GB2346169A

GB2346169A - Improvements relating to frame construction and installation

Info

Publication number: GB2346169A
Application number: GB9928387A
Authority: GB
Inventors: Alan Thomas; Ronald Alan Thomas; Michael Christopher Kelly
Original assignee: THOMAS CARPENTRY SERVICES LIMI
Current assignee: THOMAS CARPENTRY SERVICES LIMI
Priority date: 1999-01-30
Filing date: 1999-12-02
Publication date: 2000-08-02
Anticipated expiration: 2019-12-02
Also published as: GB9902007D0; GB9928387D0; GB2346169B

Abstract

The linings (1, Fig 1) of a door frame are assembled into a basic frame being fitted into a wall aperture. The or each face of this frame to be flush with a wall surface has a longitudinal groove 4 to receive a rib 6 of an architrave member(s) 2 which, when fitted, overlaps the adjacent wall 12. The corners of the frame can be mutually secured by L-shaped straps (9, Fig 2) in these grooves, subsequently concealed by the architrave. The architrave can also conceal elements 14, 15 secured to and projecting outwardly of the frame which overlap the wall and are screwed or nailed through to fix the frame. The element may be a hinge (19, Fig 4) which is movable through 180 degrees. The inward looking face of the frame may also be grooved 5 to receive the ribs 8 of stops strip 3. These and the architrave(s) can be glued in place so that no fillings over nails or screws are required.

Description

Improvements relatinq to Frame Construction and Installation This invention relates to frame construction and installation. It is primarily concerned with door frames, but could be applicable to other frames which are fitted in apertures in buildings, such as windows or hatches to lofts.

However, for convenience, reference in this specification will be made just to doors.

Conventionally in a new construction a door frame is set up first, then the brick or block work is built up around it. Sometimes, it is a studding wall. Then the wall is plastered, the finish plaster coming substantially flush with the frame. Then architraves are nailed to the frames on both sides, plus beading on the inside of the frame to create a rebate and stop for the door. Then the door is fitted, once rebates for the tinges have been cut and slots made for the catch and, possibly, a lock bolt. This is followed by filling, rubbing, down, knotting and painting, before finally the door furniture is put on.

This all occupies considerable time on site, and entails a carpenter or joiner having more than one "bite at the cherry". First, he has to fit the frame, and then he has to come back later for the finishing off jobs outlined above.

It would be far more efficient if the operation could be done all at once, with the door and its frame prepared with all the essentials in thjs factory. It is the aim of this invention to make this pdssible.

In this specification inward-looking", in relation to a frame face, refers to that face transverse to the general plane of the frame which is on the inside of the frame.

"Outward-looking"refers to the opposite face.

According to the present invention there is provided a frame construction for insertion in an aperture in a wall, the frame having longitudinal grooves in a face that is to be substantially co-planar with a wall surface, and architrave members with longitudinal ribs on their rear sides to be presented to the frame which are a close fit in said grooves and with a width such that, when engaged rib to groove with the frame, then extend beyond the frame to overlap the wall into which that frame is fitted.

Preferably, the rib of each architrave member is along one edge, and there may be a further but shallower rib on the same rear side of each architrave member and along the other edge, to engage the overlapped wall.

The grooves may serve a dual purpose, for the corners of the frame can be mutually secured by angled straps received in the ends of the grooves. The straps preferably do not occupy the whole depth of the grooves, but the ribs of the architrave members may have to be reduced at their ends to give clearance over the straps but still to engage in the grooves.

In many cases the frame dimension transverse to the wall will be substantially the same as the thickness of the wall. In that case a second face that is to be substantially co-planar with a second wall surface opposite the first wall surface may be grooved similarly to the first face. The construction cap then include second ribbed architrave members to co-operate with the second face and wall in a manner similar to the first architrave members with the first face and wall.

In another arrangement where a second face of the frame opposite the first face is similarly grooved, the construction may include abutment members with longitudinal ribs on sides to be presented to said second face which are a close fit in said grooves and with a width such that, when engaged rib to groove with th frame, they extend inwardly of the frame to overlap the internal area defined by the frame. Where the frame dimension transverse to the wall is substantially the same as the thickness of the wall, so that said second face will be substantially co-planar with a second wall surface opposite the first wall surface, the abutment members can also extend beyond the frame to overlap said second wall surface. In other words, they can provide an architrave as well as an abutment.

When there are no such abutment members, an inwardlooking face of at least one of the frame members may also be longitudinally grooved. The frame will then further comprise, for each such grooyed member, a strip with a longitudinal rib which is a close fit in the groove.

When there are these grooves, the frame construction can be secured in a wall aperture by screws or nails entered through their bases into the wall, the screws or nail heads being concealed by the subseqvently fitted strips. But accurate placement of the frame is difficult to achieve, and driving the screws or nails hard home can distort the frame if it is slightly loose in the aperture. Therefore, preferably the frame is provided with elements to secure the frame to the wall by bridging to and overlapping at least the first wall surface. Then fasteners such as screws or nails are entered through the bridging elements into the wall. The architrave members will be of a width to conceal these elements.

A first set of bridging elements may be straps pivotally secured to at least one face to be substantially co-planar with a wall surface. Alternatively, they may be hinges each with one flange fastened to an outward-looking face of the frame, the hinge axis being substantially aligned with the edge between that outward-looking face and at least one of the faces to be substantially co-planar with a wall surface, and the other flange being movable through 180 between a pre-use state flat against the co-planar face and an in-use state projecting beyond the frame to overlap the wall. With either of these embodiments the elements can be set to positions where they will not interfere with the frame being entered into an aperture in a wall.

A second set of bridging elements may be brackets fixed to the frame with a portion to be substantially co-planar with a second wall surface projecting outwardly of the frame. These can be fixed since they will not be required to pass through the wall aperture.

To install this frame construction in an aperture in a wall of matching thickness, the frame is offered up with a face having at least some of said first set of bridging elements leading into the aperture. These elements are adjusted to a position where they will not obstruct such movement. The frame is located by the bridging elements associated with the trailing fce abutting the wall. When the frame is in place the bridging elements on the leading face are adjusted to overlap the adjacent wall surface, and the frame thus trapped is secured by fasteners through the overlapping parts of the bridging elements into the wall.

The architrave members are then fitted and secured by adhesive in the rib/groove engagement.

When the inward-looking face of the frame is grooved, the or each strip is fitted and secured by adhesive in the rib/groove engagement.

When the wall is thicker than the frame, one face of the frame may be flush with one face of the wall and be secured by bridging elements. Additional security may be provided by screwing or nailing through the bases of grooves in the inward-looking face o the frame, if those are provided, as mentioned above. But such additional fasteners should only be applied once the frame is correctly fitted by the bridging elements.

This applies whether the sdes of the wall aperture are flat and square to the wall surfaces, or whether they are stepped to form a rebate into which the frame can seat.

In all these arrangements the frame is completed without any nails or screw heads exposed, requiring filling and rubbing down before painting.

While the various members could be machined from natural wood, it will be preferred to use a substitute material such as that known as MDF, which is very stable, and which can be machined to great accuracy.

For a better understanding of the invention one embodiment will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is an exploded fragmentary perspective view of parts of a door frame, Figure 2 is a perspective view of a corner of a part completed door frame, Figure 3 is a horizontal cross-section through a jamb of a door frame, Figure 4 is an edge view of a door frame fastener, as manufactured, Figure 5 is a fragmentary perspective view of a joint of a door frame with such a fastener in a pre-use condition, Figure 6 is a fragmentary perspective view of the joint with the fastener ready for securing to a wall, Figure 7 is a horizontal cross-section through a jamb of another door frame, Figure 8 is a horizontal cross-section through a jamb of a further door frame, Figure 9 is a horizontal cross-section through a jamb of yet another door frame, Figure 10 is a horizontal cross-section through a jamb of a yet further door frame, Figure 11 is a horizontal cross-section through a jamb of a sixth door frame, and Figure 12 shows, in cross section, various configurations for architrave.

In Figures 1 to 3 a door frame has three main members, namely a head and two jambs, collectively referred to as linings 1. It may also have a cill across the bottom but that is not of great concern here. It also has an architrave on each side made of moulded battens 2 which meet at mitred corners, and strip$ 3 on the inner, reveal face which create a rebate and stop for the door.

In this frame the linings 1 are of generally rectangular section, in the normal way, but they also have longitudinal grooves 4 in each, of the narrow faces which are to be flush with the wall surfaces, and a further groove 5 in the wide, inward-looking face. For some frames, this groove may be omitted from sourie or all of the linings.

The architraves 2 (only one of which is shown in Figure 1) do not have flat reverse sides. Instead each batten has a substantial rib 6 along one edge of that side and a rather lesser rib 7 along the other edge, which is the one which is to overlap the wall. The rib 6 is a close fit in the associated groove 4, but it does not necessarily reach to the bottom of the groove when. fitted. The rib 7 will abut the finish plaster and if that, is a bit proud or shy of the lining 1, the architrave will simply be set out or in by a corresponding amount, but still with plenty of rib 6 in the groove 4. These variations will generally be barely noticeable.

Each stop strip 3 has a rib 8 on its reverse side which is a close fit in the associated groove 5.

The linings 1 may be fastened together at the corners in various ways, but advantage can be taken of the grooves 4, as shown in Figure 2. An L-shaped strap 9 fits closely in the grooves 4 at their junction, and screws 10 are driven through into the linings 1. There can of course be straps 9 at both sides, and they will occupy only the bottoms of the grooves, leaving room for the ribs 6 of the architrave battens, although they might have to be reduced in depth a bit on occasions. These battens 2 will be mitred at their junctions.

Referring now to Figure 3, the basic wall is indicated at 11 and the plaster on both sides at 12. The frame is shown in place, with a door 13 hung. The frame is secured by brackets 14 and straps 15. The brackets 14 are L-shaped and fixed to the outward-looking face of the respective lining 1 by screws 16 through one limb, leaving the other limb projecting away from the frame and co-planar with one narrow face of the lining. The straps 15 are simple straight and flat members, each held by one screw 17 to the other narrow face.

For fitting, the frame consists just of the linings 1 with the brackets 14 and straps 15, the latter being pivoted about the screws 17 to lie within the envelope of the frame.

That is then offered up and pushed into the prepared aperture in the wall 11, the face with the straps 15 first.

As viewed in Figure 3, that : is from below. The frame is located by the projecting limbs of the brackets 14 coming up against the plaster 12 on the'adjacent side of the wall 11, and then the straps 15 are swung into the overlapping position shown, trapping the. frame in place. Screws 18 through the overlapping part* of the brackets and straps into the wall complete the securing of the basic frame.

Then the architrave strips are fitted, with glue between the ribs 6 and grooves 4. The shallow channels between the ribs 6 and 7 accommodate and conceal the brackets 14 and straps 15 ad any nail holes left from temporary bracing battens fastened across the frame to keep it in shape. The strips 3 are also glued in place.

All these parts can be prepared in a factory, one jamb being rebated to receive the door hinges and the other having one or more slots cut for the door catch (es) or bolt (s). So once the glue has set, the door can be hung and with the parts lightly rubbed down (no filling is necessary), they will be ready for painting. Indeed, primer and even a first coat could be applied in the factory.

As an alternative to the straps 15, a hinged fastener 19 may be employed, as shown in, Figures 4,5 and 6. It is basically a rectangle of sheet plastics material with a Vgroove 20 across its mid-length forming the hinge and separating it into two flangts 21 and 22. It will be understood that the plastic material will be of a thickness, flexibility and strngth for the V-groove 20 to allow the hinging action while not weakening the fastener at the hinge to a dangerous degree. The flange 21 has two apertures 23 with surrounding shallow bosses 24 on one side and the flange 25 has a single aperture 26 with a surrounding shallow boss 27 on the opposite side. The flange 21 is secured to the outward-looking face of the lining 1 by screws (not shown) through the apertures 23, the screw heads continuously into the bosses 24. The fastener is positioned so that the other flange 22 can be folded to lie flat against the adjacent narrow face of the lining, where it can be temporarily secured by a staple 28 whose ends embed in the base of the groove 4. It is then safely out of the way for transport and the initial stage of installation. But once the frame is in place, the staple 28 is removed, the flange 22 is swung through 180 to bear against the adjacent part of the wall, boss 27 outwards, and after drilling a screw is driven through the aperture 26 into the wall.

These hinged fasteners or the straps 15 may also be used instead of the brackets 14, so that there would be no vulnerable and possibly dangerous projections outwardly of the frame between manufacture and installation.

These wall fasteners could, however be supplemented or replaced by screws or nails through the bottoms of the grooves 5.

There may be occasions when the stop strip 3 is not appropriate, for example when the door's thickness approaches or even equals the thickness of the wall. Then, as shown in Figures 7,8 and 9, the groove 5 is not provided and, instead of a simple architrave, a combined architrave/ stop 22 is fitted to one face of the modified lining 21.

This is a plank or boyard-li member with a rib 23 to fit and be glued into a groove g4, as described, one moulded edge portion 25 to overlap the wall and act as part of an architrave, and the opposite edge portion 26 projecting beyond the lining 21 over the internal area defined by the frame. This portion therefore forms a stop for a door 27.

In Figure 7, there is a shallow rib 28, equivalent to the rib 7 and for the same purpose, namely to provide space for the fastener 29. On the other side of the rib 23 the inner face of the member 22 s stepped at 30 so that the edge portion 26 hooks round the lining 1 a variable amount according to how far the rib 2 can engage in the groove 24.

A gap will then not appear between the lining 21 and the member 22.

An alternative is shown in Figure 8, where there is no step 30 and on that side of the rib 23 the member 22 lies flat against the lining 21, affording more gluing area.

This means that the rib 28 may have to be shaved locally before the final gluing.

A further possibility is shown in Figure 9, where there is no rib 28 and the member 22 can go flat against the lining 21 either side of the groove 24, thus further increasing the gluing area. f course this means that, if there are fasteners on this side, they will have to be set back from the grooved face of the lining and sink into the wall surface. But it may be satisfactory in some circumstances to have fasteners on the other side only, in which case the member 22 could be glued in place before the frame is offered up to the aperture in the wall, other side first. When the portion 25 abuts the wall, hinged or folding fasteners on said other side are swung over and fixed.

It is also possible that frame may not be substantially of the same thickness as the wall. It may fit into a rebate as shown in Figures 10 and 11.

In Figure 10, both faces of a lining 31 are grooved, one to receive a ribbed stop board 32 that is sandwiched between the lining and the shoulder of the rebate. This board is equivalent to the member 22 without the architrave portion 25. Fasteners 33 are on one side of the frame only concealed by architrave strips 34, as described.

In Figure 11 there is no groove in the face of the lining 35 that leads into the rebate; it abuts directly against the shoulder. But there is a groove 36 in the inward-looking face of the lining, equivalent to the groove 5 of Figure 1, and this provides the anchorage for a Tsection strip 37 corresponding to the strip 3. Fasteners 38, concealed by architrave strips 39 as in other examples, may be augmented by screws 40 through the base of the groove 36. The architrave strips of Figures 1 and 3 and of Figures 10 and 11 are shown as having a simple bull-nosed section.

It will be understood that more elaborate mouldings are equally possible, and a few are shown in Figure 12.

Likewise, the moulded portions 25 of Figures 7,8 and 9 may be configured in various styles.

Claims

Claims 1. A frame construction for insertion in an aperture in a wall, the frame having longitudinal grooves in a face that is to be substantially co-planar with a wall surface, and architrave members with longitudinal ribs on their rear sides to be presented to the frame which are a close fit in said grooves and with a width such that, when engaged rib to groove with the frame, then extend beyond the frame to overlap the wall into which that frame is fitted.
2. A frame construction as claimed in Claim 1, wherein the rib of each architrave member is along one edge.
3. A frame construction as claimed in Claim 2, wherein a further but shallower rib is on the same rear side of each architrave member and along the other edge, to engage the overlapped wall.
4. A frame construction as claimed in Claim 1,2 or 3, wherein the corners of the frame are mutually secured by angled straps received in the ends of the grooves.
5. A frame construction as claimed in Claim 4, wherein the straps do not occupy the whole depth of the grooves, and the ribs of the architrave members are reduced at their ends to give clearance over the straps but still to engage in the grooves.
6. A frame construction as claimed in any preceding claim, wherein the frame dimension transverse to the wall is substantially the same as the thickness of the wall, and wherein a second face that is to be substantially co-planar with a second wall surface opposite the first wall surface is grooved similarly to the first face, the construction including second ribbed architrave members to co-operate with the second face and wall in a manner similar to the first architrave members with the first face and wall.
7. A frame construction as claimed in any one of Claims 1 to 5, wherein a second face o the frame opposite the first face is similarly grooved, the construction including abutment members with longitudinal ribs on sides to be presented to said second face which are a close fit in said grooves and with a width such that, when engaged rib to groove with the frame, they extend inwardly of the frame to overlap the internal area defined by the frame.
8. A frame construction as claimed in Claim 7, wherein the frame dimension transverse to the wall is substantially the same as the thickness of the wll, so that said second face will be substantially co-planar with a second wall surface opposite the first wall surface, and wherein the abutment members also extend beyond the frame to overlap said second wall surface.
9. A frame construction as claimed in any preceding claim, wherein an inward-looking face of at least one of the frame members is longitudinally grooved, and the frame further comprises for each such grooved member a strip with a longitudinal rib which is a close fit in the groove.
10. A frame construction as claimed in any preceding claim, wherein the frame is provided with elements to secure the frame to the wall by bridging to and overlapping at least the first wall surface and by having fasteners entered therethrough into the wall, and wherein the architrave members are of a width to conceal said elements.
11. A frame construction as claimed in Claim 10, wherein a first set of elements are straps pivotally secured to at least one face to be substantially co-planar with a wall surface.
12. A frame construction as claimed in Claim 10, wherein a first set of elements are hinges each with one flange fastened to an outward-looking face of the frame, the hinge axis being substantially aligned with the edge between that outward-looking face and at least one of the faces to be substantially co-planar with a wall surface, and the other flange being movable through 180 between a pre-use state flat against the co-planar face and an in-use state projecting beyond the frame to overlap the wall.
13. A frame construction as claimed in Claim 11 or 12, wherein a second set of elements are brackets fixed to the frame with a portion to be substantially co-planar with a second wall surface projecting outwardly of the frame.
14. A method of installing a frame construction as claimed in Claim 11,12 or 13, in an aperture in a wall, wherein the frame is offered up with a face having at least some of said first set of elements leading into the aperture, these elements being adjusted to a position where they will not obstruct such movement, wherein the frame is located by the elements associated with the trailing face abutting the wall, wherein when the frame is in place the elements on the leading face are adjusted to overlap the adjacent wall surface, and wherein the frame thus trapped is secured by fasteners through the overlapping parts of the elements into the wall.
15. A method of installing a frame construction as claimed in Claim 14, wherein the architrave members are then fitted and secured by adhesive in the rib/groove engagement.
16. A method of installing a frame construction as claimed in Claim 14 or 15 as appendant to Claim 9, wherein the or each strip is fitted and secured by adhesive in the rib/groove engagement.
17. A frame construction substantially as hereinbefore described with reference to the accompanying drawings.