CN111058728A

CN111058728A - Suspended door assembly

Info

Publication number: CN111058728A
Application number: CN201911267779.2A
Authority: CN
Inventors: 王文明; 孙见龙
Original assignee: Beijing Xinli Machinery Co Ltd
Current assignee: Beijing Xinli Machinery Co Ltd
Priority date: 2019-12-11
Filing date: 2019-12-11
Publication date: 2020-04-24

Abstract

The present invention provides a pre-hung door assembly that includes a door panel hung within a door frame. Holders of the edge distance between the door panel and the door frame (the space between the perimeter of the door and the frame) are maintained using at least one door edge distance holder, at least one door lock edge distance holder, at least one bottom edge distance holder, or a combination. The margin retainer maintains the margin and prevents accidental opening of the door during transportation and transit of the door assembly. The jamb of the doorframe may include a pre-drilled hole for securing the door assembly to the door opening. Detailed information of door frame margin retainers, door lock margin retainers and bottom margins; a method of installing the door assembly is also provided.

Description

Suspended door assembly

Technical Field

The invention relates to a pre-hung door and an installation method thereof. In particular, the pre-hung door comprises a margin holder for holding a predetermined margin between the door frame and the door panel, thereby simplifying the installation of the door, requiring no adjustment margin and being installable by a single installer.

Technical Field

Suspended door assemblies are often installed in rough openings in new and/or retrofit structures, such as houses. Such openings define passages between adjacent rooms or passages from the interior of a room to the exterior of a room. A suspended door assembly typically includes a substantially rectangular door frame having a door panel hinged thereto. The door assembly is configured for attachment within a rough opening formed in a wall, such as in a house, building, or the like. An advantage of these pre-hung door assemblies is that the frame and door are pre-aligned, requiring only the frame to be attached and aligned within the rough opening, and thus eliminating the step of aligning and aligning the door to the frame.

However, when installing a suspended door assembly, care must be taken to adjust and ensure that the margin between the frame and the door panel is maintained within a predetermined tolerance to provide the desired seal around the door. Typical installations require the door to be opened or two persons to adjust the margins (by shimming) before the frame can be permanently secured in the rough opening. In a typical two person operation, one person places the door assembly in place on the outside of the door and another person inspects the edge on the inside of the door and fills the door panel to adjust the appropriate edge. In a typical single person operation, the person installs the door assembly from the outside and then has to go to the other side of the door assembly to adjust the margins.

Accordingly, there remains a need for a pre-hung door assembly with a simplified installation process that allows for permanently securing the frame and its attached door to a rough wall opening without the need to adjust the door margins during installation while allowing for the installation process. Only from one side of the door.

Disclosure of Invention

One aspect of the present invention provides a pre-hung door assembly that includes a door panel hung within a door frame. Combinations of these holders are used, at least one door jamb holder, at least one door lock edge holder, at least one bottom edge holder or at least one door panel-to-door frame jamb (the space between the door panel and the frame perimeter). The edge retainer allows to retain the edge and prevents undesired opening of the door assembly during transport and transportation of the door assembly. The door frame of the door frame may include a pre-drilled hole for securing the door assembly over the rough opening of the door.

Another aspect of the invention provides a door frame margin retainer, a door lock margin retainer and a bottom margin retainer. Each edge retainer is configured to retain an edge between a door panel and a door frame in an assembled position and an installed position. The edge retainer may also be configured to retain the door in a closed position on the doorframe and prevent unnecessary opening of the door assembly during shipping and transport. The marginal holders are designed to be held in place without the use of fasteners such as nails or screws.

Another aspect of the present invention provides a method for installing a pre-hung door assembly without adjusting the margins during installation. The method comprises the following steps: the door assembly is secured to the wall opening prior to removal of the edge retainer.

Other aspects of the invention, including devices, apparatus, kits, processes, etc., which form a part of the invention, will become more apparent from a reading of the following detailed description of exemplary embodiments.

Drawings

The foregoing background and summary, as well as the following detailed description of the drawings, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:

fig. 1 is a front view showing an appearance of a pre-hung door assembly of an embodiment of the present invention.

Figure 2 is a partial perspective view showing the doorframe edge retainer clipped to a door panel.

Fig. 3 is a perspective view of the door jamb holder.

FIG. 4 is a partial cross-sectional view of the bottom edge bracket clipped to the door.

Figure 5 is a perspective view of the latch base of the door lock edge retainer.

Figure 6 is a perspective view of the latch pin of the door lock edge retainer.

Fig. 7 is a sectional view showing an enlarged view of the dotted rectangle of fig. 6.

Fig. 8 is a perspective view of a bottom edge retainer.

Reference will now be made in detail to exemplary embodiments and methods of the invention. It should be noted, however, that the invention in its broader aspects is not necessarily limited to the specific details, representative materials and methods, and illustrative examples shown and described in connection with the exemplary embodiments and methods. Like reference numerals refer to like parts throughout the drawings.

Referring to fig. 1, the present invention provides a suspended front door assembly 100 and a method for installing the suspended front door assembly 100 in a wall opening of a building. Installation of the door assembly 100 requires minimal labor and time by eliminating the need for margin adjustment prior to and/or during installation. The wall openings are typically framed by

building studs

114, 116 connected by an open header 118 extending between the

top studs

114, 116. The wall opening formed by the

studs

114, 116 and the header 118 is prepared for a selected door frame size so that a door frame 110 of the selected size can be installed and retained therein.

The suspended front door assembly 100 generally includes a door frame 110 and a door panel 128 suspended therein. The doorframe 110 is generally formed of parallel, spaced apart vertical doorframes 120 (hinge-side doorframes), 122 (latch-side doorframes) and a horizontal header 124 connecting the top ends of the

doorframes

120, 122. The horizontal headers 124 of the

door frames

120, 122 and 122 are typically made of wood, such as pine or fir, with pine being preferred, although hardwood, plastic or composite materials may also be used. Optionally, the door frame 110 may further include a threshold 126 mounted at the bottom of the frame 110, the threshold 126 connecting the lower ends of the

door frames

120, 122.

As best shown in fig. 1, a door panel 128 is disposed within the doorframe 110. As shown in fig. 1, to form a door assembly 100 prior to suspension. The door panel 128 may be hinged to the hinge side door frame 120 by two or more hinges 130. Fig. 1 shows three hinges 130, two, four, five, or more hinges 130 may be used to attach the door panel 128 to the hinge side doorframe 120, depending on the size of the door panel 128. The hinge 130 may be a typical door hinge for mounting a door to allow the door panel 128 to swing between a closed position and an open position. In order for the door panel 128 to be properly closed within the doorframe 100, at least one doorframe edge bracket 132 or at least one door lock edge bracket 134 is used to maintain the boundary or space between the door panel 128 and the doorframe 100. At least one bottom edge retainer 138, or a combination of such retainers. The

edge retainers

132, 134, 138 may be used together or separately to secure the door panel 128 to the door frame 110, to prevent accidental opening during shipping and installation of the pre-hung door assembly 100, and to properly retain and align the door panel 128 within the door frame 110. The

edge retainers

132, 134, 138 also maintain proper alignment of the door panel 128 relative to a door stop 200 (best shown in FIG. 2) on the frame 110. With the panel 128 in its closed position, a proper seal is preferably achieved between the door panel 128 and a weather strip 202 (best shown in fig. 2) that is typically attached to a portion of the door frame 110. Preferably, all three

edge retainers

132, 134 and 138. Importantly, the

edge retainers

132, 134, 138 allow the pre-hung door assembly 100 to be installed with minimal labor, without first adjusting the edge of the door at the installation site. Typically, two people are required to install a typical pre-hung door assembly, one for adjusting the door edge on the inside of the door and the other for securing the door frame to the stud bolts on the outside of the door frame. Because the pre-hung door assembly 100 of the present invention eliminates the need to adjust the door edge, only one person is required to install the door assembly, thereby greatly reducing labor requirements. The door side margin retainer 132 maintains a desired margin between the door panel 128 and the lockside side door 122. As shown in fig. 2-3, is configured to clip onto the contour of door panel 128 and engage the contours of door panel 128 and lockside door frame 122. As shown in fig. 3, has a generally S-shaped profile with five flat, preferably rectangular, interconnecting portions: a first substantially parallel terminal portion 300, a second terminal portion 308 and a connector portion 304 between the first and second

terminal portions

300, 308; the

contoured portions

302, 306 are substantially perpendicular to the

terminal portions

300, 308 and the connector portion 304, the first terminal portion 300 is perpendicular to the first end 310, and the first contoured portion 302 and the second contoured portion 306 are substantially parallel. A contoured portion 302. Fig. 3 illustrates the first terminal portion 300 forming a T-shape with the first end 310 of the first contoured portion 302, which is not required as long as the terminal portion 300 includes a portion opposite the connector portion 304 such that the door panel can sandwich the door panel 128 therebetween (as best shown in fig. 2, discussed in further detail below). For example, instead of T, the first terminal portion 300 may form L with the first end 310 of the first contour portion 302. A second end 312 (opposite first end 310) of first profile portion 302 and a first end 314 of second profile portion 306 are connected to opposite ends of connector portion 304, first profile portion 302 and second profile portion 306 extending in opposite directions. A second end 316 (opposite first end 314) of second profile portion 306 is connected to an end of second terminal portion 308. The

portions

300, 302, 304, 306, 308 of the edge retainer 132 preferably have a uniform thickness. The door jamb retainer is preferably a molded polymeric sheet such that the

portions

300, 302, 304, 306 and 308 are unitary.

In use, the doorframe edge retainer 132 is clamped against the contour of the door panel 128 (as best shown in fig. 2) and the contour of the jamb 122. As shown in fig. 2, the first terminal portion 300 and the connector portion 304 are sandwiched on the door panel 128 and are adjacent to and coplanar with the inner and outer surfaces of the door panel 128. When the door panel 128 is in the closed position, as shown in FIG. 2. . As shown in fig. 1, the first terminal portion 300 and the second terminal portion 308 are sandwiched on the lock-side jam 122. In this way, the door panel 128 is held in the closed position by the doorframe edge retainer 132 with the first profile portion 302 located between the door panels. 128 and the lock side door frame 122. Preferably, at least two doorframe edge retainers 132 are used, one between the vertical middle of the door 128 and the bottom of the door 128 and one between the vertical middle of the door 128 and the top of the door 128. The bottom edge retainer 138, if present, retains the desired edge between the bottom of the door panel 128 and the door sill 126. In one exemplary embodiment, the bottom rim retainer 138, as best shown in fig. 1-3, has a bottom rim retainer 138. As shown in fig. 4 and 8, has a C-shaped cross-section with a middle portion 400 having ends that are generally perpendicular to a first end 402 and a second end 404, respectively. The middle portion 400 and the first and second ends 402, 404 are substantially flat and preferably rectangular. In certain embodiments, the first and

second end portions

402, 404 may include free ends 408, 410 that curve inward toward the intermediate portion 400 (as best shown in fig. 8) to provide increased friction against the inner and outer surfaces of the door. A plate 128. One or more protrusions 406 may be present on the middle portion 400 extending the length of the bottom edge retainer 138, preferably parallel to the first and second ends 402, 404. The protrusion 406 and the first and second ends 402, 404 extend in the same direction from the middle portion 400 of the bottom edge retainer 138. The one or more protrusions 406 maintain the vertical spacing of the door panel 128 relative to the intermediate portion 400. The edge retainer 138 is also preferably made of a polymer. The material, and is preferably formed by an extrusion process. Bottom edge retainer 138 is preferably a molded polymer sheet such that

portions

400, 402, 404, 406, 408, and 410 are unitary.

In use, the bottom edge retainer 138 frictionally clamps against the contour of the door panel 128 at the bottom of the door panel 128, as best shown in FIG. 3. As shown in fig. 4, due to the flexing of the

portions

402, 404. When the door panel 128 is in its closed position, the bottom edge retainer 138 is positioned between the bottom of the door panel 128 and the door sill 126 to maintain the proper boundary between the door sills. 126 and a door panel 128. Depending on the size of the door panel 128, one or more bottom edge retainers 138 may be used on the pre-hung door assembly 100. Preferably, when a bottom edge retainer 138 is used, it is positioned closer to the lock side door frame 122 than the hinge side door frame 120. Because the bottom edge retainer 138 carries most of the weight of the door panel 128, this preferred position better allows it to prevent the door panel 128 from sagging 110 within the frame, thereby maintaining the door panel 128 in proper alignment.

In some embodiments, the door panel 128 may include one or more knob holes 140, as shown in FIGS. 1 and 2. See fig. 1 and 7 for mounting one or more locks, knobs and/or latches. In those embodiments, pre-hung door assembly 100 may include one or more door lock edge retainers 134 to hold door panel 128 in place and to maintain a desired edge between door panel 128 and lockside door frame 122. In one embodiment, door lock edge retainer 134 comprises two parts, latch base 500 and latch pin 600.

As best shown in fig. 3, latch base 500 includes a retaining member 500. As shown in fig. 5, it includes a substantially planar base 502, a knob clip 504, a door frame clip 506 and an intermediate wall 508 extending generally perpendicularly from the base 500. A knob clip 504 is located at a first end of the base 502. And has an arcuate cross-section to conform to the circumference of a knob hole 140 in the door panel 128 (as described in further detail below). An arcuate door frame clip 506 is located at a second end of the base 500 opposite the first end and is configured to allow the latch base 500 to be clipped to the exterior of the locking side door frame 122 (described in further detail). Below). Intermediate wall 508 is located between knob clip 504 and side panel clip 506 and is configured to be located between door panel 128 and lock side panel 122. Intermediate wall 508 includes a hole 510 near its center. Hole 510 is configured to align with a strike plate hole in locking side door frame 122 and includes a semi-circular guide 512, the semi-circular guide 512 extending from the circumference of hole 510 toward door frame clip 506 and generally perpendicular to the plane of intermediate wall 508. The guide 512 is configured to be inserted into a striker hole (not shown) in the lock side door frame 122 (as described in further detail below). Latch base 500 is preferably a molded polymer sheet such that base portion 502, knob clip 504, door frame clip 506 and intermediate wall 508 are integral.

Latch pin 600 cooperates with latch base 500 to hold it in place. As best shown in fig. 6, the latch pin 600 includes a pin 600. In the embodiment shown in fig. 6, it includes a generally cylindrical plug 602 connected to a flat tab 604. The end of the flat tab 604 may include an aperture 606 for facilitating removal of the door lock edge retainer 134 after installation of the door. The length LP of the cylindrical plug 602 is slightly longer than the length LB of the guide 512 on the latch base 500. The latch pin 600 is preferably a molded polymer sheet such that its components are integral.

In use, when the door panel 128 is in its closed position in the pre-suspension door assembly 100, as best shown in fig. 3, the door panel 128 is in a closed state. As shown in fig. 7, the latch base 500 is mounted such that: 1) the knob clip 504 is located near the inner periphery of the knob hole 140; and 2) intermediate wall 508 is positioned between door panel 128 and lockside door frame 122 such that guide 512 extends into the striker plate hole of door frame 122; 3) the side plate clips 506 clip on the outside of the locking side plate 122. In this position, the aperture 510 of the latch base 500 is in communication with the door panel 128 and the striker plate aperture (the cylindrical plug 602 of the latch pin 600 passes through the latch aperture in the door panel 128, through the latch base aperture 510, and inserts into the striker plate aperture in the lock-side latch 122. thus, a flat tab 604 is visible in the knob aperture 140 of the door panel 128. the cylindrical plug 602 passes closely through the aperture 510 of the middle wall 508 to secure the lockedge retainer 134 in place. when properly positioned, the locking margin retainer 134 maintains the desired margin between the door panel 128 and the lockside panel 122 and provides proper alignment between the latch aperture on the door panel 128 and the striker plate aperture on the lockside door panel 122.

The door frame curb retainer 132, the door lock curb retainer 134, and the bottom curb retainer 138 may be manufactured by any suitable technique including, but not limited to, extrusion, forming, molding, pressing, and/or milling using various methods. A material. More specifically, extrusion, co-extrusion, and injection molding techniques may be implemented to form the

edge retainers

132, 134, or 138. Alternatively, the

edge retainers

132, 134 or 138 may be molded into a suitable shape by injection molding techniques, pressed into a suitable shape using thermoplastic, fiber or composite structures, or produced using vacuum forming or extrusion processes. The

edge retainers

132, 134 or 138 may be constructed by extrusion or co-extrusion of both honeycomb and/or rigid PVC. However, it should be understood that any suitable combination of manufacturing materials, such as polystyrene, polyethylene terephthalate (PET) thermoplastics or thermoplastics, fibers, composites, and/or metals may be used. In one embodiment, door side edge retainer 132, door lock edge retainer 134 and bottom edge retainer 138 are made of a polymeric material and are preferably manufactured by an extrusion process or an injection molding process. The polymeric material may include, but is not limited to, polyethylene, polypropylene, polyvinyl chloride (PVC), polystyrene, polyethylene terephthalate (PET), Acrylonitrile Butadiene Styrene (ABS), or combinations thereof.

In certain embodiments, the hinge side door frame 120 and the locking side door frame 122 include pre-drilled holes for installing the pre-hung door assembly 100 into a thick-walled opening. The pre-drilled holes are spaced along the

door frames

120, 122, and preferably each

door frame

120, 122 contains at least three pre-drilled holes, one above the top hinge, one in the middle of the door hinge, and below the bottom hinge. Preferably, the pre-drilled holes are located toward the outside of the door frame 110 (the side from which the door opens) rather than the center or interior of the door frame 110.

Once the

studs

114, 116 are hung down during installation, the pre-hung door assembly 100 is located within a rough wall opening. After the door assembly 100 is placed in the wall opening, the

door frames

120, 122 are secured to their

respective studs

114, 116 by pre-drilling (if present) using fasteners (e.g., screws). After the door assembly 100 is secured in the wall opening, the

edge retainers

132, 134, 138 may be removed. Door lock edge bracket 134 may be removed by pulling flat tab 604 from lock side door frame 122 and opening door panel 128. The doorframe edge bracket 132 may be removed by snapping off or sliding aside the second terminal portion 308. While opening the door panel 128, the door side rail retainers 132 are preferably sufficiently flexible so that the second terminal portions 308 can be simply bent sideways to open the door panel 128. The bottom edge retainer 138 simply drops out or can easily slide off. When the door panel 128 is opened, it is removed. Once the door panel 128 is opened, the interior of the door assembly 110 may be accessed for further adjustment and installation steps. There is no need to adjust the edges of the door assembly 100 during installation.

The pre-hung door assembly and method of the present invention allows the door assembly to be fully installed on one side of the door, preferably the outside. Since the edge of the door is set and maintained by one or more edge holders, no edge adjustment is required during installation. Thus, no second person is required inside the door to check the margins and to level the door. The present invention simplifies installation of a suspended door assembly and saves a great deal of labor during installation.

While certain presently preferred embodiments of the present invention have been described in detail herein, it will be apparent to those skilled in the art that variations and modifications of the various embodiments shown and described herein may be made without departing from the spirit and scope of the invention.

Claims

1. A hanging door assembly comprising:

a) a frame comprising parallel, spaced apart vertical hinged side jambs and lock jambs, a horizontal header connecting the top ends of the jambs and a doorsill connecting the bottom ends of the door frames;

b) a door panel hingedly mounted to the hinged side door in a closed position, the door panel including opposing inner and outer surfaces; and

c) at least one door frame edge distance support, comprising

i. A rectangular flat first terminal portion;

a rectangular flat first profile portion having a first end and a second end, the first end of the first profile portion being connected to the first terminal portion and extending perpendicular to the first terminal portion;

a rectangular flat connector portion having a first end and a second end, the first end of the flat connector portion extending perpendicularly from the second end of the first profile portion;

a rectangular flat second profile portion having a first end and a second end, the first end of the second profile portion extending perpendicularly from the second end of the connector portion, and

v. a rectangular flat second terminal portion having a first end and a second end, the first end of the second terminal portion extending perpendicularly from the second end of the second profile portion,

wherein the first terminal portion and the connector portion are clipped to the door panel and adjacent to and coplanar with the inner surface and the outer surface of the door panel, respectively, and the first terminal portion and the second terminal portion are clipped to the locking side lock.

2. The pre-hung door assembly as defined in claim 1, further comprising a door lock edge retainer.

3. The pre-hung door assembly as defined in claim 2, wherein the door latch margin retainer is configured to be mounted to the lockrand jamb and knob hole on the door panel.

4. The pre-hung door assembly as defined in claim 3, wherein the door lock edge retainer comprises:

a. a latch base including a base portion, a knob clip, a doorframe clip and an intermediate wall extending generally perpendicularly from the base portion, wherein the knob clip and the doorframe clip are at opposite ends of the base portion and the intermediate wall is between the knob clip and the doorframe clip and has an aperture. And

b. the latch pin has a cylindrical plug configured to pass through the aperture of the latch base.

5. The pre-hung door assembly as defined in claim 4, wherein a semi-circular guide extends from the aperture of the latch base toward the door frame.

6. The pre-hung door assembly as defined in claim 4, wherein the knob clip has an arcuate cross-section.

7. The pre-hung door assembly as defined in claim 4, wherein the latch pin further includes a flat lug connected to the cylindrical plug, the flat lug including a hole therein.

8. The pre-hung door assembly as defined in claim 1, further comprising a bottom edge retainer.

9. The pre-hung door assembly as defined in claim 8, wherein the bottom edge retainer is configured to clip onto the bottom of the door panel.