GB2378476A

GB2378476A - Method for assembling doorframe with door

Info

Publication number: GB2378476A
Application number: GB0119685A
Authority: GB
Inventors: Alfred Lambert; Michael Cullen
Original assignee: Individual
Current assignee: Individual
Priority date: 2001-08-11
Filing date: 2001-08-11
Publication date: 2003-02-12
Also published as: GB0119685D0

Abstract

A method for assembling a timber doorframe, consisting of a main frame and a liner frame, using a worktable 51. After assembly, the main frame is positioned against one side of an opening, and the liner frame is positioned against the other side, with the liner frame engaging a groove in the main frame to form an adjustable co-operation between the two frame to form the full doorframe. The liner frame and main frame include a lintel, architraves and opposed jambs. A door is supported on one side of the main frame. The work table consists of a movable jamb fence 56 and a moveable door saddle fence 58, together with a fixed lintel fence 57. The various components of the main frame and liner frame can be mounted in the worktable, and the frame is mechanically brought together by adjusting the movable fences to exert pressure on the components. The doorframe and door can be pre-assembled off-site to save installation time.

Description

"Doors and Doorframes" Introduction The present invention relates to a construction of doorframe, a construction of door and doorframe and in particular to a method of making such a doorframe.

The doorframe of the present invention is of the type for mounting a door in an opening in an ope in a wall, the doorframe comprising a main frame and a cooperating liner frame, the main frame being mountable in and against one side of the ope for the support of a door thereon and the liner frame being mountable against the other side of the ope and engagable with the main frame within the ope, the main frame comprising: a pair of opposed jambs, a lintel extending between the upper ends of the jambs and a saddle board extending between the lower ends of the jambs; each jamb and lintel comprising a main support member and an architrave mounted thereon; the liner support member having an inner support member mating surface and an outer architrave receiving surface, each architrave having an architrave exterior surface and an interior wall and support member architrave mating surface ; the inner liner receiving surface of each main support member having a liner receiving groove extending into it for reception of portion of the liner support member thereon to a greater or lesser depth depending on the thickness of the wall surrounding the ope.

These doorframes are particularly useful in the sense that what happens is that the door and doorframe can be totally assembled in a factory and delivered onto a site. In use, the main frame is first entered into an ope with the architrave bearing against one face of the ope and then the liner frame is engaged on the other side of the ope with the liner frame engaging within the main frame. The two frames are then connected together by gluing, nailing or the like or may not in fact be connected together but may be simply independently mounted within the ope Usually the door is hung in position by lift-off hinges. Thus, the person erecting the door and doorframe at the work site has relatively little work to do. However, heretofore the manufacture of such doorframes has been relatively complex and requires a considerable amount of carpentry within a joinery. A further problem is that the main doorframe and the liner frame are often separately manufactured and they require manipulation to successfully

engage each other on site.

The present invention is directed towards providing an improved construction of such a doorframe and more particularly to an improved method of manufacturing such a doorframe.

Statements of Invention According to the invention, there is provided a method of making a doorframe for mounting a door in an ope in a wall, the doorframe comprising a main frame and a cooperating liner frame, the main frame being mountable in and against one side of the ope for the support of a door thereon, and the liner frame being mountable against the other side of the ope and engagable with the main frame within the ope, the main frame comprising a lintel extending between the upper ends of the jambs and a saddle board extending between the lower ends of the jambs; each jamb and lintel comprising a main support member and an architrave mounted thereon, the support member having an interior related door edge receiving surface, an ope facing exterior surface, an outer architrave receiving surface and an inner liner receiving surface; each liner frame comprising a pair of opposed jamb liners and a lintel liner extending between two ends of the jamb liners, each liner comprising a liner support member and an architrave mounted thereon, the liner support member having an inner support member mating surface and an outer architrave receiving surface; each architrave having an architrave exterior surface and an interior wall and support member architrave mating surface; the inner liner receiving surface of each main support member having a liner receiving groove extending into it for reception of portion of the liner support member therein to a greater or lesser depth depending on the thickness of the wall surrounding the ope, the method comprising the steps, not necessarily sequentially of :- preparing lengths of timber to form saddle boards, support members and architraves including forming co-operating male and female members in the architrave receiving surface of each support member and in the architrave mating surface ;

applying adhesive to at least one of each co-operating male and female member of a support member and its architrave; pre-assembling by loosely mating each support member and its respective architrave; placing a pair of jambs, a lintel and a saddle board together on a workable ; laterally pushing the pre-assembled support members and saddle board together on the workable ; pressing down the support members and their respective architraves on the workable to secure them together to form the main frame; relaxing the pressure on the main frame; placing a pair of pre-assembled jamb liners and a pre-assembled lintel liner on the main frame with the liner support members engaging the liner receiving grooves; laterally pushing all the liner support members and saddle board together; and pressing down the architraves into their respective liner support members and thus the liner frame into the main frame.

In another method according to the invention, the main support members and their respective architraves are mitred by pre-assembling a length of support member shaped timber and architrave shaped timber together and then cutting the mitre.

Alternatively, the liner support members and their respective architraves are mitred by pre-assembling a length of liner support member shaped material and architrave shaped timber together and then cutting the mitre.

Preferably, the pre-assembly of the jambs and the lintel comprises the additional initial steps of :- placing three architraves on the workable, each with its architrave mating surface upwards; applying adhesive to the architrave mating surfaces; and placing a pair of jamb support members and a lintel support member in position engaging the architraves.

In one embodiment of the invention, the jambs and lintels are placed on the workable with the architraves uppermost and then the main frame is reversed on the workable before placing the liners in position.

It is also envisaged that prior to placing the jamb liners and the lintel liner on the main frame, they are first formed into a liner frame by carrying out the steps, not necessarily sequentially of :- laterally pushing the liner support members together ; pressing down the architrave into the liner support members; and mechanically fixing the lintel liner to the jamb liner.

It is also envisaged that the pre-assembly of the liner frame comprises the steps of :- placing a liner support member so as to engage the liner receiving grooves of the main liner support members on the workable ; applying adhesive to the outer architrave receiving surface of the liner support member ; and

placing an architrave with its frame mating surface in contact with the adhesive.

It is also envisaged that when preparing the jamb support members, a door lock receiver is mounted in one jamb support member and portion of a lift-off hinge in the other. In this latter method, a door having a lock on one edge and portion of a hinge on the other end is assembled on the doorframe.

The saddle board is preferably mechanically fixed to the jambs and similarly the jambs and lintels may be mechanically fixed together as may adjacent architraves. This can be done by screwing, nailing, crimping, etc. Again, on assembly, the liner frame may be securely fixed to the main frame.

Further, the invention provides a doorframe manufactured in accordance with the invention and also provides an assembly of door and doorframe manufactured in accordance with the invention.

Detailed Description of the Invention The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which :- Fig. 1 is a perspective view of an assembled doorframe according to the invention; Fig. 2 is a perspective view of a door according to the invention; Fig. 3 is a perspective view of a door in a doorframe according to the invention; Fig. 4 is a typical sectional view of a doorframe according to the invention; Fig. 5 is an exploded view of the sectional view of Fig 4; Fig. 6 is a detailed perspective view of a comer of the doorframe showing part

of the door saddle, Fig. 7 is a perspective view of another comer of the doorframe; Fig. 8 is a perspective view of a crimp used in accordance with the invention; Fig-9 is an exploded view of one part of the doorframe; Fig. 10 is an exploded view of the remainder of the doorframe; Fig. 11 is a perspective view of a frame forming machine according to the invention; Fig. 12 is a plan diagrammatic view illustrating the operation of the machine of Fig. 11; Fig. 13 is a detailed plan view of the machine of Fig. 11; Fig. 14 is a view similar to Fig. 13 with a doorframe in position.

Fig. 15 is a perspective view of a screwing machine according to the invention; Fig-16 is a perspective view of a crimping machine; Fig. 17 is a perspective view of an altemative frame-forming machine according to the invention; Fig. 18 is an exploded view of the machine of Fig. 17; Fig. 19 is a perspective view of a still further frame-forming machine; Fig. 20 is a perspective view of another frame-forming machine; and Fig. 21 is a view similar to Fig. 5 of an alternative construction of frame

according to the invention.

Referring initially to Figs. 1 to 3, there is illustrated a doorframe, indicated generally by the reference numeral 1, in which IS mounted a door 2.

Referring now to Figs. 4 to 10 inclusive, the doorframe 1 is shown mounted within an ope 3 in a wall 4, only one side of which wall 4 is illustrated. The doorframe 1 comprises a main frame, indicated generally by the reference numeral 5, and a liner frame 6. The main frame 5 comprises a pair of opposed jambs 10, a lintel 11 extending between the upper ends of the jambs 10 and a saddle board 12 extending between the lower ends of the jambs 10. Each opposed jamb 10 and lintel 11 comprises a main support member 20. The main support member 20 has an outer architrave receiving surface 21, an inner liner receiving surface 22, an interior rebated door edge receiving surface 23 and an ope facing exterior surface 24. Each jamb 10 and lintel 11 also includes an architrave 25 having a architrave mating surface 26.

Each main support member 20 and architrave 25 have c-operating male and female members in the architrave receiving surface 21 and the architrave mating surface, in this case, formed by a groove 27 in the outer architrave receiving surface 21 and a nose 28 formed on the architrave mating surface 26. The inner liner receiving surface of the main support member 20 has a liner receiving groove 29 Each liner frame 6 comprises a pair of opposed jamb liners 30 and a lintel liner 31 Each liner comprises again a liner support member 35. The liner support member 35 has an inner support member facing surface 36, an outer architrave receiving surface 37, an ope facing exterior surface 38 and an interior ope facing surface 39. The inner support member facing surface 36 carries a nose-like projecting strip 40 having an arcuate outer surface 41. The outer architrave receiving surface 37 has a groove 42 similar to the groove 27 to again receive the nose 28 of the architrave 25. Nails 45 secure the saddle board 12 to the main support members 20 of the jambs 10 It will also be noted that the ends of the jambs 10 and the saddle board 12 are rebated in conventional fashion and further, mitre joints are used where appropriate. Further, screws 46 connect the main support members 20 of the jambs 10 and lintel 11 together, while crimps 47 secure the architraves 25 together.

Referring now to Figs. 11 to 14, there is illustrated a frame forming machine indicated generally by the reference numeral 50 comprising a workable 51 mounted on legs 52.

The workable 51 carries a pair of movable jamb fences, namely a fixed jamb fence 55 and a movable jamb fence 56. A lintel fence, indicated generally by the reference numeral 57 and a movable door saddle fence, indicated generally by the reference numeral 58, are also provided. Each jamb fence 55, 56 comprises a longitudinal side bearing member 60. The side bearing member 60 of the jamb fence 56 is slidably mounted on the workable 51 and movable thereon by drive screws 90.

Each jamb fence 55,56 comprises an L-shaped member having a base 76 and a side wall 77. Clamps 80 are mounted by pivot arms 81 on a rail 82 on the jamb fences 55.

The clamps are air operated clamps, the air motors are not illustrated. The clamps 80 can be pivoted to project in over a work piece or to lie free to allow a work piece to be removed.

The lintel fence 57 comprises two fixed support members each having a base 85 and a side wall 86.

Each door saddle fence 58 comprises a pair of shoes 87 slidably mounted on the jamb fences 55 and 56 and movable thereon by screws 91.

Referring now to Fig. 12, each drive screw 90 engages a threaded connector 92 in the movable jamb fence 55 and is rotatably mounted In a further connector 93 in the jamb fence 56. Both drive screws 90 are connected through drive connectors 94 with a further drive screw 95 driven by a motor 96. Each drive screw 91 is driven through a gearbox 97 by a drive chain 98 from a drive motor 99 through a drive connector 99a Each shoe 90 includes an aperture 98 to accommodate a nailing machine, not shown in Fig. 11 but shown in outline in Figs. 13 and 14.

Mounted on the jamb fences 55 adjacent the lintel fence 56 are a pair of screwing

machines 100 and crimping machines 110.

.

Referring to Fig. 15, each screwing machine 100 comprises height adjustable rams

101 and a laterally adjustable mechanism 102 together with a screwing device 103 carrying a screwing bit 104. There is also provided a screw containing magazine 105 having a distribution 106 for delivery of a screw, identified by the reference numeral 107, to the screw bit 104. Needless to say, any form of screwing machine could be used.

Referring now to Fig. 16, there is illustrated the crimper 110, which crimper comprises a magazine 111, an adjustable support arm 112 and a movable crimping arm 113 above a crimping mechanism 114.

In operation, to manufacture a door and doorframe as illustrated in Figs. 1 to 3, various steps are carried out, not all of which are necessarily carried out sequential, however, they are described below in one way in which they could be carried out. It will be appreciated, for example, that doors may be formed while other parts are being made and so on. However, it is easier to describe them as a sequential operation.

In the first operation, the door is sized and manufactured in accordance with the requirements for the door. Then, the saddle board 12, the main support member 20, the liner support member 35 and the architraves 25 are all cut in conventional manner.

Then, depending on the requirements, they are suitably sized and mitred. Any grooves and slots required, as described already, are cut prior to mitring. Any other joints, etc. are cut such as fork and tennon and the like for the saddle board 12 and the ends of the main support members 20 of the opposed jambs 10. At some stage during the operation, a keeper is sunk into one of the main support members 20 in conventional manner as are hinges. The hinges will generally be portion of a lift-off hinge and the other portion of the lift-off hinge will be fitted to the door 2 at some suitable time. The parts are then ready to assemble the door and doorframe.

Firstly, adhesive is applied to at least one of each c-operating male and female member of a support member and its architrave. In this particular method, it is carried out on a suitable gluing machine. Since the adhesive used will be one that will take some time to cure, the architrave can be loosely fitted, possibly with hand pressure, onto the support member and then effectively jambs and lintels are formed. Similarly. a pair of opposed jamb liners and a lintel liner is also formed. In this present method,

two jamb liners and two lintel liners are mounted together to form a liner frame with suitable screwing and crimping. The loosely assembled opposed jambs and lintel are placed in the frame forming machine 50 with the architraves uppermost. Then, the jambs are pushed together against the lintel and the door saddle fence is moved to push the door saddle up against the ends of the jambs and to rigidly secure them all together. Then, the clamps 80 are moved outwards above the architraves which are then forced downwards into their respective support members. Then the screwing machine 100 is operated to screw the jambs and lintel together as is the crimping machine to crimp the architraves. Similarly, the nailing machine 120 is used to secure the saddle board to the respective jambs. Then, the assembled main frame is removed, the liner frame 6 is assembled on it, a door 2 is then placed in the preassembled doorframe and it is ready for fitting.

In an alternative method, the mainframe is first assembled as described above. The frame is then reversed in the frame forming machine and the liner frame which has not been pre-assembled is then assembled in the main frame by engaging the liner support members in the liner receiving grooves 29. Then, in exactly the same manner in which the main frame was screwed, crimped and assembled, the liner frame is similarly assembled. In this way, a complete doorframe is assembled.

Referring now to Figs. 17 and 18, there is illustrated an alternative construction of frame forming machine, indicated generally by the reference numeral 130 comprising a workable, indicated generally by the reference numeral 131 having a pair of side rails 132 and 133, a rear rail 134, and a movable rail 135, all of which are mounted on legs 136. The side rail 132 forms the lintel fence, the side rail 133 forms the door saddle fence and the rear rail 134 and the movable rails 135 form parts of the jamb fences.

The side rails 132 and 133 carry grooves 137 within which the movable rail 135 can slide. The movable rail 135 is movable within the guide grooves 137 by a drive screw 138 which is driven by a motor, not shown for clarity. Mounted on each of the rails 132,133, 134, and 135 on a support bar 140 are a plurality of inwardly directed clamps 141 which are laterally slidable on the support bar 60. Also mounted on the rear rail 134 and movable rail 135 are a pair of L-shaped support bars 142 mounting laterally movable downwardly directed damps dz Locators 145 are also provided on the side rail 132. Screwing machines 100 and crimping machines 110 are also provided.

Effectively, the clamps 141 provide the support fences. In Fig. 17, there is illustrated how the full doorframe can be assembled within the machine.

Referring to Fig. 19, there is illustrated an alternative construction of frame forming machine, indicated generally by the reference numeral 150 which is substantially identical to the frame forming machine of Figs. 17 and 18 and thus parts similar to those described with reference to Figs. 17 and 18, are identified by the same reference numerals. In this embodiment, there is mounted above the frame forming machine 150, a gluing assembly, indicated generally by the reference numeral 160, comprising a rail 161 connecting to an orthogonal rail 162 carrying a gluing head 163 fed by glue through a tube 164 from a glue container 165. The glue head 163 is height adjustable on a support 166 and is movable on the rails 161 and 162 by a motor 167. Not all of the gluing assembly 160 is illustrated. Instead of a screwing machine 100 for securing the saddle board in position, a nailing machine 169 of conventional construction are provided.

In this embodiment, three architraves are first placed in position, adhesive is applied to the architrave frame mating surface, a pair of jamb support members and a lintel support member are then placed in position engaging the architraves with the clamps 141 initially used to support the work piece in position and then the clamps 143 are lowered to secure the support members 20 in their respective architraves 25. Then, the damps 143 are retracted, the liner support members 35 are then placed in position, adhesive applied to the outer architrave receiving surfaces 37 of the liner support members 35 by the gluing assembly 160, the respective architraves placed in position and the damps 143 are then used again to secure the liner frame. Then further crimping and screwing is carried out.

Referring now to Fig. 20, there is illustrated a still further modification of the frame forming machine illustrated in Fig. 19, indicated generally by the reference numeral 170 Again, parts similar to those described with reference to Figs. 17 to 19 are identified by the same reference numerals. In this embodiment, above the frame forming machine170, there is mounted a nailing assembly 175 carrying nailing machines 176 on a A-frame177 which A-frame is adjustable in the direction of the arrow. This would allow the nailing machine to accommodate different sizes of frame

and is particu ! ahy suitable for nailing an architrave onto a frame where either additional securement is required or for some reason, it is desired not to glue the architrave in position.

Referring now to Fig. 21, there is illustrated in a view similar to Fig. 5, an alternative construction of doorframe, again indicated generally by the reference numeral 1, which can be manufactured in accordance with the invention. In this embodiment, again the strip 40 has an arcuate surface 41 and the liner receiving groove 29 is rebated at 43 to further facilitate mating between the main frame 5 and liner frame 6.

It will be appreciated that the machine may be controlled by a programmable logic controt) er (PLC).) t wi !) a) so be appreciated that depending on the accuracy required, some or all of the operations in accordance with the invention can be carried out in the frame forming machine. It will also be appreciated that various modifications can be provided. It will be appreciated that while a corrugated crimp has been used in the manufacture of frames in accordance with the invention, any suitable fixing means may be employed to secure the architrave joints. It will also be appreciated that glue, screws, crimps, staples and the like, may be used to secure any parts together.

In the specification the terms"comprise, comprises, comprised and comprising"or any variation thereof and the terms"include, includes, included and including"or any variation thereof are considered to be totally interchangeable and they should all be afforded the widest possible interpretation.

The invention is not limited to the embodiments hereinbefore described but may be varied in both construction and detail.

Claims

CLAIMS 1. A method of making a doorframe for mounting a door in an ope in a wall, the doorframe comprising a main frame and a c-operating liner frame, the main frame being mountable in and against one side of the ope for the support of a door thereon, and the liner frame being mountable against the other side of the ope and engagable with the main frame within the ope, the main frame comprising a lintel extending between the upper ends of the jambs and a saddle board extending between the lower ends of the jambs; each jamb and lintel comprising a main support member and an architrave mounted thereon, the support member having an interior related door edge receiving surface, an ope facing exterior surface, an outer architrave receiving surface and an inner liner receiving surface; each liner frame comprising a pair of opposed jamb liners and a lintel liner extending between two ends of the jamb liners, each liner comprising a liner support member and an architrave mounted thereon, the liner support member having an inner support member mating surface and an outer architrave receiving surface ; each architrave having an architrave exterior surface and an interior wall and support member architrave mating surface; the inner liner receiving surface of each main support member having a liner receiving groove extending into it for reception of portion of the liner support member therein to a greater or lesser depth depending on the thickness of the wall surrounding the ope, the method comprising the steps, not necessarily sequentially of :- preparing lengths of timber to form saddle boards, support members and architraves including forming co-operating male and female members in the architrave receiving surface of each support member and in the architrave mating surface ; applying adhesive to at least one of each co-operating male and female member of a support member and its architrave; pre-assembling by looselY mating each support member and its respective architrave;

<Desc/Clms Page number 14>

placing a pair of jambs, a lintel and a saddle board together on a workable ; laterally pushing the pre-assembled support members and saddle board together on the workable ; pressing down the support members and their respective architraves on the workable to secure them together to form the main frame; relaxing the pressure on the main frame; placing a pair of pre-assembled jamb liners and a pre-assembled lintel liner on the main frame with the liner support members engaging the liner receiving grooves; laterally pushing all the liner support members; and pressing down the architraves Into their respective liner support members and thus the liner frame into the main frame.
2. A method as claimed in claim 1, in which the main support members and their respective architraves are mitred by pre-assembling a length of support member shaped timber and architrave shaped timber together and then cutting the mitre
3. A method as claimed in claim 1, in which liner support members and their respective architraves are mitred by pre-assembling a length of liner support member shaped material and architrave shaped timber together and then cutting the mitre.
4. A method as claimed in claim 1, in which mitring is carried out by pre- assembling a length of support, member shaped timber, a length of liner support member shaped timber and two lengths of architrave timber together

<Desc/Clms Page number 15>

and then cutting the mitre.
5. A method as claimed in any preceding claim, in which the pre-assembly of the jambs and the lintel comprises the additional initial steps of :- placing three architraves on the workable, each with its architrave mating surface upwards; applying adhesive to the architrave mating surfaces ; and placing a pair of jamb support members and a lintel support member in position engaging the architraves.
6. A method as claimed in any preceding claim, in which the jambs and lintels are placed on the workable with the architraves uppermost and then the main frame is reversed on the workable before placing the liners in position.
7. A method as claimed in any preceding claim in which prior to placing the jamb liners and the lintel liner on the main frame, they are first formed into a liner frame by carrying out the steps, not necessarily sequentially of :- laterally pushing the liner support members together ; pressing down the architrave into the liner support members; and mechanically fixing the lintel liner to the jamb liner.
8. A method as claimed in any of claims 1 to 6, in which the pre-assembly of the liner frame comprises the steps of :- placing a liner support member so as to engage the liner receiving grooves of the main liner support members on the workable ; applying adhesive to the outer architrave receiving surface of the liner

<Desc/Clms Page number 16>

support member ; and placing an architrave with its frame mating surface in contact with the adhesive.
9. A method as claimed in any preceding claim, in which when preparing the jamb support members, a door lock receiver is mounted in one jamb support member and portion of a lift-off hinge in the other.
10. A method as claimed in claim 9, in which a door having a lock on one edge and portion of a hinge on the other end is assembled on the doorframe.
11. A method as claimed in any preceding claim, in which the saddle board is mechanically fixed to the jambs.
12. A method as claimed in any preceding claim in which the jambs and lintel are mechanically fixed together.
13. A method as claimed in any preceding claim, in which adjacent architraves are secured together.
14. A method as claimed in any preceding claim, in which the lintel liner is mechanically fixed to the jamb liners
15. A method substantially as hereinbefore described with reference to the accompanying drawings.
16 A door frame manufactured In accordance with the method of claims 1 to 9 and of any of claims 11 to 15
17 A door and doorframe manufactured In accordance with claim 10
18. A doorframe substantially as described herein with reference to and as illustrated in Figs. 1 and 3 to 10 of the accompanying drawings.

<Desc/Clms Page number 17>
19. A door and doorframe substantially as described herein with reference to and as illustrated in Figs. 1 to 10 of the accompanying drawings.