MXPA00002339A - Composite door frames - Google Patents

Abstract

A frame assembly (1) for mounting doors and the like comprising a pair of jambs (2, 3) and a header (4) for connecting said jambs, and, where required, a sill, each said jambs and header and sill (5) where required being a compression molding of filler, waste, or recycled particulate material bound together by a thermoplastic binder, each said jambs (2, 3) and header (4) presenting when assembled an inwardly facing planar surface of a width to receive a door to be mounted in said frame assembly and an inwardly projecting door stop shoulder formation projecting inwardly of said planar surface.

Description

COMPOSITE DOOR FRAMES FIELD OF THE INVENTION 5 This invention relates to frames for doors, and to the frame members from which those frames are assembled.

BACKGROUND OF THE INVENTION 10 At present, most door frames are made of wood and include a pair of upright members and a head cross member. If this is an external door, the door frame also includes a sill, although in the case of internal doors the uprights are extend to the floor. Where large volumes are wrapped, the members of the door frame can be manufactured in a factory, ready to be assembled at the work site or, in some cases, at the factory. Frequently, however, the members of the door frame are cut from the wood at the work site and drilled and milled to provide bolt females and hinge mounting areas, and then adjusted in position for each individual door. In addition to wood, there are other door frames material or other material together with wood. The Patent of the United States of North America Number 1,606,780, issued on November 16, 1926, describes a metal door frame. The Patent of the United States of North America Number 4,281,481, issued on August 4, 1981, describes a aluminum door frame, while the Patent of the United States of America Number 3,287,856, issued on October 16, 1964, describes an extruded metal frame. U.S. Patent Number 4,531,337, issued July 30, 1985, discloses a door frame of a metal-wood combination, while U.S. Patent No. 4,505,080, issued on 19 March 1985, describes a combination door frame of extruded metal or plastic and wood, while US Patent No. 5,293,723, issued March 15, 1994, discloses a plastic combination door frame and wood. In the case of wooden door frames, not only is wood relatively expensive, but the wooden members from which the frame is made are subject to twisting and warping, adversely affecting the accuracy of the frame. Metal frames, on the other hand, do not lend themselves to adjustments in the field, to meet the circumstances of the openings that receive the frame in the wall. On the other hand, these are expensive and also involve E fcJiftS Bfe ». ? ü Usually in assembly with some wood. In addition, metal is a good conductor of heat, and therefore is a poor insulator. The members of the extruded plastic web do not have the inherent strength of the wood, and they are not quickly secured without the use of wood inserts.

RECOGNITION OF THE PREVIOUS TECHNIQUE The European Patent Application 0-586213 Al, published on 03/09/94, describes a hollow window or structural door component that can be extruded or molded by injection, from a polymer and wood fiber. However, since it can be extruded, the walls of the hollow component have uniform dimensions along their length, and the component is open at the ends. These components can be joined at right angles by cutting diagonally and welding the ends thereof, but they do not provide any interengaged seat configuration. The Patent of the United States of North America No. 4,154,034, issued May 15, 1979, discloses door frame components of generally J-shaped cross section, molded from glass fiber reinforced polystyrene. However, these components depend on the tip turned upwards from the bottom of the J as a door stop, and use the back of & # * «J to mount the metal strips to join the component to the framework.

SUMMARY OF THE INVENTION The present invention is directed to providing a door frame that is much more economical than existing door frames, which exhibits all the advantages of solid wood frames for manageability and insulation, but which is stronger , impervious to elements and insects, and not splintering, cracking, warping, corroding or rust, or requiring maintenance wrapped with wooden frames. According to the invention, the door frame is formed from compression molded composite components, in exact profiles ready for quick, easy and accurate assembly. More particularly, according to the invention, the components of the frame are moldings by compression of particles or small pieces of filler, waste, or recycled (hereinafter "particulate material") joined together by means of a thermoplastic material, which can be a waste or recycled thermoplastic. These compression molded components, in accordance with the preferred form of the invention, are formed to provide interengaged locating elements, 'Xa & .1 £ & ~~ to ensure that they are put together in the precisely accurate register, ready for assurance by appropriate fasteners. In this connection, by providing the precise interengagement of the component assembly, a minimum number of fasteners is required to secure the members of the frame in assembled relation, allowing the door frame to be assembled quickly, easily and accurately. Since they are molded, the invention allows the members of the upright frame and head frame to be shaped as elongated channels or boxes, adequately internally reinforced, having stepped lower surfaces that will face the inside of the frame. door, receiving the opening that is going to frame with the door frame. These outer frame members, in fact hollow, therefore require a minimum of members that create lightweight material, for ease of handling and installation. In addition, by compression molding the frame members, they can be formed to provide integral perforated channels, protuberances or thickened areas to receive, support and accommodate the passage of screws or the like therethrough, to secure the members of the frame to the opening of the door frame. On the other hand, by forming the elements of the door frame in the molding or other operation, provision can be made to accurately locate the mounting areas of the hinges and the striking plate, and to provide internally recessed, appropriately placed recessed or reinforced material blocks to accept the insert of the bolt and screw fitting of a door. In addition, in accordance with the invention, the members of uprights and crossbar can be molded to produce a precisely accurate integral molding, to meet the masonry (sometimes refined to a brick molding) when the door frame is for a external door. Where it is desired to employ a separate brick molding, in accordance with the invention, there is provided an elongated, compression-molded channel member with chamfered ends, and transverse webs including webs that run angularly or obliquely, through, between channel walls, and webs running perpendicularly through, between the channel walls, whereby the molding can be cut at appropriate locations, to form head rail molding with chamfered ends, of different length, depending on the width of the door, and the molding of the uprights having chamfered upper ends for a door upright either on the left or on the right.

Also, in accordance with the invention, the sill of the door frame, where required, is formed as a composite structure molded with an internal repeating pattern, such that it can be cut at appropriate points to conform to the width of the door. the door that will receive the door frame. These and other features of the invention will be apparent from the following detailed description, taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view illustrating a molded door frame for an oscillating door, with a separate brick trim or molding, in accordance with the invention. Figure 2 is an enlarged perspective view, illustrating the connection of the upper part of one of the uprights of the frame of Figure 1, with the head cross member. Figure 3 is a perspective view illustrating how the lower part of one of the uprights is connected to the sill, and which shows the upright of the trim or brick molding, in position to be connected to the upright of the frame. Figure 4 is a view similar to Figure 3, but showing an outward swinging door. Figure 5 is a vertical section through the door frame, with the trim or separate brick molding attached. Figure 6 is a perspective view of a molded hearth, according to the invention, which can be cut to fit different frame sizes, to accommodate different door widths. Figure 7 is a perspective view of an elongated molded structure, from which the uprights and cross-members of the counterframe or separate brick molding can be formed for the door frame. Figure 7a in a elevational view that sees inside the lower molding of Figure 7, which has been placed on its side. Figure 8 is a perspective view of one of the uprights of the door frame, showing how it joins the opening that receives the door in a building wall. Figure 9 is a horizontal sectional detail of the upright and the wall structure of Figure 8, showing a door in place, displacing the resilient flexible bead, which is used to hide the joint screws when the door is open, illustrating only one screw. Figure 10 is a view similar to Figure 9, but with the door open, showing the resilient flexible weather strips, now covering and hiding the joint screw. Figure 11 is a perspective view of a section of the door pillar to which the door is to be hinged, and showing one of the cavities that receive the hinge. Figure 12 is a perspective view, taken from the rear of the upright shown in Figure 11, showing the configuration of the channels or protuberances formed with through passages or perforations, 10 to receive the screws for joining the hinge to the door stud. Figure 13 is a perspective view of the upright that will receive the striking plate for the door, and that incorporates the cavities of the bolt and the locking bolt of the door. Figure 14 is a perspective view of the upright of Figure 13, taken from the rear, showing the blocks or channels of the molded reinforcement material for acceptance of the bolt mechanism and the locking bolt. Figure 15 is a front elevational view of the door frame according to the invention, in which the brick trim is molded integrally with the uprights and the head cross member of the door frame. 25 Figure 16 is a perspective view of the frame of door of Figure 15, ready to be inserted into the opening of a wall that receives the door. Figure 17 is a perspective view illustrating the assembly of the head rail with the integral brick trim, with the top portions of the uprights having the integral brick trim. Figure 18 is an elongated perspective view illustrating the connection between one of the uprights illustrated in Figure 17, and one end of the head cross member engaging. Figure 19 is a perspective view illustrating how to connect the lower part of the upright on the left to the floor for an inward swinging door. Figure 20 illustrates the right-hand upright that is to be joined to the other end of the sill. Figure 21 is a horizontal sectional view showing the door frame with its integral brick trim or trim, mounted in the opening that receives the door, with a door in the closed position. Figure 22 is a vertical sectional view of the door frame assembly of Figure 21. Figure 23 is a perspective view illustrating a door frame and side light frame ready for attachment to a separate brick trim or trim. . Figure 24 is an elevational view showing the t a aaKgfifat_-HM »_Mfctr« - ~ bttít éS £ & s? & .. x & *. < door frame and separate side light frame, assembled with attached peripheral molding.

DETAILED DESCRIPTION OF COMPLIANCE WITH THE PREFERRED MODALITIES OF THE PRESENT INVENTION With reference to Figure 1, there is shown a door macro generally designated at 1, comprising a left hand upright 2, a right hand upright 3, a crossbar head 4, and a hearth 5. Also in Figure 1 there is shown a separate frame or brick molding for attachment to the frame 1, comprising a left molding strut 6, a right molding strut 7, and a molding head crossbar 8. Each of the uprights of the door frame 2 and 3, the head cross member 4, and the sill 5, are formed of synthetic material comprising compression moldings of filler, waste material , or recycled, joined together by a thermoplastic binder, which is conveniently a waste or recycled thermoplastic. Similarly, each of the molding members 6, 7 and 8 are also compression moldings of similar synthetic material. The particulate material to be used in the members of the door frame is selected to provide the required properties such as stability to temperature, strength, and hardness. Where substantial temperature changes are to be exposed to the door frame, the particulate material of filler, waste, or recycle preferably comprises, at least in part, a fibrous material such as wood dust, sawdust, cloth or waste paper crushed and / or ground. The thermoplastic binder material may comprise, for example, PVC or recycled polyethylene, and the proportion in The weight would preferably be from about 30 percent to about 60 percent to 70 percent particulate, with the balance being the thermoplastic binder material, or primarily the thermoplastic binder material along with, if desired, some material in additional particles such as very fine ash or kiln powder, to impart hardness and strength. For example, since sawdust quantities are usually readily available, a composite material particularly common for external door frames, exposed to wide ranges of temperature, comprises approximately 50 percent sawdust and 50 percent recycled polyethylene. It will be understood, however, that the percentage and nature of the filler, waste, or recycled material and the thermoplastic material can vary widely, depending on the requirements of the door frame, and there may be certain cases where the proportion of the particulate material to the thermoplastic material can be as high as 90 percent to 10 percent, and vice versa. With respect to the thermoplastic material, the Recycled polyethylene can be low, medium or high density polyethylene. Other examples of useful recycled thermoplastics include polypropylene, polyethylene terephthalate (PET), nylon, and ABS reshaped. Other examples of particulate materials The filler, waste or recycled that is to be joined together by means of the thermoplastic binder may include, for example, without limiting the same, glass fibers or particles, reeled thermocracked materials, ground peels such as peanut shells, and skins such as skins rice and corn, ground particles of rubber or metal or other hard material. In molding the components of the door frame, the filler, waste or recycling material is preferably introduced and the plastic material recycled, inside the compression mold, as an intimate mixture of hot particulate material having its particles coated with the molten thermoplastic material, after which, under the compression forces in the compression molding operation, the thermoplastic material cast encapsulates and glued the coated particles, in a »^^ t.« Fc *. j. "" X. "X", strong compacted bonded mat, each of the uprights 2 and 3, and the head cross member 4 are molded to form an elongated ca.-like structure.The uprights have elongated side walls 9, and end walls 10, with the head cross member 4 having the elongated side walls 11 and the end walls 12. The standard doors are 200.66 centimeters high and come in widths ranging from typically 76.2 centimeters to 106.68 centimeters, with most the doors being either 81.28 centimeters or 91.44 centimeters wide, however, it will be understood that the heights of the doors may vary, some doors being for example 243.84 centimeters high, and the width of the double doors will be of course substantially As a result, it will be noted that the uprights 2 and 3 must have a length to accommodate the height of the doors, while the length of the crossbar of head will vary to accommodate the different widths of the doors. As shown in Figures 2, 3 and 4, the box-like structures of each of the uprights 2 and 3, are formed with a stepped lower part that is to be faced inwards from an opening to receive the door , which is to be framed with the door frame, and comprises a first step 13 having a first outer lower flattened surface 13a extending '^ ^ * ß fcf longitudinally, of a width to receive the thickness of the edge of a door, such as the door 14 shown in Figure 15, which is to be mounted on the frame. Extending along the side of the first step 13, and projecting inward beyond its flattened surface 13a, there is a second step 15 having a second lower flattened surface 15a extending longitudinally. The connection between the steps 13 and 15 defines a shoulder of the door stop 16. The interior of each of the uprights 2 and 3 is divided to half its width, in line with the connection of the first and second steps 13 and 15 , by a longitudinally extending wall 17, which in effect divides the interior of the uprights into two adjoining channels 17a and 17b, with the channel 17a being shallower than the channel 17b. The edge 18 of the wall 17 ends in the same plane as the edges 19 of the walls 9 and 10 of the uprights. The configuration is such that when the uprights 2 or 3 are mounted in the opening of the wall of the building, as illustrated in Figure 4, the edges 18 and 19 will be contiguous with the framing of the opening of the wall of the building, constituted by example by the wooden strip of two by four inches 20, and the lining or the wall partitions 21. The stepped bottom of each of the uprights 2 and 3 is formed with a slot 22, at the junction of The steps 13 and 15 with this groove 22, which extends into the longitudinally extending wall 17 , and which is adapted for mounting therein of the resiliently flexible weatherseal 23, for a purpose which will be described hereinafter more fully.The second step 15 of the uprights, projecting inward, is shown as ending short of the end walls 10 of the stile As particularly illustrated in Figure 2, the upper end of the step 15 terminates in a flat shoulder 24, which is adapted to form a locating seat for the head cross member 4, as will be described hereinafter more fully. Similarly, the lower end of the step 15 ends short of the lower end of the upright, in a shoulder 25 slightly inclined, adapted to sit on the hearth 5, as will be described later herein more fully. As shown in Figure 5, the molded head cross member 4, like the uprights 2 and 3, has Preferably a stepped lower surface which, when the head cross member is installed, faces into the opening of the door frame, the stepped lower part of the head cross member comprising a first step 26, which has the flattened lower surface 26a outside , That extends longitudinally, of a width to receive the shore í ^ &? £ ^ * ÉáJít¿ ¿-. of a door to be mounted in the door frame, and a second step 27 having the lower surface 27a flattened longitudinally extending, the step 27 projecting inward, beyond the surface 26a, to provide a door stop shoulder 28, as shown in Figure 5. A longitudinal wall 29 corresponding exactly to the junction of the steps 26 and 27, divides the interior of the head cross member in the middle of its width, in a pair of 10 adjoining channels 30 and 31, with the channel 30 being shallower than the channel 31. It will be understood that the edge 32 of the wall 29 will be in the same plane as the edges 33 of the walls 11 and 12 of the head cross member, for assembly in the opening of the wall that receives the door frame, in which the door frame and the door are to be mounted, as illustrated in Figure 4. In the configuration shown, particularly in Figure 2 , the length d e the steps 26 and 27 of the head cross member, and the channels 30 and 31 of the head cross member, are the same, in such a way that the end wall 12 at each end of the head cross member, will have contact with the front area 34 of the respective upright on the upright projection 24, with the lower surface 27a of the step 27 of the head crosspiece resting on the shoulder 24. As illustrated in Figure 2, the end wall 12 ^ -a ^ - -fif * '_jfe._ »*. * -. The Jß & i of the head cross member is provided with generally semicircular, spaced notches 35, while the upright 3 is shown with integral lugs or protuberances 36, which fit into the notches 35, to ensure the proper fitting assembly corresponds exactly, between the head crosspiece and the upright with the head crosspiece seated on the shoulder 24 of the upright. The interior of the end wall 12 of the head cross member is provided with integral protuberances 37, for provide a body of material having a depth to receive and provide adequate clamping power for the screws 38, which pass through the post and into the end of the head cross member, and into the protuberances 37 in the cross member assembly. head with the stile.

The head cross member can be cut transversely to adjust to different door widths, or to be used in lateral light frames, as will be explained later herein, by providing, as shown in Figure 2, one or more internal transverse walls 12 ', provided with notches 35' corresponding to the notches 35, and with protuberances 37 'corresponding to the notches 37. It will be understood that the configuration at one end of the head cross member, as illustrated in the Figure 2, it will duplicate at the other end when assembling the crossbar of ;.: '- ^ «a ~ .'_. , s_¿Su ^ aáSfc ....-; ^ £ __ "., .. ^^ head to the mullions. As shown in Figure 1, the inside of the pillar 2 is provided with integral integral protrusions 39, which extend out from the inner surface of the bottom wall, to provide support for the screws 38, for the assembly of the upright and the crossbar of head Preferably these protuberances 39 are formed with passages or perforations 39a extending therethrough, these perforations being shown as arising from the wall portion 40, on the shoulders 24 of the pillar 3 on the right in Figure 2, meaning that the left and right mullions are identical with respect to the configuration for the exact correspondence and the securing with the head crosspiece. The uprights 2 and 3 are preferably provided with transverse reinforcing webs 41, which run between the longitudinal intermediate wall 17 and the side walls 9 of the uprights. Similar webs 42 are provided in the head cross member 4 running between the intermediate longitudinal wall 29 of the head cross member and the side walls 11 of the head cross member. As in the case of the uprights, the stepped lower surface of the head cross member 4 is provided with a slot 43, at the junction of the steps 26 and 27 with this slot extending upwards, inside the intermediate wall 29 for mounting the flexible resilient weather strip 23. By providing perforations through the protuberances 39, with a diameter such that they tightly tighten the screws 38, the uprights can be secured to the head cross member, without the rotation of the screws that lowers the uprights of the ends of the head crossbar. The sill 5 shown in Figures 3, 4, 5, and particularly Figure 6, such as the uprights 2 and 3 and the head cross member 4, is formed by means of compression molding a composite material comprising particulate material. of filler, waste, or recycled, and a thermoplastic binder as stated above. As shown in Figure 6, the sill is preferably formed as an elongated member to cover the full range of widths or sizes of doors, and is adapted to be cut at different points corresponding to the width of the door that is intended to be receive the door frame. As shown in Figure 6, in its elongated form, the upper part of the hearth comprises a narrow horizontal portion 44 running the length of the hearth, and a wider inclined portion 45, separated by a longitudinal groove 46.

Extending between the end walls 47 and 47a of the hearth, are the external walls or struts 48 and 49, and the intermediate struts 50 and 51, all of which struts terminate in a common plane with the lower edges 52 of the end walls 47 and 47a. The end walls 47 and 47a are provided with the notches 53 for receiving correspondingly shaped pins or projections 54, provided on the bottom of the uprights 2 and 3, as illustrated in Figure 3. Inside the end walls 47 and 47a of the hearth, integral protrusions 55 projecting inward are provided, to provide a depth of the material to be meshed by means of, and to provide clamping power for the fasteners or screws 56 that are used to assemble the studs to the sill, as illustrated in Figure 3. Through the provision of the projections 54 in the uprights, and the notches 53 in the end walls 47 and 47a of the sill, a good exact correspondence between the uprights and the sill can be obtained. , before securing the members together. As indicated in Figure 1, uprights 2 and 3 are also provided with internal projections 57, to provide support for the fasteners 56, and again AJ ^ Z these projections are formed with the perforations 57a, to receive the fasteners 56 tightly, in such a way that when screws are used, the rotation of the screws does not reduce the lower end of the uprights, as that the screws penetrate the material of the projections 55 of the hearth. As illustrated in Figure 6, the end walls 47 and 47a essentially duplicate at points along the length of the sill member shown in Figure 6, to provide the sills of different widths of doors, or a floor for a door with a side light, as will be explained hereinafter more fully. In this way, by cutting the sill of Figure 6 on the outside of the walls 58a, 58b, and 58c, the end walls / i71, 472, and 473 will be provided complete with the notches 53 and the projections 55. Similarly, if the elongated sill of Figure 6 is cut on the outside of the walls 59a and 59b, the right-hand end wall 47a will be duplicated, as the end walls 47ax and 47a2 end with notches 53 and projections 55. When installed, the sill 5 preferably has its wider inclined surface 45 covered with an aluminum extrusion 60, and its upper horizontal surface 44 covered with a vinyl extrusion 61, configured for . ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^. aluminum 60 in an oscillating door, or vinyl extrusion 61 in an outwardly swinging door When assembling the door posts 2 and 3 to the ends of the head cross member 4, only two screws are required for each upright, these screws passing through the perforated protrusions 39 of the upright, and into the protrusion 37 of the head crosspiece Similarly, only two screws are required for each upright to secure the upright to the sill 5, the screws passing through the perforated projections or protuberances 57 of the upright, and within the protuberances 55 of the sill, in this way the entire door frame can be assembled with only eight screws. 2 and 3 of the assembled door frame, reference is made in Figures 8, 9 and 10 to the opening in the wall to receive the door frame. As illustrated in Figure 8, the lower flattened surface 13a facing inward from the step 13 of the upright is hollowed out as in 63, at intervals along its length. As shown in Figures 9 and 10, the inside of the upright behind the recessed area 63, has a solid column of material 64, which extends the depth of the - * & £. step 13, and this solid column 64 is formed with a perforation 65 extending therethrough, of a diameter for tightly receiving the fasteners or screws 66, such that when the upright is mounted against the frame member 20. of opening that receives the frame of the door, then the rotation of the screw 66 to penetrate the frame member 20, to secure the upright to the frame member will not act to lower the upright. Figure 9 illustrates the pillar mounted with the door 14 in the closed position, compressing the flexible resilient bezel 23, which clears the head of the screw 66, which is seated in the cavity 63. However, the head of the screw will not be visible with door 4 in the closed position. Figure 10 is a view similar to Figure 9, but without the door 14 present, and showing the resilient flexible bead recovered to extend over the screw 66, hiding it from the view with the door open. It will be understood that when the door 14 is mounted, the door will be hinged to one of the uprights 2 or 3, and the other upright will accommodate the knocking plate door bolt and the door bolt where required. Figures 11 and 12 illustrate, as an example, the post 3 to which the door is to be hinged. As shown in Figure 11, the first flat lower surface 13a, facing inward, of a step 13, is hollowed out as in 68, for level mounting of a hinge hinge 69 shown in Figure 12. On the reverse side of the upright behind the area recessed 68, the interior of the upright is formed with a series of interconnected integral projections or columns 70, extending the depth of step 13, to provide a body of material, to receive the screws or fasteners 71 of the hinge. In Figure 13 the flattened surface 13a of the opposite upright, ie the upright 2, is shown as being recessed at 72 to receive a striking plate, which is not shown, and also recessed as in 73 to receive a bolt plate, that is not shown Behind the cavity of the striker plate 72 inside the step 13, there is an integral block of material 74 extending the depth of the step 13. The cavity of the striker plate 72 is formed with a rectangular perforation projecting inside the block 74, to provide an opening for the door bolt. Similarly, behind the bolt cavity 73 is a block of material 74 ', with the recessed area of the bolt 73 being provided with a rectangular bore 76 extending through the integral block of material 74', to receive a bolt. of locked. It will be understood that when the swinging door is seen in Figure 1 from outside a building, it will be stud 3 on the right which will be formed to receive the hinges, usually employing three hinges. The left-hand upright will be formed to accommodate the door bolt and door bolt where it is used. However, it will be understood that the swing of the door can be reversed, in which case the upright on the left will receive the hinges, and the upright on the right will receive the bolt and the door bolt. The role of these uprights will be reversed in the case of an outward swinging door. To dress the door frame 1 of Figure 1, the molding comprising the molding uprights 6 and 7 and the head cross member 8 is provided. As mentioned, this molding is formed as a compression molding of composite material as shown in FIG. described earlier. Since the molding members 6, 7 and 8 do not bear the load of the door, it will be understood that the nature of the particulate material, and the percentage of particulate material and the thermoplastic material may vary from that employed in the molding of the frame. of door itself. These molding members 6, 7 and 8, of course can be individually molded, or can be obtained conveniently by means of appropriately cutting the elongated molding channel 79 shown in Figure 7. This channel 79 is formed with chamfered ends 80, a series of biased inner webs i **, and straight angular webs 82 extending between the side walls 83 of the channel. By cutting along the appropriate lines 84, which coincide with the biased inner webs 81, the appropriate length of the head cross member 8 can be obtained, so that it adapts to the size of the door frame required for the size of the web. selected door or, if a side door light is used, the length necessary to frame the door head and the side door light. It will be understood that the cut will take place, in such a way that both ends of the head cross member are chamfered. By cutting the molding 79 transversely at right angles to the walls 83, the door struts 6 and 7 can be formed. When the head cross member 8 and the uprights 6 and 7 are joined to the frame 1 as by means of nails of Finished, for example, frame members will form oblique upper corners. Although the uprights 3 and 4 are preferably formed in such a way that the stop shoulders of the door 16, presented by the second steps 15, are shorter than the surfaces 13a receiving the edge of the door, ~ i - & & amp; ^ ^ - presented by the first steps 13, to provide the mounting projections 24, as shown in Figure 2, and the shoulder stop of the door 28, presented by the second step 27 of the head cross member 4, extends the complete length 5 of the head crosspiece, if desired this relationship can be reversed. That is, the second step 27 of the cross member and consequently the stop shoulder of the door 28, can be formed to terminate short of both ends of the first step 26 of the head cross member, while the shoulders of stop 16 of the uprights may continue to the tops of the uprights. It will be understood that in the case of internal doors, where the soleras are not required, the uprights will extend down to rest on the floor. Figures 15 to 18 illustrate a door frame generally designated at 85, having struts 86 and 87, and a head cross member 88, which are identical to the uprights 2, and to the head cross member 4, except that these have the moldings corresponding to the molding of uprights 6 and 7 and to the molding crossbar head 8, molded integral with them. Because in all other aspects the uprights 86 and 87 and the head cross member 88 correspond to the uprights 2 and 3 and the head cross member 4, the same parts are given the same numbers. Solera 5 remains without changes. ís éa. Figure 15 shows the door frame 85 with the uprights with their integral moldings 89, the head rail with its integral molding 90 and the sill 5 assembled ready for introduction into the opening of the door. a wall that receives the frame. Figure 16 illustrates the assembled door frame 85, which is to be mounted in the opening of the wall, to be joined to the reception frame members 20, which may be, for example, wooden slats two in length. four inches. As shown in Figures 17 and 18, and particularly in Figure 22, the integral head cross member molding 90, in the case of an inwardly swinging door, which represents the largest portion of the market, extends outward from the side wall 11 of the head cross member, at a spaced point on the wall of the flat head cross member 15, as shown in Figure 22. The head cross member molding 90 is, in effect, an elongated L-shaped section, having a short counter hinge portion 91, extending outward, perpendicular to the wall of the head cross member 11, at a retracted point of the flattened surface 27a, and a longer counter hinge portion 92, extending at right angles to it, which forms the front wall of the head rail molding projecting out of the opening defined by the door frame, as shown in Figure 22.

As shown in Figures 17 and 18, the ends of the head cross member molding 90 are closed with an inclined wall 93, and a short return wall 94, to provide chamfered mounting surfaces, for engagement with the head moldings. mullions 89, to provide oblique corners when the head cross member 88 is assembled with the uprights 86 and 87, as described below. As shown particularly in Figure 21, as in the case of the head cross member molding 90, each of the upright moldings 89 is an elongated formation generally L-shaped, having a short counter hinge 95, which projects outwards, at right angles from the wall 9 of the uprights, at a retracted point of the flattened surfaces of the upright 15a, and a longer counterbust portion 96, projecting outwardly from the opening defined by the door frame . Figure 21 illustrates the function of the integral molding moldings 89, which not only provide a trimmed appearance to the door frame, but extend to meet the masonry indicated at 97 (and consequently are called brick molding), to which these are sealed by caulking 98, to provide an air gap 99 between the building wall structure, consisting of the two by four inch wood slats 20 and the wall partitions 21, to provide a insulating effect. It will be understood that a similar function will be formed by means of the head cross member molding 90. As shown in Figures 17 and 18, the upper ends of the upright moldings 89 are closed by an oblique wall 100 and a wall 100 short return 101. The lower portions of the uprights 89 are provided with feet turned in 102, as shown in FIG. shows in Figure 19. The assembly of the uprights 86 and 87 with their moldings 89 integrally molded with the sill 5, is identical to that described in connection with the uprights 2 and 3 and the sill 5, as illustrated in the Figures 19 and 20. 15 In many cases, the installation of a door frame can request the provision of a side light on one side, or even a side light on both sides. Figures 23 and 24 illustrate an installation that surrounds a sidelight frame, generally designated at 103, for joining frame 1.

It will be understood that this sidelight frame 103 is adapted to receive a conventional double glass window unit (not shown) having a thickness corresponding to the thickness of a door, in the same way that the frame 1 is adapted to receive a door The light frame side 103 is formed of the uprights 104, the crossbar of affeHteastfcy .., &** ** .j »*. Aa *?» J «?» i * Bfc head 105, and hearth 106, which correspond to the uprights 2 and 3 and to the crossbar 4 and the sole 5 , respectively, except that the uprights have no provisions for the assembly of the hinges, and the reception of the door hardware and the internal raceways wrapped with that hardware, but as will be understood, they have appropriate internal raceways (not shown) to be assembled with the frame 1, and to mount in the opening of the wall to receive the same. The head cross member 105 is provided by cutting a head cross member corresponding to the head cross member 4, on an appropriate inner wall 12 '(see Figure 2), in accordance with the width of the side light. The sill _ 06 is provided by cutting a sill corresponding to the sill 5 of Figure 6, in an appropriate inner wall, for example 47a, in accordance with the width of the sidelight. After the frames 1 and 103 are secured together in abutting relationship, the combined frames are given an integrated appearance, by the addition of an aluminum profile piece 107, which corresponds to the member 62 shown in Figure 20, which extends to the length of the combined frames. To accommodate this continuous bridging of the profile piece 107, through the combined frames, the front edges of the neighboring bottom portions of these frames are notched at 108 and 109 respectively. It will be understood that, if desired, the sills 5 and 106 can also be made as a continuous piece with the appropriate notching on the rear edges of the lower parts of the adjacent frame struts. After assembling frames 1 and 103, a separate frame molding 110 is applied, with the head cross member 111 and the posts 112 being cut from the elongated molding shown in Figures 7 and 7a to the appropriate lengths. It will be understood that the door frame assembly can also include, if desired, a cross-member frame using a head cross member 4, and short uprights that surround the basic structure of the uprights 2 and 3. Although preferred embodiments have been described of the structure of frames and compression molding components according to the invention, it will be understood that variations can be made in the structural details of these frames and components, and these can be compression molded from a very narrow range. broad of composite materials, comprising particulate materials bonded together by means of a thermoplastic binder, all within the scope of the appended claims.

Claims (29)

1. A door frame assembly comprising a pair of molded uprights (2, 3) and a molded head cross member (4), molded of composite material, characterized in that each of the uprights is formed to present a first and second channels longitudinal parallel openings (17a, 30) (17b, 31), having spaced side walls (9, 11) and a common central wall (17, 29), 10 respectively, whose edges (18, 32) are in the same plane as the edges (19, 33) of the uprights and the head crosspiece respectively, those channels being closed at their ends (10, 12), the second channels (17b, 31) presenting lower parts (15a, 27a) projecting 15 beyond the lower parts (13a, 26a) of the first channels (17a, 30) and parallel thereto, such that in the assembly of the head cross member and the uprights, the lower parts of the first channels define an opening to receive the door, with the lower parts of the 20 first channels of the uprights being adapted for mounting the door fitting to them, and the lower parts of the second channels (17a, 31) project into the openings that receive the door, with the first and second channels forming a shoulder formation of 25 door stop (76). ^^^^ m ^ m? im ^ a ^^^^ ggSgg ^^ «x? s aam? w S S ^ ^ ^ .z ^ íL t ^ s, ^, ^ ^^ m

2. A door frame assembly, as claimed in Claim 1, characterized in that the lower parts presenting the second channels of the uprights, projecting beyond the lower parts of the first channels, terminate short of the upper ends of the door. the stiles and form support shoulders (24) for the head crosspiece.

A door frame assembly, as claimed in Claim 1 or 2, characterized in that it additionally includes a hearth (5) of molded composite material, having a longitudinal grooved formation closed at the ends (47, 47a).

A door frame assembly, as claimed in claim 3, characterized in that the lower parts presenting the second channels of the uprights, projecting beyond the lower parts of the first channels, end short of the ends lower of the uprights and form shoulders (25) to seat the uprights in the floor.

A door frame assembly, as claimed in any of the preceding claims, characterized in that in the common central wall (17, 29) of the channels of said uprights and the head cross member, is formed with a slot to receive a weatherstrip (22, 43), which opens in the same to the lower part of the channels.

6. A door frame assembly, as claimed in any of the preceding claims, characterized in that each of the members of the uprights and of the head cross member is formed with an integral molding (89, 90) on one face thereof, presented as an outer frame face when assembled to define an opening that receives a door, each of those integral moldings comprising an L-shaped strut, having a short strut portion extending laterally (95, 91), which extends perpendicular to its respective outer frame face, at a point displaced outwardly from the opening for receiving the door, and a longer outwardly extending strut portion (96, 92), which extends outwardly. from that opening to receive the door, and perpendicular to said short strut.

A door frame assembly, as claimed in any one of the preceding claims, characterized in that the uprights and the head traverses are formed to provide exact interengaged matching formations (35, 36) to exactly match them in the appropriate relative position, preparatory to securing them together.

8. A door frame assembly, as claimed in any of the preceding claims, characterized in that the interior of at least said first^? "& .. * _ & __ > aa. channel (17a, 30) of each of the uprights and the head cross member, is formed with a configuration of integral thickened areas (70, 37), adapted to receive and support the fasteners inserted therethrough.

A door frame assembly, as claimed in any of Claims 1 to 8, characterized in that the first channels of the uprights and the head cross members are formed with inner channels (64) adjacent to their common walls, the channels. having holes (65) through them, for the passage of fasteners through them, to secure the uprights and the head cross member to an opening that receives the door frame.

A door frame assembly, as claimed in any of the preceding claims, characterized in that the composite material comprises filler, waste, or recycled material, bonded together by a thermoplastic binder.

11. A door frame assembly, as claimed in Claim 10, characterized in that the thermoplastic binder is a recycled thermoplastic.

12. A molded post (2 or 3), molded of composite material, characterized in that it is formed to present first and second parallel parallel longitudinal open channels (17a, 17b), which have side walls spaced (9) and a common central wall (17), whose edge (18) is in the same plane as the edges (19) of said walls (9), the channels being closed at their ends (10), the seconds channels having a lower part (15a) projecting beyond the lower part (13a) of the first channel, and being parallel thereto, the lower parts of the first channel being adapted for mounting the door fitting therein, the first and second channels forming a shoulder stop (16).

13. An amount, as claimed in the Claim 12, characterized in that the presented lower part (15a) of the second channel projecting beyond the lower part (13a) of the first channel stops short of the upper part of the upright to provide a support shoulder (24).

An upright, as claimed in claims 12 or 13, characterized in that the presented lower part (15a) of the second channel, projecting beyond the lower part (13a) of the first channel, stops short of the lower part of the upright, to provide a settlement shoulder (25).

A stud, as claimed in any of Claims 12, 13 or 14, characterized in that the common central wall (18) has a weatherstrip groove (22) therein, which opens to the lower parts of the channels . 7 ^ Ss ^ íS S ^ & »^?

16. A pillar, as claimed in any of Claims 12 to 15, characterized in that the lower part of the first channel has a row of cavities (63) receiving screw heads, adjacent to the shoulder of 5 door (46). An upright, as claimed in any of the preceding Claims 12 to 16, characterized in that the upright is provided with an exact headrest cross member (36), adjacent to the part. 10 above it, and an exact hearth matching element (54), adjacent to the bottom thereof. An upright, as claimed in any of the preceding Claims 12 to 17, characterized in that it has an L-shaped molding (89) formed 15 integrally with it. An upright, as claimed in any of claims 12 to 18, characterized in that the interior of at least the first channel (17a) is formed with a configuration of integral thickened areas (70), adapted 20 for receiving and supporting fasteners inserted through them. 20. An upright (3) as claimed in any of Claims 12 to 18, characterized in that the lower part (15a) of the first channel (17a) is formed with 25 cavities (63) to receive hinges, and the interior of the first £ SÍJi $ ñ £ ¿¿- *. The channel opposite the hinge receiving cavities is formed with a pattern of integral interior channels (70) to receive fasteners to secure the hinges received in said cavities. An upright (12) as claimed in any of Claims 12 to 18, characterized in that the lower part (13a) of said first channel (17a) is formed with cavities (775, 76) to receive a strike plate and hardware of door latch, and the interior of the first channel has a configuration of integral internal blocks (74, 74 ') of material, opposite the cavities to receive the fasteners for attaching the strike plate and the door bolt hardware. 22. A pillar, as claimed in any of Claims 12 to 21, characterized in that the composite material comprises filler, waste, or recycled material, joined together by a thermoplastic binder. 23. A door pillar, as claimed in Claim 22, characterized in that the thermoplastic binder is a recycled thermoplastic. 24. A head cross member (4) for a molded composite door frame, characterized in that it is formed to present first (30) and second (31) adjacent parallel longitudinal open channels, which have spaced side walls (11) and a common central wall (29), whose edge is in the same plane as the edges (33) of the side walls 11, the channels being closed at their ends (12), the second channel presenting a lower part (27a) projecting beyond the lower part (20a) of the first channel and parallel to it, the first and second channels forming a shoulder stop (28). 25. A head cross member, as claimed in Claim 24, characterized in that the common central wall 0 (29) has a groove (43) for receiving a weatherstrip, which opens to the lower parts of said channels. 26. A head cross member, as claimed in Claims 24 or 25, characterized in that it also has a counter frame molding (90) integrally formed with the outer wall of the first channel (30). 27. A head cross member, as claimed in Claims 24, 25 or 26, characterized in that the composite material comprises filler, waste, or recycled material, bonded together by a thermoplastic binder. 28. A head cross member, as claimed in Claim 27, characterized in that the thermoplastic binder is a recycled thermoplastic. 29. A molded structure (79) characterized 5 because this is a molding from which they can be cut The moldings for frames comprising a pair of uprights and a head cross member connecting said uprights to accommodate different frame widths, the molding structure comprising an elongate compression molded channel, formed of particulate material joined together by medium of a thermoplastic binder, the molding structure having lateral walls (83) extending longitudinally, and closed chamfered ends (80) with the chamfer at one end opposite the chamfer at the other end, the channel having extending between the side walls , a series of obliquely inclined transverse walls (81), and a series of straight angular transverse walls (82), the configuration being such that by means of it the cutting of the channel can be provided in the selected ones of said moldings of the crosspiece of head of transverse walls inclined obliquely, for different widths of frames, while you can of providing the cutting of said channel in the selected ones of the straight angled transverse wall mullions with chamfered upper ends selected for attachment to a left-hand upright or a right-hand upright.