IE940178A1 - A prefabricated wooden door frame assembly and a process for¹producing a wooden door frame assembly - Google Patents

Abstract

A prefabricated wooden door frame assembly (40) for 5 mounting in an associated ope (41) in a wall (42) has an outer mounting frame (45) carrying a door. The mounting frame (45) is engageable within the ope (41) and has a flanged mounting frame architrave (57) for engagement against one face of the wall (42) at a periphery of the 10 ope (41). An inner frame (46) is engageable with the mounting frame (45). The inner frame (46) has a flanged inner frame architrave (83) for engagement against an opposite face of the wall (42). A door stop strip (64) is mounted on an inner face (52) of the mounting frame (45) 15 at an opposite side to the mounting frame architrave (57) and projects outwardly of the mounting frame (45) for engagement with the inner frame (46). A liner (62) is mounted on an outer face of the mounting frame (45) defining together with the door stop strip (64) a socket 20 for reception of the inner frame (46). Thus, the frames can be prefabricated and pushed together from opposite sides of the ope (41) for interlocking the frames (45, 46) to mount the door frame assembly (40) in the ope (41).

Description

A Prefabricated Wooden Door Frame Aaaeahlv and a Process for Producing the Door Frame Assembly' This invention relates to a prefabricated wooden door frame assembly for mounting in an opening in a wall and to a process for manufacturing the door frame assembly.

The mounting of closure members such as doors and windows in a building is a relatively skilled and time consuming task particularly where there are a large number of such closure members to be provided in the building. Typically the closure members are built in situ, for example, a door frame is constructed in an opening and then a door is hung within the frame and then both the frame and door are finished by painting or polishing as required. If subsequent work has to be carried out within the building such as painting or decorating, the closure member can be damaged or splashed with paint or the like for example.

British Patent Specification No. GB 2 012 848-A describes a two-part prefabricated door assembly having two frame parts one of which carries the door, the frame parts being pushed together from opposite sides of an ope and interlocking to mount the door frame assembly in the ope. However, the prefabricated door frame assembly is of a somewhat complicated construction which does not lend itself to easy manufacture and installation.

The present invention is directed towards providing an improved prefabricated wooden door assembly which can be cheaply produced and readily easily and quickly fitted in an opening.

According to the invention there is provided a process for manufacturing a prefabricated wooden door frame assembly, comprising the steps: OPEN τη pi >B1 ΙΓ INSPECTION JNiji· 3 SECTION 28 AND RULE 23 JNL No.......OF forming a door frame for reception of a door, a pair of associated architraves being mounted on opposite sides of the door frame and projecting outwardly therefrom to define with an outer face of the door frame a channel for reception of a periphery of an ope in a wall; cutting around the door frame between the architraves and separating the door frame into an outer mounting frame on which the door is mounted and a complementary inner frame, the inner and outer frame each carrying an architrave; attaching a door stop strip along an inner face of the outer mounting frame, the door stop strip projecting outwardly of the outer mounting frame for engagement with an inner face of the inner frame; attaching a liner along an outer face of one of the inner and outer frames, the liner projecting outwardly of the outer face for engagement with the outer face of the other of the inner and outer frame.

In one embodiment of the invention the process includes the steps: mounting a first set of architrave elements on an associated support frame; aligning the architrave elements on the support frame and securing the architrave elements together to form a first architrave of U-shaped construction having a pair of spaced-apart substantially parallel side architrave elements 94 o 178a interconnected at one end by a top architrave element; mounting a set of door frame members on an inner face of the first architrave to form a U-shaped door frame attached to the first architrave and projecting outwardly from the inner face of the first architrave; mounting a second set of architrave elements along an outer free edge of the door frame opposite the first architrave, aligning the set of architrave elements and securing the architrave elements on the door frame to form a second architrave; mounting a saddle board between the lower ends of the door frame; attaching a door stop strip along an inner face of the door frame; cutting around the door frame between the architraves and intermediate the sides of the door stop strip and separating the door frame into an outer mounting frame carrying the door and the door stop strip and a complementary inner frame, the inner and outer frames each carrying an architrave; attaching a liner along an outer face of one of the inner and outer frames, the liner projecting outwardly of the outer face for engagement with the outer face of the other of the inner and outer frames; and mounting a door on the outer mounting frame. '940178 In another embodiment the process includes the step of attaching the liner to an outer face of the mounting frame to define together with the door stop strip a socket for reception of the inner frame.

In a further embodiment the process includes the step of cutting the door frame by means of a rotary cutter mounted on a guide means, the rotary cutter having a rotary cutter blade projecting downwardly of a lower face of the guide means a distance equal to the thickness of the door frame members, the guide block being mounted within the channel defined by an outer face of the door frame and the architraves with the lower face of the guide slidably engaging with the outer face of the frame and sides of the guides slidably engaging inner faces of the architraves, the cutter being drawn along the channel while rotating the blade to cut the door frame.

Preferably the process includes the step of joining the architraves and the door frame by means of a hot melt adhesive.

In another embodiment the door frame members each have tongues provided along opposite side edges of the door frame members, each tongue being engaged in a complementary groove in one of the architrave elements to interconnect the door frame and the architraves.

Preferably the process includes the step of gluing and stapling the liner to the inner or outer frame.

In another aspect the invention provides a prefabricated wooden door frame assembly for mounting in an associated ope in a wall, the door frame assembly having an outer mounting frame carrying a door, the mounting frame being PA 0 1784 engageable within the ope and having a flanged mounting frame architrave on an outer side of the mounting frame for engagement against one face of the wall at a periphery of the ope, and an inner frame engageable with the mounting frame, the inner frame having a flanged inner frame architrave for engagement against an opposite face of the wall to the mounting frame architrave at a periphery of the ope, a door stop strip mounted on an inner face of the mounting frame at an opposite side to the mounting frame architrave and projecting outwardly of the mounting frame for engagement with an inner face of the inner frame, a liner mounted along an outer face of one of the inner frame and the outer frame, the liner projecting outwardly of the outer face for engagement with the outer face of the other of the inner and the outer frames.

In a preferred embodiment the liner is mounted on the outer face of the mounting frame, defining together with the door stop strip a socket for reception of the inner frame.

Conveniently the door stop strip is tapered, the door stop strip having an inner edge spaced inwardly of the outer side of the mounting frame and extending perpendicularly outwardly of the inner face of the mounting frame, the door stop strip having a flat inside face lying against the inner face of the mounting frame, and the door stop strip having an outside face which tapers inwardly between the inner edge and an outer edge of the door stop strip.

Preferably each architrave has an elongate groove on an inner face of the architrave which engages a complementary elongate tongue on its associated inner or outer frame.

In a particularly preferred embodiment the mounting frame has a pair of spaced-apart upstanding substantially parallel side members with a top member interconnecting upper ends of the side members, a saddle board extending between lower ends of the side members, the mounting frame architrave extending around the side and top members of an outer side of the mounting frame, the door stop strip being mounted on and extending around inner faces of the side and top members and projecting outwardly of an inner side of the side and top members, the liner being mounted on and extending around outer faces of the top and side members and projecting outwardly of an inner side of the top and side members, and the inner frame is of U-shaped construction having a pair of upstanding substantially parallel side members interconnected at their upper end by a top member, the inner frame architrave being mounted on and extending around an outer side of the inner frame side and top frame members.

The invention will be more clearly understood by 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 detail sectional plan view showing portion of a prefabricated door assembly according to the invention; Fig. 2 is a perspective partial cut-away view showing a door frame assembly according to another embodiment of the invention; Fig. 3 is an elevational view of the door frame assembly of Fig. 2; Fig. 4 is an end elevational view of the door frame assembly of Fig. 2; Fig. 5 is a plan view of the door frame assembly of Fig. 2? Fig. 6 is an enlarged detail perspective partially sectioned view illustrating the door frame assembly of Fig. 2 mounted in an ope; Fig. 7 is a detailed partially sectioned perspective view of portion of the door frame assembly of Fig. 2; Fig. 8 is an exploded detail view showing portion of the door frame assembly of Fig. 2; Fig. 9 is an exploded perspective view of portion of the door frame assembly of Fig. 2 shown at an intermediate stage of manufacture according to a process of the invention; Fig. 10 is a perspective of portion of the door frame assembly of Fig. 2 shown at an intermediate stage of manufacture; Fig. 11 is a detailed partially sectioned perspective view showing portion of the door frame assembly of Fig. 2 at an intermediate stage of manufacture; Fig. 12 is a detailed partially sectioned perspective view of portion of the door frame assembly of Fig. 2 shown at an intermediate stage of manufacture; Fig. 13 is a sectional end view illustrating the door frame assembly of Fig. 2 at an intermediate stage of manufacture; and Fig. 14 is a perspective of a rotary cutter used in the process according to the invention for manufacturing the door frame assembly of Fig. 2.

Referring to the drawings, and initially to Fig. 1 thereof there is shown a prefabricated wooden door assembly according to the invention indicated generally by the reference numeral 10.

The drawing shows a section through one side of the door assembly 10, the other side and top of the door assembly 10 being of similar construction.

The door assembly 10 is mounted in an opening 12 in a block wall 14 with plaster 15 on each face of the wall 14. The door assembly 10 is of two-part construction having a mounting frame indicated generally at 16 carrying a door 17. The mounting frame 16 is engageable within the opening 12 and has a first flanged architrave surround 18 engageable against a periphery 19 of the opening 12 at one face of the wall 14. A second frame 20 of the door assembly 10 is engageable with the mounting frame 16 and has a second flanged architrave surround 21 engageable against a periphery of the opening 12 on the opposite face of the wall 14 to the first architrave surround 18. The second architrave surround 21 is mounted on a frame member 22 which is telescopically slidable within a complementary socket 23 formed on the mounting frame 16. Thus, the second frame 20 can be adjusted in the direction of arrows A to adjust the spacing between the architrave surrounds 18, 21 to accommodate different widths of wall 14 or irregularities in the wall 14.

The mounting frame 16 has a frame member 25 to which the first architrave surround 18 is attached at one end extending laterally of the member 25. At a rear of the 117 8 1 member 25 there is attached a liner 26 having a free end 27 which projects outwardly of the member 25. On the opposite side of the member 25 there is provided a shaped facing board 28 having a free end 29 which projects outwardly of the member 25 to define with the free end 27 of the liner 26 and the member 25 the socket 23 for reception of the second frame. Mounted between the liner 26 and the wall 14 is a packer 30 and a sub-frame 31. Mounted on an outer face of the frame member 25 intermediate it's ends is a block 35 with a door sealing strip 36 against which the door 17 is engageable. The block 35 conceals a number of spaced-apart bolts which secure the frame member 25 to the wall 14.

In use, the mounting frame 16 is mounted within the opening 12, being adjusted to ensure correct operation of the door 17 and it is then secured to the wall 14 by the mounting bolts (not shown). Then the frame member 22 of the second frame 20 is inserted into the socket 23 of the mounting frame 16 and pushed home until the second architrave surround 21 abuts the plaster 15 of the wall 14. Glue is applied between the frame member 22 and the socket 23 to secure the second frame 20 to the mounting frame 16 this being applied prior to pushing the frames 16, 20 together.

It will be noted that the frame members 22, 25 can be conveniently pre-polished prior to assembly in the opening 12. Thus, any portion of the frame member 22 showing subsequent to assembly will have a finished look matching the rest of the door assembly.

It will be appreciated that curved frame sections for forming gothic arches or the like may be formed for assembly into suitable openings if required. 9401784 It will be appreciated that the two frame members can be telescopically adjusted to accommodate a range of wall widths and also to accommodate irregularities in wall construction.

Referring now to Figs. 2 to 8 there is illustrated a prefabricated wooden door frame assembly according to another embodiment of the invention indicated generally by the reference numeral 40. The door frame assembly 40 is for mounting in an associated ope 41 in a wall 42 which typically will have plaster 43 applied to front and rear faces of the wall 42. A door (not shown) is mounted within the door frame assembly 40. The door frame assembly 40 is of two-part construction comprising an outer mounting frame 45 carrying the door and an associated inner frame 46 which can be brought together and interengaged from opposite sides of the ope 41 to mount the door frame assembly 40 within the ope 41.

The mounting frame 45 is formed by a pair of spaced-apart upstanding substantially parallel side members 48 with a top member 49 interconnecting upper ends of the side members 48 and a saddle board 50 extending between lower ends of the side members 48. Each of the side members 48 and top member 49 are of similar rectangular cross section having an inner face 52, an outer face 53, an inner side 54 and an outer side 55. A mounting frame architrave 57 is mounted on and extends around the side members 48 and top member 49 and is glued to the outer side 55. An elongate tongue 58 extending along each outer side 55 engages within a complementary elongate groove 59 on an inner face 60 of the architrave 57 . It will be noted that the architrave 57 extends outwardly of the outer face 53 of each frame member 48, 49 so that upon installation in an ope 41 the inner face 60 of the architrave 57 engages against one face of the wall 42 at a periphery of the ope 41. The inner face 60 of the architrave 57 and the outer face 53 of the frame member 48, 49 are substantially perpendicular.

A liner 62 is mounted along the outer face 53 of each frame member 48, 49, the liner 62 projecting outwardly of the inner side edge 54 for engagement with the inner frame 46.

A door stop strip 64 is mounted on the inner face 52 of each frame member 48, 49 adjacent the inner side 54 of each frame member 48, 49 and projects outwardly of the inner edge 54 to define with the liner 62 a socket 65 for reception of the inner frame 46. The door stop strip 64 has an inner edge 68 which extends perpendicularly outwardly of the inner face 52 of each frame member 48, 49. A flat inner face 69 of the door stop strip 64 is bonded to the inner face 62 of the frame member 48, 49. It will be noted that an outer profiled face 70 tapers inwardly from the inner edge 68 towards a free edge 72 of the door stop strip 64. Thus, the door stop strip 64 is of tapered section. The inner face 68 forms a land against which a door (not shown) abuts in use.

The inner frame 46 is of generally U-shaped construction having a pair of upstanding substantially parallel side members 75 interconnected at their upper end by a top member 76 (Fig. 8). The inner frame members 75, 76 are of rectangular section having an inner face 78, an outer face 79, an inner side edge 80 and an outer side edge 81. An inner frame architrave 83 is mounted on the outer edge 81. An elongate tongue 84 extending along the outer edge 81 is engageable within an associated groove 85 extending along an inner face 86 of the architrave 83. The architrave 83 projects outwardly of the outer face 79 of the inner frame members 75, 76 for engagement against an opposite face of ► 940 the wall 42 to the mounting frame architrave 57 at a periphery of the ope 41.

In use, the mounting frame 45 and inner frame 46 are inserted into the ope 41 from opposite sides of the wall 42 and interengaged. The mounting frame 45 is first mounted within the ope 41 with its architrave 57 abutting one face of the wall 42. The inner frame 46 is then inserted into the ope engaging the frame members 75, 76 within the socket 65 formed in the mounting frame 45, the inner frame 46 being pushed inwardly until an inner face 86 of the architrave 83 abuts the opposite face of the wall 42. Glue is applied within the socket 65 prior to engagement of the inner frame 46 with the mounting frame 45 to lock the inner frame 46 to the mounting frame 45 upon interengagement. Adhesive foam is injected between the liner 62 and the wall 42 to take up any irregularities between an exterior of the frame 40 and the wall 42.

It will be appreciated that the door frame assembly may be relatively easily and quickly fitted in an ope. The door frame assembly can be constructed and finished under controlled factory conditions and installed in a building when it is completed. The adjustable frame advantageously allows for discrepancies in wall thickness.

Referring now in particular to Figs. 9 to 14 a process for production of the door frame assembly will be described. A set of architrave elements comprising side architrave elements 90 each having a mitred upper end 91 and a top element 92 having mitred ends 93 are mounted on a support frame and glued together to form a U-shaped architrave 57. The architrave 57 is then inverted on the support frame such that the inner face 60 of the architrave 57 is upwardly facing. A set of frame elements, namely a pair of side frame elements 95 having a mitred upper end 96 and fc04O 1784 - 13 a top frame element 97 having mitred ends 98 is then assembled on the architrave 57. Tongues on the frame members 95, 97 engage in the associated groove 59 on the inner face 60 of the architrave 57. The frame members 95, 97 are glued together at their mitred edges and also to the architrave 57 by means of a hot melt adhesive which advantageously has a short setting time, typically in the order of 15-30 seconds. A second architrave 83 is then built up from architrave elements on the upper free side edge of the frame elements 95, 97 to form a U-shaped composite frame 100 with a pair of flanged architraves 57, 83 as shown in Fig. 10. The door stop strip 64 is then attached along an inner face 52 of the composite frame 100, the door stop strip 64 being attached adjacent its inner edge 68. The saddle board 50 is then attached across the free ends of the composite frame 100.

The composite frame 100 is then cut by means of a rotary cutter 110 (Figs. 13 and 14) mounted on a guide block 111. The cutter 110 has a rotary cutter blade 112 projecting downwardly of a lower face 113 of the guide 111 by a distance equal to the thickness of the frame 100. The guide block 111 is mounted within the channel 115 defined by the outer face 53 of the frame 100 and the architraves 57, 83 with the lower face 113 of the guide 111 slidably engaging the outer face 53 of the frame 100 and sides 116 of the guide 111 slidably engaging inner faces 60, 86 of the architraves 57, 83, the cutter 110 being drawn along the channel 115 while rotating the blade 112 to cut the door frame 110. Thus, the composite frame 100 is separated into the outer mounting frame 45 and the inner frame 46.

Once separated the liner 62 is glued and stapled to the inner face 53 of the mounting frame 45 to form the socket 65 together with the door stop strip 64. A door (not shown) is then hung on the mounting frame 45. 4940178 - 14 It will be appreciated that the construction of the wooden door frame assembly and the process for manufacturing the wooden door frame assembly are such as to facilitate rapid and easy manufacture and installation of the door frame assembly. The door frame assembly can typically be manufactured in 30-50 minutes and the door frame assembly can be installed in an ope within 5-10 minutes.

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

Claims (5)

CLAIMS:

1. A process for manufacturing a prefabricated wooden door frame assembly, comprising the steps: forming a door frame for reception of a door, a pair of associated architraves being mounted on opposite sides of the door frame and projecting outwardly therefrom to define with an outer face of the door frame a channel for reception of a periphery of an ope in a wail; cutting around the door frame between the architraves and separating the door frame into an outer mounting frame on which the door is mounted and a complementary inner frame, the inner and outer frame each carrying an architrave; attaching a door stop strip along an inner face of the outer mounting frame, the door stop strip projecting outwardly of the outer mounting frame for engagement with an inner face of the inner frame; attaching a liner along an outer face of one of the inner and outer frames, the liner projecting outwardly of the outer face for engagement with the outer face of the other of the inner and outer frame. A process as claimed in claim 1 comprising the steps: -940178^ mounting a first set of architrave elements on an associated support frame; aligning the architrave elements on the support frame and securing the architrave elements together to form a first architrave of U-shaped construction having a pair of spaced-apart substantially parallel side architrave elements interconnected at one end by a top architrave element; mounting a set of door frame members on an inner face of the first architrave to form a U-shaped door frame attached to the first architrave and projecting outwardly from the inner face of the first architrave; mounting a second set of architrave elements along an outer free edge of the door frame opposite the first architrave, aligning the set of architrave elements and securing the architrave elements on the door frame to form a second architrave; mounting a saddle board between the lower ends of the door frame; attaching a door stop strip along an inner face of the door frame; cutting around the door frame between the architraves and intermediate the sides of the door stop strip and separating the door frame into an outer mounting frame carrying the door and the door stop strip and a 9 4 0 1 7 8^ complementary inner frame, the inner and outer frames each carrying an architrave; attaching a liner along an outer face of one of the inner and outer frames, the liner projecting outwardly of the outer face for engagement with the outer face of the other of the inner and outer frames; and mounting a door on the outer mounting frame. A process as claimed in claim 1 or claim 2 including the step of attaching the liner to an outer face of the mounting frame to define together with the door stop strip a socket for reception of the inner frame. A process as claimed in any preceding claim including the step of cutting the door frame by means of a rotary cutter mounted on a guide means, the rotary cutter having a rotary cutter blade projecting downwardly of a lower face of the guide means a distance equal to the thickness of the door frame members, the guide block being mounted within the channel defined by an outer face of the door frame and the architraves with the lower face of the guide slidably engaging with the outer face of the frame and sides of the guides slidably engaging inner faces of the architraves, the cutter being drawn along the channel while rotating the blade to cut the door frame. A process as claimed in any preceding claim including the step of joining the architraves and the door frame by means of a hot melt adhesive. «40 1/8 - 18 6. A process as claimed in any preceding claim wherein the door frame members each have tongues provided along opposite side edges of the door frame members, each tongue being engaged in a complementary groove in one of the architrave elements to interconnect the door frame and the architraves. 7. A process as claimed in any preceding claim including the step of gluing and stapling the liner to the inner or outer frame. 8. A process for manufacturing a prefabricated wooden door frame assembly substantially as hereinbefore described with reference to the accompanying drawings. 9. A prefabricated wooden door frame assembly whenever produced by the process as claimed in any preceding claim. 10. A prefabricated wooden door frame assembly for mounting in an associated ope in a wall, the door frame assembly having an outer mounting frame carrying a door, the mounting frame being engageable within the ope and having a flanged mounting frame architrave on an outer side of the mounting frame for engagement against one face of the wall at a periphery of the ope, and an inner frame engageable with the mounting frame, the inner frame having a flanged inner frame architrave for engagement against an opposite face of the wall to the mounting frame architrave at a periphery of the ope, a door stop strip mounted on an inner face of the mounting frame at an opposite side to the mounting frame architrave and >»40 1 7 8 ϋ projecting outwardly of the mounting frame for engagement with an inner face of the inner frame, a liner mounted along an outer face of one of the inner frame and the outer frame, the liner projecting outwardly of the outer face for engagement with the outer face of the other of the inner and the outer frames. 11. A prefabricated wooden door frame assembly as claimed in claim 10 wherein the liner is mounted on the outer face of the mounting frame, defining together with the door stop strip a socket for reception of the inner frame. 12. A prefabricated wooden door frame assembly as claimed in claim 10 or claim 11 wherein the door stop strip is tapered, the door stop strip having an inner edge spaced inwardly of the outer side of the mounting frame and extending perpendicularly outwardly of the inner face of the mounting frame, the door stop strip having a flat inside face lying against the inner face of the mounting frame, and the door stop strip having an outside face which tapers inwardly between the inner edge and an outer edge of the door stop strip. 13. A prefabricated wooden door frame assembly as claimed in any of claims 10 to 12 wherein each architrave has an elongate groove on an inner face of the architrave which engages a complementary elongate tongue on its associated inner or outer frame. 14 . A prefabricated wooden door assembly as claimed in any of claims 10 to 13 wherein the mounting frame has a pair of spaced-apart upstanding 94 U 1 / β -20substantially parallel side members with a top member interconnecting upper ends of the side members, a saddle board extending between lower ends of the side members, the mounting frame

2. 5 architrave extending around the side and top members of an outer side of the mounting frame, the door stop strip being mounted on and extending around inner faces of the side and top members and projecting outwardly of an inner side of the side

3. 10 and top members, the liner being mounted on and extending around outer faces of the top and side members and projecting outwardly of an inner side of the top and side members, and the inner frame is of U-shaped construction having a pair of

4. 15 upstanding substantially parallel side members interconnected at their upper end by a top member, the inner frame architrave being mounted on and extending around an outer side of the inner frame side and top frame members.

5. 20 15. A prefabricated wooden door frame assembly substantially as hereinbefore described with reference to the accompanying drawings.