NZ280071A - Modular door or window frame construction method; door or window reveal unit - Google Patents

Description

28 0071 Patents Form No. 5 Our Ref: RL800861 NEW ZEALAND PATENTS ACT 1953 Complete After Provisional No. 280071 Filed: 21 September 1995 COMPLETE SPECIFICATION WINDOW AND DOOR FRAME CONSTRUCTION METHOD I, ALLAN BRUCE SAYER, a citizen of New Zealand of 16B Swithland Place, Avonhead, Christchurch 8004, New Zealand hereby declare the invention, for which I pray that a patent may be granted to me and the method by which it is to be performed, to be particularly described in and by the following statement: PTOB28727 28007 WINDOW AND DOOR FRAME CONSTRUCTION METHOD The invention relates to an improved method of fitting door and window frame units to building structures.

At present doors and window frames are fitted during a buildings construction and they are normally fitted before internal wall panelling is finished. This enables plaster finishing of gib panel walls to be undertaken up to architraves which surround door and window frames.

A problem with this construction method is that the door and window frames can be damaged while builders, contractors and/or painters continue to work in the building after the frames are installed. This can be a significant extra cost to a builder if the door or window frame has to be replaced.

This damage normally comes about because of the use of veneered timber for the more expensive timber which has been used in the past. If the veneer is damaged the door or frame must be replaced because it is not possible repair or readily hide damage to the veneer.

An object of the present invention is to overcome the above problems and provide a method of fitting door and window frame units near to or at the end of the building being constructed.

A further object of the invention is to provide a consumer with a useful alternative choice. 28 0 0 According to a first aspect of the invention there is provided a method of fitting a door and/or window reveal unit to a building structure, the method including the steps of: forming a door profile aperture in a wall; finishing wall linings associated with the profile aperture; cutting the aperture to a size so that a door reveal unit and integia! architrave unit can slidingly engage therein; fitting the shaped door reveal unit and integral architrave to one side or the aperture; fitting from the other side of the aperture an architrave unit to the door reveal unit; fixing the architrave unit in place after the reveal unit and door has been plumbed and fixed in position.

The shaped door reveal unit and integral architrave can be fitted plumb fixed in position using a foaming adhesive.

According to another aspect of the invention there is provided a door or window reveal unit incorporating a door panel or panels and/or a sash unit, and an associated reveal, the reveal having on one side a set of architraves and having on the other side of the reveal a tongue and/or groove on or into which an architrave unit is fitted after the reveal unit has been positioned in an aperture in a wall.

Further aspects of the invention will become app following description which is given by way of example. 280071 An example of the invention will now be described with reference to the accompanying drawings.

In the accompanying drawings: Figure 1 shows a plan view through a door jamb, door and wall; Figure 2 shows, exploded apart, a fitting adapted for use with the door jamb and studs to locate and fix the door jamb in position; Figure 3 shows a side view of the fittings shown in Figure 2; Figure 4 shows a side view of a wall in which a door opening is to be created; Figure 5 shows a door template used for forming an opening in a wall; Figure 6 shows a perspective view of a stud template used for creating holes in a stud for fittings of the type shown in Figures 2 and 3; and Figure 7 shows a plan view of the template shown in Figure 5 and showing a plate for locating it temporarily in position on a wall.

Examples of the invention will now be described with reference to the placement of a door in an internal wall. It is however to be appreciated that with minor modifications the present invention can be used for external walls 280071 or for windows or other fittings adapted to be fitted in openings to be created in a building structure.

In Figure 1 is shown a section through a door jamb 1 and door 2 located relative to an internal wall generally indicated by arrow 3.

The wall 3 is formed is known manner with vertical studs (one of which is shown at 4). Over each opening there is a lintel (not shown). The studs 4 when in position have wall panelling such as gib board panelling 5 fixed in known manner to each face. The panelling 5 need not be cut or finished adjacent the opening as is shown in Figure 4. In Figure 4 the gib board sheets 6 are shown and the eventual profile of a door space is shown dotted (arrow 7). An opening 8 can be left to provide access between spaces divided by the door.

In practice after the wall panelling 5 is placed in position a template 9 Figure 5, is used to cut a proposed opening size. The template 9 can itself be formed in two halves 10, 11 adjustable in width by members 12. Different sizes and shapes of templates may be provided for different situations.

In Figure 5 the template 9 has at each corner a locating hole 13 into which a jigsaw or router is fitted so as to cut the profile of the opening formed by edges 14, 15 and 16 of the template 9.

The template 9 can be fitted in position by stud locators 17 also shown in Figure 7. The locators 17 enable the template to be locked in position 280071 between opposing studs and under a lintel. This is assisted by height adjustable feet 18.

The template 9 can be used after the wall finishing has been concluded including painting, papering and/or plastering. This makes the plasterers or other workmens task easier in that they do not have to finish plastering or papering around an architrave as is the case in existing building construction techniques.

The template 9 can include a plumb level 19.

The inner side walls 14, 15 of the template 9 have rebates 20 which can be used as described below to assist in fixing the door or window frame in place.

In one method after the proposed opening has been formed a template 21 such as that shown in Figure 6 is used to form fixing holes 22 in the studs.

The fixing holes 22 have placed therein an internally screw threaded member 23 into which a bolt 24 is engageable. The bolt 24 can have a washer 25 attached and the bolt and washer have thereon a lock nut 26. The bolt 24 and lock nut 26 are then fitted loosely into the fitting 23 in preparation for placement of a door frame in position.

The door frame itself is formed with a jamb. The jamb 1 can be formed from a veneered timber or medium density fibreboard or chipboard member 27 with a veneer 28 on its face. The face 28 can have prefitted a 2800 71 door stop or clashing strip member 29 and the door 2 is hinged at 30. The hinge side of the jamb 1 has fixed in place an architrave 31 which in the example has the architrave 31 fitted in place by a tongue and groove connection. The two parts, architrave 31 and jamb 1, are prefixed together in a door or window joinery factory ready for fitment to a building structure. The jamb 1 also has a removable architrave 31 cut in the factory to size but not glue fixed to the jamb 1. In this case the veneer 28 is cut thicker than normal to provide strength.

At the preset positions aligned with holes 22 in the inner face 33 of the jamb 1 are placed fitting members one of which 34 is shown. It is screw or nail fixed to the jamb 1. The fitting member 34 has the shape shown in Figures 2 and 3 and includes a slot 35 so that when the frame unit is delivered to the site and after the profiled openings have been formed in the wall and with the architrave 32 removed the associated jamb 1 and architrave 31 are slidingly fitted into the opening 7. This movement in the direction of the arrow A shown in Figure 1 results in the slot 35 sliding over the bolt 24.

In this position the jamb 1 and door can be set plumb by adjusting the positions of the bolt 24. Access to the bolts can be gained from the rebates 22 formed in the profiled opening 7 so that a suitable spanner can be used to adjust the position of the jamb 1. The lock nut 26 is then tightened against the side of the fitting member 34. When plumb the space 35 between the jamb 1 and the stud 4 can be back filled with an expanding foam (not shown) which sets to provide a more rigid than normal mount for the door jamb. 280071 After this the other architrave 32 can be fitted. The size, depth and length of the tongue 36 and groove 37 connection between the architrave 32 and the door jamb 27 is such that small differences in dimensions between the wall thickness can be allowed for.

The architrave 32 is fixed in position using a suitable adhesive. Placement of the architrave can finish the job.

The architraves, door jamb and door can be prefinished with an appropriate paint, polyurethane or the like finish before the door is fitted.

In an alternative construction method not shown an adhesive foam can be used to locate the door frame. In this construction after a template or the like has been used to form a proposed opening the jamb 1 is located in position. After the jamb has been plumbed to the required degree adhesive foam is used to fill the space between the jamb and adjacent studs. The removable architrave 31 can then be glue fixed in place to complete installation of the door frame.

In addition to the ease of manufacture another advantage of the present invention is that significant savings in material costs can be undertaken because of the use of veneered door jambs which are less expensive than those normally used.

Particular examples of the invention have been described and it is envisaged that improvements and modifications can take place without departing from the scope of the attached claims. - 9 280071 Where in the aforegoing description particular mechanical or other integers have been described, it is envisaged that their mechanical or other equivalents are contemplated even though they are not set forth herein.

Claims (8)

- 10- 280 0 WHAT I CLAIM IS:

1. A method of fitting a door and/or window reveal unit to a building structure, the method including the steps of: forming a profile aperture in a wall; finishing wall linings associated with the profile aperture; cutting the aperture to a size so that a door and/or window reveal unit and integral architrave unit can slidin^ly engage therein; fitting the reveal unit and integral architrave to one side of the aperture; fitting from the other side of the aperture an architrave unit to the reveal unit; fixing the architrave unit in place after the reveal unit has been plumbed and fixed in position.

2. A method as claimed in Claim 1 wherein the shaped door reveal unit and integral architrave is fitted, plumbed and fixed in position using a foaming adhesive.

3. A method as claimed in claim 1 or claim 2 wherein the door profile is formed by utilising a template.

4. A method as claimed in claim 3 wherein the template is formed in two halves which allow the width of the door profile aperture produced to be adjustable.

5. A method as claimed in claim 3 or claim 4 wherein the^tefrfblate T?.y % i fitted in position by stud locators. (j "* 1.:' '097 -11 - 28 0 0 7 t

6. A method of fitting a door and/or window reveal unit to a building structure as claimed in Claim 1 and substantially as hereinbefore described with reference to the accompanying drawings.

7. A door or window reveal unit incorporating a door panel or panels and/ or a sash unit, and an associated non-structural reveal constructed from non-solid timber such as a laminated, reconstituted or finger jointed timber material, the reveal having prefitted on one side architraves and having on the other side of the reveal a tongue and/or groove on or into which an architrave unit is fitted after the reveal unit has been positioned in an aperture in a wall.

8. A door or window reveal unit as claimed in Claim 7 and substantially as herein before described with reference to the accompanying drawings. ALLAN BRUCE SAYER BALDWIN SQNT& CAREY ASPEC09370 END OF CLAIMS