50 of the frame member 32 and the rounded channel 40 of the door jamb member 30 is strong, and is simple in design and may advantageously be fabricated at a low cost. Moreover, the inherent strength of the "bullnose"
joint advantageously eliminates the need for additional fasteners between the door jamb member 30 and the frame member 32, such as for example screws. Additionally, the rounded longitudinal edge 50 can advantageously be formed in a facile manner, and without folining burrs or surface roughness that might otherwise occur during formation of non-rounded edges by machining. As will be understood, the absence of burrs or surface roughness advantageously ensures a secure fit between the rounded channel 40 and the rounded longitudinal edge 50. Additionally, and as will be understood, the rounded longitudinal edge 50 does not have longitudinal corners or edges that would otherwise be likely to tear or chip upon insertion into a receiving channel of a member fabricated of non-wooden material.
1000351 As will be appreciated, the corner key 24 is configured to join two (2) door jamb portions 22 without requiring the ends of the door jamb portions 22 to be cut to a specific angle, other than the 90 degree angle formed during manufacture of the door jamb member 30. As will be appreciated, this eliminates the need to modify the ends of the door jamb portions 22, such as for example by cutting an end to a 45 degree angle by miter saw, during on site assembly of the door jamb assembly 20.
This allows the door jamb assembly 20 to be assembled from "stock" or unmodified parts, which advantageously reduces the cost of assembly of the door jamb assembly 20, and which advantageously allows parts that may have been damaged during transport or during assembly to be easily replaced.
[00036] The brick mold is not limited to that described above, and in other embodiments, the other brick molds may be used. For example, Figure 8 shows
- 9 -another embodiment of a door jamb assembly, which is generally indicated by reference numeral 120. Door jamb assembly 120 is configured to be installed in a doorway opening of an exterior wall of a building, such as for example a house, for accommodating a door D. The door jamb assembly 120 is generally similar to the door jamb assembly 20 described above and with reference to Figures 1 to 6, and comprises three (3) door jamb portions 22 that are connected by two (2) corner keys 24. In this embodiment, each door jamb portion 22 comprises an extruded, longitudinal door jamb member 30 and a longitudinal frame member 32, as described above and with reference to Figures 1 to 6.
[00037] The door jamb assembly 120 also comprises a brick mold assembly comprising a plurality of extruded, longitudinal brick mold portions 150. One of the brick mold portions 150 may be better seen in Figures 9a and 9b. In this embodiment, each brick mold portion 150 is fabricated of PVC "cap stock", and is formed by co-extrusion of recycled (or "regrind") PVC and new PVC so as to provide a body of recycled PVC that is coated with layer of new PVC, as is known in the art. The brick mold portion 150 comprises a plurality of longitudinal internal cavities, which extend the length of the brick mold portion 150 and which are separated by longitudinal internal webs. The brick mold portion 150 further comprises a longitudinal fastening flange 152 extending outwardly from the brick mold portion 150, and which extends the length thereof. The brick mold portion 150 also comprises a longitudinal flange 154 and a biased, longitudinal clip member 156 that extends outwardly from the brick mold portion 150, both of which extend the length of the brick mold portion 150 and which together define an external, longitudinal channel 157 therebetween. The longitudinal clip member 156 has a longitudinal rib 158 disposed along an outer side thereof, and which extends the length thereof.
[00038] The brick mold assembly also comprises a plurality of longitudinal connectors 160, each connector 160 being configured for connecting the brick mold portion 150 to the door jamb portion 22. In this embodiment, the connector 160 is formed by extrusion, and is fabricated of extruded PVC. Each connector 160 comprises a biased, first longitudinal clip member 162 and a biased, second longitudinal clip member 164 that are joined by a longitudinal intermediate portion 166. The longitudinal axis of the first longitudinal clip member 162 is parallel to the
[00037] The door jamb assembly 120 also comprises a brick mold assembly comprising a plurality of extruded, longitudinal brick mold portions 150. One of the brick mold portions 150 may be better seen in Figures 9a and 9b. In this embodiment, each brick mold portion 150 is fabricated of PVC "cap stock", and is formed by co-extrusion of recycled (or "regrind") PVC and new PVC so as to provide a body of recycled PVC that is coated with layer of new PVC, as is known in the art. The brick mold portion 150 comprises a plurality of longitudinal internal cavities, which extend the length of the brick mold portion 150 and which are separated by longitudinal internal webs. The brick mold portion 150 further comprises a longitudinal fastening flange 152 extending outwardly from the brick mold portion 150, and which extends the length thereof. The brick mold portion 150 also comprises a longitudinal flange 154 and a biased, longitudinal clip member 156 that extends outwardly from the brick mold portion 150, both of which extend the length of the brick mold portion 150 and which together define an external, longitudinal channel 157 therebetween. The longitudinal clip member 156 has a longitudinal rib 158 disposed along an outer side thereof, and which extends the length thereof.
[00038] The brick mold assembly also comprises a plurality of longitudinal connectors 160, each connector 160 being configured for connecting the brick mold portion 150 to the door jamb portion 22. In this embodiment, the connector 160 is formed by extrusion, and is fabricated of extruded PVC. Each connector 160 comprises a biased, first longitudinal clip member 162 and a biased, second longitudinal clip member 164 that are joined by a longitudinal intermediate portion 166. The longitudinal axis of the first longitudinal clip member 162 is parallel to the
- 10 -longitudinal axis of the second longitudinal clip member 164, and the second longitudinal clip member 164 is oriented relative to the first longitudinal clip member 162 so as to define an angle 8therebetween, as shown in Figure 10. In this embodiment, the angle is about ninety (90) degrees. The first longitudinal clip member 162 and the longitudinal intermediate portion 166 define a longitudinal inner channel 168 therebetween, and the second longitudinal clip member 164 and the longitudinal intermediate portion 166 define a longitudinal outer comer 170 therebetween.
[00039] The second longitudinal clip member 164 of the connector 160 is configured to matingly engage the channel 51 of the door jamb member 30, and to cooperate with the longitudinal clip member 48 for connecting the connector 160 to the door jamb portion 22. When the connector 160 and door jamb portion 22 are connected in this manner, the longitudinal outer corner 170 abuts a longitudinal corner of the door jamb portion 22 in a nestled manner, as shown in Figure 11.
[00040] The longitudinal clip member 156 of the brick mold portion 150 is configured to matingly engage the longitudinal inner channel 168 of the connector 160, and to cooperate with the first longitudinal clip member 162 for connecting the brick mold portion 150 to the connector 160. Reciprocally, the first longitudinal clip member 162 of the connector 160 is configured to matingly engage the longitudinal channel 157 of the brick mold portion 150, for cooperating with the longitudinal clip member 156 of the brick mold portion 150. When the brick mold portion 150 and connector 160 are connected in this manner, the longitudinal rib 158 abuts an outer surface of the longitudinal clip member 48 of the door jamb member 30. As will be understood, when engaged in this manner, the longitudinal rib 158 covers the joint between the longitudinal clip member 48 and the longitudinal clip member 156, and urges the longitudinal clip member 48 toward the second longitudinal clip member, 164 for securing the connection between the door jamb member 30, the brick mold portion 150 and the connector 160.
[00041] In use, the brick mold assembly 120 is assembled by providing two (2) corner keys 24 and three (3) door jamb portions 22, and namely two (2) door jamb portions 22 of a first length and configured for being oriented generally vertically and one (1) door jamb portion 22 of a second length and configured for being oriented
[00039] The second longitudinal clip member 164 of the connector 160 is configured to matingly engage the channel 51 of the door jamb member 30, and to cooperate with the longitudinal clip member 48 for connecting the connector 160 to the door jamb portion 22. When the connector 160 and door jamb portion 22 are connected in this manner, the longitudinal outer corner 170 abuts a longitudinal corner of the door jamb portion 22 in a nestled manner, as shown in Figure 11.
[00040] The longitudinal clip member 156 of the brick mold portion 150 is configured to matingly engage the longitudinal inner channel 168 of the connector 160, and to cooperate with the first longitudinal clip member 162 for connecting the brick mold portion 150 to the connector 160. Reciprocally, the first longitudinal clip member 162 of the connector 160 is configured to matingly engage the longitudinal channel 157 of the brick mold portion 150, for cooperating with the longitudinal clip member 156 of the brick mold portion 150. When the brick mold portion 150 and connector 160 are connected in this manner, the longitudinal rib 158 abuts an outer surface of the longitudinal clip member 48 of the door jamb member 30. As will be understood, when engaged in this manner, the longitudinal rib 158 covers the joint between the longitudinal clip member 48 and the longitudinal clip member 156, and urges the longitudinal clip member 48 toward the second longitudinal clip member, 164 for securing the connection between the door jamb member 30, the brick mold portion 150 and the connector 160.
[00041] In use, the brick mold assembly 120 is assembled by providing two (2) corner keys 24 and three (3) door jamb portions 22, and namely two (2) door jamb portions 22 of a first length and configured for being oriented generally vertically and one (1) door jamb portion 22 of a second length and configured for being oriented
- 11 -generally horizontally, and namely as a "header" door jamb portion 22, the first length being greater than the second length. In this embodiment, each door jamb portion 22 is provided with the door jamb member 30 already secured to the frame member 32.
Each end of the "header" door jamb portion 22 of the second length is then connected to a corresponding end of a door jamb portion 22 of the first length using a corner key 24, in the manner described above for door jamb assembly 20 and with reference to Figures 1 to 6.
[00042] Three (3) connectors 160 are provided, namely two (2) connectors each having generally the same length as the door jamb portion 22 of the first length, and one (1) connector 160 having generally the same length as the header door jamb portion 22 of the second length. Each connector 160 is connected to its corresponding door jamb portion 22 by inserting the second longitudinal clip member 164 into the longitudinal channel 51 of the door jamb portion 22, such that the second longitudinal clip member 164 cooperates with the longitudinal clip member 48, and such that the longitudinal outer corner 170 abuts a longitudinal corner of the door jamb portion 22 in a nestled manner.
[00043] Three (3) brick mold portions 150 are provided, namely two (2) brick mold portions 150 each having a third length generally corresponding to the length of the door jamb portion 22 of the first length plus the width of one (1) corner key 24, and one (1) brick mold portion 150 having a fourth length generally corresponding to the length of the header door jamb portion 22 of the second length plus the width of two (2) corner keys 24. Both longitudinal ends of the brick mold portion 150 having the fourth length are cut to about a forty-five (45) degree angle, while only one longitudinal end of each brick mold portion 150 having the third length is cut to about a forty-five (45) degree angle. Each brick mold portion 150 is connected to its corresponding connector 160 by inserting the longitudinal clip member 156 into the longitudinal inner channel 168 of the connector 160, such that the longitudinal clip member 156 cooperates with the first longitudinal clip member 162. When connected in this manner, the longitudinal rib 158 of the brick mold portion 150 abuts an outer surface of the longitudinal clip member 48 of the door jamb portion 22. As will be understood, once all three (3) brick mold portions 150 are installed, the ends of the
Each end of the "header" door jamb portion 22 of the second length is then connected to a corresponding end of a door jamb portion 22 of the first length using a corner key 24, in the manner described above for door jamb assembly 20 and with reference to Figures 1 to 6.
[00042] Three (3) connectors 160 are provided, namely two (2) connectors each having generally the same length as the door jamb portion 22 of the first length, and one (1) connector 160 having generally the same length as the header door jamb portion 22 of the second length. Each connector 160 is connected to its corresponding door jamb portion 22 by inserting the second longitudinal clip member 164 into the longitudinal channel 51 of the door jamb portion 22, such that the second longitudinal clip member 164 cooperates with the longitudinal clip member 48, and such that the longitudinal outer corner 170 abuts a longitudinal corner of the door jamb portion 22 in a nestled manner.
[00043] Three (3) brick mold portions 150 are provided, namely two (2) brick mold portions 150 each having a third length generally corresponding to the length of the door jamb portion 22 of the first length plus the width of one (1) corner key 24, and one (1) brick mold portion 150 having a fourth length generally corresponding to the length of the header door jamb portion 22 of the second length plus the width of two (2) corner keys 24. Both longitudinal ends of the brick mold portion 150 having the fourth length are cut to about a forty-five (45) degree angle, while only one longitudinal end of each brick mold portion 150 having the third length is cut to about a forty-five (45) degree angle. Each brick mold portion 150 is connected to its corresponding connector 160 by inserting the longitudinal clip member 156 into the longitudinal inner channel 168 of the connector 160, such that the longitudinal clip member 156 cooperates with the first longitudinal clip member 162. When connected in this manner, the longitudinal rib 158 of the brick mold portion 150 abuts an outer surface of the longitudinal clip member 48 of the door jamb portion 22. As will be understood, once all three (3) brick mold portions 150 are installed, the ends of the
- 12 -brick mold portions 150 cut to about forty-five (45) degree angles abut to form miter joints, as shown in Figure 8.
1000441 Figure 12 shows a section of the door jamb assembly 120 installed in the doorway opening of an exterior wall of a building, such as for example a house.
As may be seen, the door jamb portion 22 is positioned generally adjacent an inner surface 182 of a frame 180 surrounding the doorway opening. The brick mold portion 150 is connected to the door jamb portion 22 by the connector 160, and generally finishes the joint between the door jamb portion 22 and an exterior surface adjacent the doorway opening.
[00045] Other configurations are possible. For example, Figures 13 to 15 show a door jamb portion, a connector and a brick mold portion forming part of another embodiment of a door jamb assembly. Similar to door jamb assembly 120 described above and with reference to Figures 8 to 12, the door jamb assembly of this embodiment is configured to be installed in a doorway opening of an exterior wall of a building, such as for example a house, for accommodating a door. The door jamb assembly of this embodiment is generally similar to the door jamb assembly 20 described above and with reference to Figures 1 to 6, and comprises three (3) door jamb portions 22 that are connected by two (2) corner keys 24.
1000461 In this embodiment, each door jamb portion 22 comprises an extruded, longitudinal door jamb member 230 and a longitudinal frame member 32. The longitudinal frame member 32 has been described above and with reference to Figures 1 to 6. Door jamb member 230 is generally similar to the door jamb member 30 described above and with reference to Figures 1 to 6, but further comprises a longitudinal rib 253 extending the length thereof. The longitudinal rib 253 has a generally square-shaped profile that defines a first longitudinal outer corner 249 and a second longitudinal outer corner 255, as shown in Figure 15. The door jamb member 230 also comprises a biased, longitudinal clip member 248 spaced from the longitudinal outer corner 249 which together define an external, longitudinal channel 251 therebetween.
[00047] The door jamb assembly of this embodiment comprises a plurality of brick mold portions 150. The brick mold portion 150 has been described above and with reference to Figures 8 to 12.
1000441 Figure 12 shows a section of the door jamb assembly 120 installed in the doorway opening of an exterior wall of a building, such as for example a house.
As may be seen, the door jamb portion 22 is positioned generally adjacent an inner surface 182 of a frame 180 surrounding the doorway opening. The brick mold portion 150 is connected to the door jamb portion 22 by the connector 160, and generally finishes the joint between the door jamb portion 22 and an exterior surface adjacent the doorway opening.
[00045] Other configurations are possible. For example, Figures 13 to 15 show a door jamb portion, a connector and a brick mold portion forming part of another embodiment of a door jamb assembly. Similar to door jamb assembly 120 described above and with reference to Figures 8 to 12, the door jamb assembly of this embodiment is configured to be installed in a doorway opening of an exterior wall of a building, such as for example a house, for accommodating a door. The door jamb assembly of this embodiment is generally similar to the door jamb assembly 20 described above and with reference to Figures 1 to 6, and comprises three (3) door jamb portions 22 that are connected by two (2) corner keys 24.
1000461 In this embodiment, each door jamb portion 22 comprises an extruded, longitudinal door jamb member 230 and a longitudinal frame member 32. The longitudinal frame member 32 has been described above and with reference to Figures 1 to 6. Door jamb member 230 is generally similar to the door jamb member 30 described above and with reference to Figures 1 to 6, but further comprises a longitudinal rib 253 extending the length thereof. The longitudinal rib 253 has a generally square-shaped profile that defines a first longitudinal outer corner 249 and a second longitudinal outer corner 255, as shown in Figure 15. The door jamb member 230 also comprises a biased, longitudinal clip member 248 spaced from the longitudinal outer corner 249 which together define an external, longitudinal channel 251 therebetween.
[00047] The door jamb assembly of this embodiment comprises a plurality of brick mold portions 150. The brick mold portion 150 has been described above and with reference to Figures 8 to 12.
- 13 -[00048] The brick mold assembly of this embodiment also comprises a plurality of longitudinal connectors 260, each connector 260 being configured for connecting the brick mold portion 150 to the door jamb portion 22. In this embodiment, the connector 260 is formed by extrusion, and is fabricated of extruded PVC. Each connector 260 comprises a biased, first longitudinal clip member 262 and a biased, second longitudinal clip member 264 joined thereto. The longitudinal axis of the first longitudinal clip member 262 is parallel to the longitudinal axis of the second longitudinal clip member 264, and the second longitudinal clip member 264 is oriented relative to the first longitudinal clip member 262 so as to define an angle 61 therebetween, as shown in Figure 14. In this embodiment, the angle is about ninety (90) degrees. The connector 260 also comprises a longitudinal bracket 266 comprising a longitudinal flange 267 that is spaced from the second longitudinal clip member 264 so as to define a longitudinal inner channel 268 therebetween. As shown in Figure 14, the second longitudinal clip member 264 and the longitudinal bracket 266 define a first longitudinal inner corner 269 therebetween, and the longitudinal flange 267 of the longitudinal bracket 266 defines a second longitudinal inner corner 270 therein.
1000491 The second longitudinal clip member 264 of the connector 260 is configured to matingly engage the channel 251 of the door jamb member 230, and to cooperate with the longitudinal clip member 248 for connecting the connector 260 to the door jamb member 230. Reciprocally, the longitudinal rib 253 of the door jamb member 230 is configured to matingly engage the longitudinal inner channel 268 of the connector 260. When the connector 260 and door jamb member 230 are connected in this manner, the first and second longitudinal outer corners 249 and 255 abut the first and second longitudinal inner corners 269 and 270, respectively, in a nestled manner, as shown in Figure 15.
1000501 The first longitudinal clip member 262 of the connector 260 is configured to matingly engage the longitudinal channel 157 of the brick mold portion 150, for cooperating with the longitudinal clip member 156 of the brick mold portion 150. Reciprocally, the longitudinal clip member 156 of the brick mold portion 150 is configured to abut an end of the longitudinal clip member 248, and to cooperate with the first longitudinal clip member 262 for connecting the brick mold portion 150 to
1000491 The second longitudinal clip member 264 of the connector 260 is configured to matingly engage the channel 251 of the door jamb member 230, and to cooperate with the longitudinal clip member 248 for connecting the connector 260 to the door jamb member 230. Reciprocally, the longitudinal rib 253 of the door jamb member 230 is configured to matingly engage the longitudinal inner channel 268 of the connector 260. When the connector 260 and door jamb member 230 are connected in this manner, the first and second longitudinal outer corners 249 and 255 abut the first and second longitudinal inner corners 269 and 270, respectively, in a nestled manner, as shown in Figure 15.
1000501 The first longitudinal clip member 262 of the connector 260 is configured to matingly engage the longitudinal channel 157 of the brick mold portion 150, for cooperating with the longitudinal clip member 156 of the brick mold portion 150. Reciprocally, the longitudinal clip member 156 of the brick mold portion 150 is configured to abut an end of the longitudinal clip member 248, and to cooperate with the first longitudinal clip member 262 for connecting the brick mold portion 150 to
- 14 -the connector 260. When the brick mold portion 150 and connector 260 are connected in this manner, the longitudinal rib 158 abuts an outer surface of the longitudinal clip member 248 of the door jamb member 230. As will be understood, when engaged in this manner, the longitudinal rib 258 covers the joint between the longitudinal clip member 248 and the longitudinal clip member 156, and urges the longitudinal clip member 248 toward the second longitudinal clip member 264 for securing the connection between the door jamb member 230, the brick mold portion 150 and the connector 260.
[00051] In use, the brick mold assembly of this embodiment is assembled by providing two (2) corner keys 24 and three (3) door jamb portions 22, and namely two (2) door jamb portions 22 of a first length and configured for being oriented generally vertically and one (1) door jamb portion 22 of a second length and configured for being oriented generally horizontally, and namely as a "header" door jamb portion 22, the first length being greater than the second length. In this embodiment, each door jamb portion 22 is provided with the door jamb member 30 already secured to the frame member 32. Each end of the "header" door jamb portion 22 of the second length is then connected to a corresponding end of a door jamb portion 22 of the first length using a corner key 24, in the manner described above for door jamb assembly 20 and with reference to Figures 1 to 6.
[00052] Three (3) connectors 260 are provided, namely two (2) connectors each having generally the same length as the door jamb portion 22 of the first length, and one (1) connector 260 having generally the same length as the header door jamb portion 22 of the second length. Each connector 260 is connected to its corresponding door jamb portion 22 by inserting the second longitudinal clip member 164 into the longitudinal channel 251 of the door jamb portion 22, such that the second longitudinal clip member 264 cooperates with the longitudinal clip member 248, and such that the first and second longitudinal outer corners 249 and 255 of the longitudinal rib 253 abut the first and second longitudinal inner corners 269 and 270, respectively, of the longitudinal channel 268 in a nestled manner.
[00053] Three (3) brick mold portions 150 are provided, namely two (2) brick mold portions 150 each having a third length generally corresponding to the length of the door jamb portion 22 of the first length plus the width of one (1) corner key 24,
[00051] In use, the brick mold assembly of this embodiment is assembled by providing two (2) corner keys 24 and three (3) door jamb portions 22, and namely two (2) door jamb portions 22 of a first length and configured for being oriented generally vertically and one (1) door jamb portion 22 of a second length and configured for being oriented generally horizontally, and namely as a "header" door jamb portion 22, the first length being greater than the second length. In this embodiment, each door jamb portion 22 is provided with the door jamb member 30 already secured to the frame member 32. Each end of the "header" door jamb portion 22 of the second length is then connected to a corresponding end of a door jamb portion 22 of the first length using a corner key 24, in the manner described above for door jamb assembly 20 and with reference to Figures 1 to 6.
[00052] Three (3) connectors 260 are provided, namely two (2) connectors each having generally the same length as the door jamb portion 22 of the first length, and one (1) connector 260 having generally the same length as the header door jamb portion 22 of the second length. Each connector 260 is connected to its corresponding door jamb portion 22 by inserting the second longitudinal clip member 164 into the longitudinal channel 251 of the door jamb portion 22, such that the second longitudinal clip member 264 cooperates with the longitudinal clip member 248, and such that the first and second longitudinal outer corners 249 and 255 of the longitudinal rib 253 abut the first and second longitudinal inner corners 269 and 270, respectively, of the longitudinal channel 268 in a nestled manner.
[00053] Three (3) brick mold portions 150 are provided, namely two (2) brick mold portions 150 each having a third length generally corresponding to the length of the door jamb portion 22 of the first length plus the width of one (1) corner key 24,
- 15 -and one (1) brick mold portion 150 having a fourth length generally corresponding to the length of the header door jamb portion 22 of the second length plus the width of two (2) corner keys 24. Both longitudinal ends of the brick mold portion 150 having the fourth length are cut to about a forty-five (45) degree angle, while only one longitudinal end of each brick mold portion 150 having the third length is cut to about a forty-five (45) degree angle. Each brick mold portion 150 is connected to its corresponding connector 260 by inserting the longitudinal clip member 156 between the longitudinal clip member 248 and the connector 260, such that the longitudinal clip member 156 cooperates with the first longitudinal clip member 262. When connected in this manner, the longitudinal rib 158 of the brick mold portion 150 abuts an outer surface of the longitudinal clip member 248 of the door jamb portion 22.
[00054] It will be understood that the brick mold assembly is not limited to use with the door jamb portion described above, and in other embodiments, the brick mold assembly may alternatively be used with a door frame assembly comprising door jamb portions each having a different cross-sectional profile than that of the door jamb portion described above, and/or comprising a header having a different cross-sectional profile than that of the header door jamb portion described above.
1000551 Although in embodiments described above, the door jamb assembly comprises two (2) door jamb portions having a first length and one (1) door jamb portion having a second length, where the first length being greater than the second length, in other embodiments, other configurations are possible depending on the dimensions of the doorway opening. For example, in other embodiments, the first length may alternatively be less than the second length, or the door jamb assembly may alternatively comprise three (3) door jamb portions having the same length.
[00056] Although in embodiments described above, the brick mold portion is fabricated of polyvinyl chloride (PVC) "cap stock", in other embodiments, the brick mold portion may alternatively be fabricated of virgin PVC, recycled PVC, or of any other suitable extrudable polymer. In still other embodiments, the brick mold portion may alternatively be fabricated of extruded aluminum, extruded aluminum alloy, or pulltruded fiberglass composite.
[00057] It will be understood that the cross-sectional profile of the brick mold portion is not limited to that of the embodiments described above, and in other
[00054] It will be understood that the brick mold assembly is not limited to use with the door jamb portion described above, and in other embodiments, the brick mold assembly may alternatively be used with a door frame assembly comprising door jamb portions each having a different cross-sectional profile than that of the door jamb portion described above, and/or comprising a header having a different cross-sectional profile than that of the header door jamb portion described above.
1000551 Although in embodiments described above, the door jamb assembly comprises two (2) door jamb portions having a first length and one (1) door jamb portion having a second length, where the first length being greater than the second length, in other embodiments, other configurations are possible depending on the dimensions of the doorway opening. For example, in other embodiments, the first length may alternatively be less than the second length, or the door jamb assembly may alternatively comprise three (3) door jamb portions having the same length.
[00056] Although in embodiments described above, the brick mold portion is fabricated of polyvinyl chloride (PVC) "cap stock", in other embodiments, the brick mold portion may alternatively be fabricated of virgin PVC, recycled PVC, or of any other suitable extrudable polymer. In still other embodiments, the brick mold portion may alternatively be fabricated of extruded aluminum, extruded aluminum alloy, or pulltruded fiberglass composite.
[00057] It will be understood that the cross-sectional profile of the brick mold portion is not limited to that of the embodiments described above, and in other
- 16 -embodiments, the brick mold portion may alternatively have a different cross-sectional profile. For example, the brick mold portion may alternatively have a different configuration of longitudinal internal cavities and flanges.
1000581 It will be understood that the cross-sectional profile of the connector is not limited to that of the embodiments described above, and in other embodiments, the connector may alternatively have a different cross-sectional profile. For example, the angle defined between the second longitudinal clip member and the first longitudinal clip member may be different than ninety (90) degrees. In such an embodiment, the brick mold portion and/or the door jamb portion, or other door frame portion to which the connector is configured to be connected, would be suitably configured to accommodate the connector comprising the first and second longitudinal clip members.
1000591 Although in embodiments described above, during assembly of the door jamb assembly, three (3) connectors are provided, each having generally the same length as its corresponding door jamb portion, in other embodiments, a different number of connectors may alternatively be provided, where one or more of the connectors has a shorter length than its corresponding door jamb portion.
1000601 Although in embodiments described above, the connector is formed by extrusion, in other embodiments, the connector may alternatively be formed by another suitable method.
1000611 Although in embodiments described above, the connector is fabricated of PVC, in other embodiments, the connector may alternatively be fabricated of another suitable material.
1000621 Although in embodiments described above, the longitudinal internal cavities and the longitudinal channels of the brick mold portion extend the length of the brick mold portion, in other embodiments, at least one of the longitudinal internal cavities and/or at least one of the longitudinal channels may alternatively not extend the length of the brick mold portion.
[00063] The invention also contemplates a kit of parts which, when assembled, forms the door jamb assembly of one or more of the embodiments described above.
1000641 Although embodiments have been described above with reference to the accompanying drawings, those of skill in the art will appreciate that variations and
1000581 It will be understood that the cross-sectional profile of the connector is not limited to that of the embodiments described above, and in other embodiments, the connector may alternatively have a different cross-sectional profile. For example, the angle defined between the second longitudinal clip member and the first longitudinal clip member may be different than ninety (90) degrees. In such an embodiment, the brick mold portion and/or the door jamb portion, or other door frame portion to which the connector is configured to be connected, would be suitably configured to accommodate the connector comprising the first and second longitudinal clip members.
1000591 Although in embodiments described above, during assembly of the door jamb assembly, three (3) connectors are provided, each having generally the same length as its corresponding door jamb portion, in other embodiments, a different number of connectors may alternatively be provided, where one or more of the connectors has a shorter length than its corresponding door jamb portion.
1000601 Although in embodiments described above, the connector is formed by extrusion, in other embodiments, the connector may alternatively be formed by another suitable method.
1000611 Although in embodiments described above, the connector is fabricated of PVC, in other embodiments, the connector may alternatively be fabricated of another suitable material.
1000621 Although in embodiments described above, the longitudinal internal cavities and the longitudinal channels of the brick mold portion extend the length of the brick mold portion, in other embodiments, at least one of the longitudinal internal cavities and/or at least one of the longitudinal channels may alternatively not extend the length of the brick mold portion.
[00063] The invention also contemplates a kit of parts which, when assembled, forms the door jamb assembly of one or more of the embodiments described above.
1000641 Although embodiments have been described above with reference to the accompanying drawings, those of skill in the art will appreciate that variations and
- 17 -modifications may be made without departing from the scope thereof as defined by the appended claims.
Claims (47)
1. A brick mold assembly for a door frame, comprising:
a brick mold portion configured to be installed adjacent a door jamb portion; and a connector configured for connecting the brick mold portion to the door jamb portion, the connector comprising a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.
a brick mold portion configured to be installed adjacent a door jamb portion; and a connector configured for connecting the brick mold portion to the door jamb portion, the connector comprising a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.
2. The brick mold assembly of claim 1, wherein the first longitudinal clip member is configured to engage the brick mold portion.
3. The brick mold assembly of claim 2, wherein the brick mold portion comprises at least one feature configured for receiving the first longitudinal clip member.
4. The brick mold assembly of claim 3, wherein the at least one feature is a longitudinal channel comprising a longitudinal clip member configured to cooperate with the first longitudinal clip member.
5. The brick mold assembly of claim 4, wherein the connector further comprises a longitudinal intermediate portion joining the first longitudinal clip member and the second longitudinal clip member.
6. The brick mold assembly of claim 5, wherein the intermediate portion comprises a longitudinal channel for receiving the longitudinal clip member of the brick mold portion.
7. The brick mold assembly of any one of claims 1 to 6, wherein the second longitudinal clip member is configured to engage the door jamb portion.
8. The brick mold assembly of claim 7, wherein the door jamb portion comprises at least one feature configured for receiving the second longitudinal clip member.
9. The brick mold assembly of claim 8, wherein the at least one feature is a longitudinal channel comprising a longitudinal clip member of the door jamb portion configured to cooperate with the second longitudinal clip member.
10. The brick mold assembly of claim 7, wherein the connector further comprises a longitudinal corner configured to abut a corresponding corner of the door jamb portion when the second longitudinal clip member engages the door jamb portion.
11. The brick mold assembly of claim 7, wherein the connector further comprises a longitudinal channel configured to receive a feature of the door jamb portion.
12. The brick mold assembly of claim 11, wherein the feature of the door jamb portion is a longitudinal rib shaped to engage the longitudinal channel.
13. The brick mold assembly of claim 12, wherein the longitudinal rib defines a first longitudinal outer corner and a second longitudinal outer corner.
14. The brick mold assembly of claim 12, wherein the longitudinal rib has a generally square-shaped profile.
15. The brick mold assembly of claim 11, wherein the connector further comprises a bracket having a longitudinal flange, the longitudinal flange being spaced from the second longitudinal clip member to define the longitudinal channel therebetween.
16. The brick mold assembly of any one of claims 1 to 15, wherein the angle defined by the first and second longitudinal clip members is about 90 degrees.
17. The brick mold assembly of any one of claims 1 to 16, wherein the connector is extruded.
18. A kit for assembly of a brick mold assembly for a door frame, comprising:
a brick mold portion configured to be installed adjacent a door jamb portion; and a connector configured for connecting the brick mold portion to the door jamb portion, the connector comprising a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.
a brick mold portion configured to be installed adjacent a door jamb portion; and a connector configured for connecting the brick mold portion to the door jamb portion, the connector comprising a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.
19. The kit of claim 18, wherein the first longitudinal clip member is configured to engage the brick mold portion.
20. The kit of claim 19, wherein the brick mold portion comprises at least one feature configured for receiving the first longitudinal clip member.
21. The kit of claim 20, wherein the at least one feature is a longitudinal channel comprising a longitudinal clip member configured to cooperate with the first longitudinal clip member.
22. The kit of claim 21, wherein the connector further comprises a longitudinal intermediate portion joining the first longitudinal clip member and the second longitudinal clip member.
23. The kit of claim 22, wherein the intermediate portion comprises a longitudinal channel for receiving the longitudinal clip member of the brick mold portion.
24. The kit of any one of claims 18 to 23, wherein the second longitudinal clip member is configured to engage the door jamb portion.
25. The kit of claim 24, wherein the door jamb portion comprises at least one feature configured for receiving the second longitudinal clip member.
26. The kit of claim 25, wherein the at least one feature is a longitudinal channel comprising a longitudinal clip member configured to cooperate with the second longitudinal clip member.
27. The kit of claim 23, wherein the connector further comprises a longitudinal corner configured to abut a corresponding corner of the door jamb portion when the second longitudinal clip member engages the door jamb portion.
28. The kit of claim 24, wherein the connector further comprises a longitudinal channel configured to receive a feature of the door jamb portion.
29. The kit of claim 28, wherein the feature of the door jamb portion is a longitudinal rib shaped to engage the longitudinal channel.
30. The kit of claim 29, wherein the longitudinal rib defines a first longitudinal outer corner and a second longitudinal outer corner.
31. The kit of claim 29, wherein the longitudinal rib has a generally square-shaped profile.
32. The kit of claim 28, wherein the connector further comprises a bracket having a longitudinal flange, the longitudinal flange being spaced from the second longitudinal clip member to define the longitudinal channel therebetween.
33. The kit of any one of claims 18 to 32, wherein the angle defined by the first and second longitudinal clip members is about 90 degrees.
34. The kit of any one of claims 18 to 33, wherein the connector is extruded.
35. A connector for connecting a brick mold portion to a door frame, the connector comprising:
a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.
a longitudinal body comprising a first longitudinal clip member and a second longitudinal clip member, the second longitudinal clip member being oriented relative to the first longitudinal clip member so as to define an angle therebetween.
36. The connector of claim 35, wherein the angle is about 90 degrees.
37. The connector of claim 35 or 36, wherein the first longitudinal clip member is configured to engage the brick mold portion.
38. The connector of any one of claims 35 to 37, wherein the second longitudinal clip member is configured to engage a door jamb portion.
39. The connector of any one of claims 35 to 38, wherein the connector further comprises a longitudinal intermediate portion joining the first longitudinal clip member and the second longitudinal clip member.
40. The connector of claim 39, wherein the intermediate portion comprises a longitudinal channel for receiving a feature of the brick mold portion.
41. The connector of claim 40, wherein the feature is a longitudinal clip member of the brick mold portion.
42. The connector of claim 38, wherein the connector further comprises a longitudinal channel configured to receive a feature of the door jamb portion.
43. The connector of claim 42, wherein the longitudinal channel is shaped to receive a longitudinal rib of the door jamb portion.
44. The connector of claim 43, wherein the longitudinal channel comprises a first longitudinal inner comer and a second longitudinal inner corner.
45. The connector of claim 43, wherein the longitudinal channel has a generally square-shaped profile.
46. The connector of claim 42, wherein the connector further comprises a bracket having a longitudinal flange, the longitudinal flange being spaced from the second longitudinal clip member to define the longitudinal channel therebetween.
47. The connector of any one of claims 35 to 46, wherein the connector is extruded.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2835577A CA2835577A1 (en) | 2013-10-31 | 2013-11-29 | Brick mold assembly, connector for same and kit for assembly of same |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2,831,991 | 2013-10-31 | ||
| CA2831991A CA2831991A1 (en) | 2013-10-31 | 2013-10-31 | Brick mold assembly, and connector for same and kit for assembly of same |
| CA2835577A CA2835577A1 (en) | 2013-10-31 | 2013-11-29 | Brick mold assembly, connector for same and kit for assembly of same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2835577A1 true CA2835577A1 (en) | 2015-04-30 |
Family
ID=53040228
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2831991A Abandoned CA2831991A1 (en) | 2013-10-31 | 2013-10-31 | Brick mold assembly, and connector for same and kit for assembly of same |
| CA2835577A Abandoned CA2835577A1 (en) | 2013-10-31 | 2013-11-29 | Brick mold assembly, connector for same and kit for assembly of same |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2831991A Abandoned CA2831991A1 (en) | 2013-10-31 | 2013-10-31 | Brick mold assembly, and connector for same and kit for assembly of same |
Country Status (1)
| Country | Link |
|---|---|
| CA (2) | CA2831991A1 (en) |
-
2013
- 2013-10-31 CA CA2831991A patent/CA2831991A1/en not_active Abandoned
- 2013-11-29 CA CA2835577A patent/CA2835577A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| CA2831991A1 (en) | 2015-04-30 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |
Effective date: 20161130 |