US2887219A

US2887219A - Prefabricated door package assembly

Info

Publication number: US2887219A
Application number: US497189A
Authority: US
Inventors: Jr Lawson L Lester
Original assignee: Individual
Current assignee: Individual
Priority date: 1955-03-28
Filing date: 1955-03-28
Publication date: 1959-05-19
Anticipated expiration: 1976-05-19

Description

May 19, 1959 YL. L; LESTER, JR 2,887,219

PREIF'ABRICATED DOR PACKAGE ASSEMBLY Filed March 28, 1955 zsneets-sneet 1 Avi-rvs,

United States Patent O PREFABRICATED DOOR PACKAGE ASSEMBLY Lawson L. Lester, Jr., Martinsville, Va.

Application March 28, 1955, Serial No. 497,189

8 Claims. (Cl. 20660) This invention relates generally to preformed door and frame constructions and to the manner of packaging the same.

Of primary importance in connection with this invention is the provision of improved means for packaging preformed door and frame constructions and generally of means calculated to simplify the process of packaging such articles for shipment.

A11 object of this invention is to provide an improved combination of corner packing means and securing blocks which cooperate to `enable the corner packing means to be separately applied.

Another object of this invention is to provide a combination of securing blocks and corner packing means in which the corner packing means are aixed to the securing blocks to hold a preformed door and frame construction in proper relationship for shipping. l

Still another object of this invention is to provide a specially formed securing block for use in conjunction with corner securing means, wherein the blocks are provided With grooves or notches to receive fasteners which will at once prevent movement of two parts in one direction but will permit their ready disengagement in another direction and to provide corner securing means operable in conjunction with the securing blocks to preclude the disengagement of parts until such time as the corner means themselves are removed.`

Still` another object of this invention resides in the provision of reinforcing wedge means for the door and frame construction to rigidify the same both during the shipping process and after installation of the preformed construction. p p

These and other objects inherent in the invention hereinafter described will become apparent as the description proceeds.

Illustrativeembodiments of the invention are shown in the accompanying drawings but it is to be understood that this showing is illustrative only and is not intended to be limiting to the exact construction shown since obviously changes `can be made both in detailed construction and arrangement of parts without forming a departure from the spirit and scope of this invention `as set forth and delined in the appended claims.

In the drawings:

Fig. l is a perspective view of the package unit;

Fig. 2 is an enlarged vertical section taken generally along line 2 2 in Fig. l;

Fig. 3 is an enlarged horizontal section taken along line 3--3 in Fig. l;

Fig. 4 is an enlarged perspective view of one of the upper corners of the package unit with the corner boot removed;

Fig. 5 is an enlarged perspective of one of the lower corners of the package unit with the corner boot removed; and

Fig. 6 is an elevational view showing a portion of the prefabricated door assembly being assembled into a door opening andillustrating the manner of `using the wedges.

ice

` Referring now more particularly to the drawings, the reference numeral 10 indicates the package unit generally which includes the preformed door and frame assembly as well as the elements cooperable therewith and affixed with particular relation thereto to form the package adapted for shipping the door assembly.

The door and frame assembly itself consists of two side frame members which are interconnected at their upper ends by a header, effecting a generally inverted Uf shaped conguration with the door proper being hingedly secured to one of the side frame members and cooperable with the latch and lock mechanism on the other side frame member in a conventional and well understood manner. As will be seen most clearly in Figs. 2 and 3, the side frame members and the header each consist of a pair of spaced molding strips which will be designated the inner molding strip 11 and the outer molding strip 12, it being understood that these molding stripsmay take any desired ornamental configuration. Rigidly aixed by any suitable means `to the inner and outer molding strips 11 and 12 are the inner and

outer jamb sections

13 and 14. These jamb sections extend at right angles to the molding strips adjacent to one longitudinal edge thereof such as to afford an L-shapedv cross-sectional construction and during normal engagement ofparts, the cross-sectional configuration of the side pieces and the header is channel like as shown. The inner or free longitudinal edges of the

jamb sections

13 and 14 are provided with notches or grooves 15` and 16 which extend longitudinally thereof which are of such dimension as tobe substantially the same width as the

tongue portions

17 and 18 which are formed by the notches so that when the parts are interengaged in a manner `indicated in Figs. 2 and 3, the

tougue portions

17 and 18 willfrictionally engage within the corresponding notches to effect a telescoping, overlapping interengagement between the inner and

outer molding strips

13 and 14.

The inner jamb strip 13 of both side frame members and the header is provided with a longitudinal cut-away portion or notch 19 which extends to and opens upon the inner edges of these jarnb strips for the purpose of receiving the door structure 20 therein and form a peripheral stop surface 21 for the door in a manner well understood. The door is provided with suitable `hinges 22 connecting it to the inner 1jamb strip` 13 in the manner illustrated.

The above described construction is not in itself intended to form the subject matter of this invention, the invention residing incertain constructions and 'arrangement of parts cooperable therewith to be utilized for the purpose of shipping` the preformed` door and frame structure such that it may arrive at its destination in a Wholesome andintact state devoid of damage such as chipping, marring, scratching or the like.

For the purpose of rigidifying the side frame members during shipment and for rigidifying them during and p end 27 of the innerwedge such that the two together initially form a rectangular block. A single fastening element such as the nail 28 is driven through the outer wedge 24 and into the inner wedge 23 to hold the outer wedge in place during shipment and before installation. In this respect, it will be noted that as shown most clearly in Fig. 3, the head of the fastener 28 is preferably left gesegelt;

in such a manner that it is spaced somewhat from the outer surface of the wedge 24 so that it may be easily removed by claw hammer or the like. The purpose of the fastener 28 is solely to hold the outer wedge 24 in place prior to installation of the preformed assembly. In installing the preformed assembly, the longitudinally separable portions of the door frame are parted and the inner section including the molding 11 and the jamb section 15 together with the door 20 are placed in approximately the, desired position within the door opening defined in part by the vertical studs indicated by the

reference characters

29 and 30. Of course, prior to the installation of this portion of the unit, the outer wedges 24 have been removed from the inner wedges. When the door and frame portion is in approximately the correct position, the outer wedges 24 are inserted in place in the manner shown in Fig. 6 and may be driven downwardly in respect tc the inner wedges to tightly wedge the preformed portion between the

Vertical studding

29 and 30 and similar but opposite studding not shown which is cooperable with the other side of the unit. Thus, the wedge construction is not only desirable in connection with the packaged unit wherein it rgidiiies and strengthensthe side frame members but also it serves the purpose of properly positioning the door frame and door assembly and wedging the same in place when the unit is installed.

Asv will be evident from Fig. l, the packaged unit includes the previously described door and frame assembly provided at each corner thereof with the

boot members

31, 32, 33 and 34, a second mechanism for holding the door frame sections together against separation and to serve as a base to which the corner boot members are secured, and the front and back

protective sheets

35 and 36. Each of the corner boots includes a pair of spaced side wall pieces 37 and 3S which have at least two interl secting right

angular edge portions

39 and 40 and corner pieces 41 and 42 joining the wall pieces along these intersecting edges in the manner shown most clearly in Fig. l with yreference to the corner boot 31.

As is tor be seen most clearly in Figs. 2 and 4, a pair of securing

block members

43 and 44 are associated with each of the upper corners of the door and frame construction, the securing blocks being of such length as to extend between and abut the molding strips 11 and 12 when the tongue and groove connections of the

jamb sections

13 and 14 are fully engaged. The lower surface of each block is cut-away as indicated by the reference character 45 for substantially half its length to provide clearance for the stepped relation between the jamb sectionsv13 and 14. Additionally, the vertical notch 46 is provided in the side face 47 of each block and the depth ofv this notch, although not critical, preferably extends to about half the thickness of the securing blocks. Further, there is another vertical notch 48 provided in each securing block in one end face thereof such as to extend longitudinally of the block.

Fasteners

49 and 50 extend through the respective notches 46y and 48 and into the

respective jamb sections

13 and 14 serving to rigidly retain the securing blocks in place when the

boots

31 and 32 are placed in enveloping relation over the upper corners of the door and frame construction. To then maintain the corner boots in position,

fasteners

51 and 52 are driven through the corner pieces 41 and 42 thereof into the

securingblocks

43 and 44. Thus, a rigid, protective assemblage is provided for the upper corners of the door and frame construction. It is to be noted that the height of each securing block is such as to space the upper face 51 thereof somewhat below the outer edge of the inner and outer molding strips, thus permitting the securing

block fasteners

49 and 50 to be driven to such as extent that their

heads

52 and 53 are not crushed into the body of the blockbut' lie outwardly thereof between the blocks and overlying'corner pieces 41 and 42. This in turn permitsy ready removal of the blocks after the corner boots are removed. Also, and moreimportant, it permits the fasteners 5() to slide freely within the groove 48 so that once the corner boots have been removed, the jamb section 14 and its associated parts may be withdrawn and disengaged from the jam section 13. Thereafter, removal of the fasteners 50 will be relatively simple since they project a very substantial distance above the surface of the jamb section 14. Also, the securing blocks will then present a free end portion projecting beyond the jamb section 13 so that light hammer blows 0n this free end will easily pull out the fasteners 49 and free the securing blocks.

The situation relative to the lower corner boots is similar in some respects to the upper corner boots in that securing blocks 54 are associated with the lower portions of the side frame members. These blocks are fastened to the inner and outer jamb sections by means of

fasteners

55 and 56 which project through the

vertical notches

57 and 58 of blocks 54, similarly to the manner in which the previously described securing blocks are fastened. If it is desired, the blocks 54 may be provided with notches 59 on their undersurfaces to clear an associated wedge assembly 60 disposed therebeneath and fastened to the inner jamb section in the manner previously described. Of course, the blocks 54 include lower surface notches 61 to clear the step formed between the two jamb sections.

Secured to the lower edge of the door adjacent each corner of the door and frame construction is a spacer block 62, securement being occasioned for example by a pair of

fasteners

63 and 64. Since the width of the spacer blocks 62 is such as to extend between the side walls of the

boots

33 and 34, they project a substantial distance beyond one side of the door 20 so that When the

corner boots

33 and 34 are removed, the spacer blocks are also easilyV removed by merely hitting them with a hammer or similar object. Fasteners 65 and 66 are driven through the corner pieces of the

boots

33 and 34, into the securing blocks 54 and spacer blocks 62 respectively, firmly securing these boots in place for shipping.

Thus it will be apparent that a simple and readily packaged unit is effected by the construction described. It is to be noted that the

protective sheets

35 and 36 are preferably of substantially the same area as the door and frame construction so that when the corner boots are in place thereover, the sheets are eiectively held in place. The sheets may be made of cardboard, plywood or any desired material and in addition to the protective feature, they additionally serve to present a compartment 67, with door 20, within which the door hardware such as lock and knob assembly may be placed.

This is particularly useful in constructions of the same general type as shown inasmuch as the door 20 is offset to one side and cannot therefore carry the usual knob assembly without interfering with the protective sheet 36.

The invention above described can also be applied in window constructions Whereina window frame may be positioned in like manner to the door 20 and arranged for sliding movement, swinging movement or otherwise, as desired. In this case it is desirable to provide means for associating a screen panel with the window and for this purpose longitudinally extending strips may be applied at the top and bottom of the outer jamb or frame section 14 in slightly spaced relation to the edge 68 of the inner jamb section 13 so as to dene therewith slots or grooves which will receive upper and lower marginal edge portions of the screen frame. The strip at the top of the screen would be of greater thickness than that at the bottom so as to provide a deeper groove at the top such that the screen panel may be easily removed by rst inserting the upper marginal portion thereof into the relatively deep groove and then placing the lower edge in vertical registry above the lowerv groove, whereafter when the screen panel is released and allowed to drop into the lower groove, it will be projected slightly into both the upper and `lower grooves to thus hold the screen firmly in place.

It will be appreciated that the window unit when constructed may be formed such that the longest dimension is upright or, if desired, the longest dimension can be horizontal. In either case, the strips for holding the screen panel in place are positioned so as to be in upper and lower relationship and they are preferably spaced from the edge 68 as shown in Fig. 3, a distance slightly greater than the width of the screen panel.

l. A packaging assembly for preformed door and frame constructions including side frame members joined by a header with a door hingedly secured to one of the side frame members, the side frame members and header being longitudinally separable, the side frame members and header including molding strips joined by jamb sections to provide a channel-like cross section, said assembly comprising corner packing means for each of the corners of the construction to be packaged, said means including spaced side wall pieces joined along adjacent, right angularly disposed edges by corner wall pieces, securing blocks fastened to the jamb sections adjacent each corner of the preformed door and frame construction, said securing blocks being notched in a direction toward one of the molding strips, with the means fastening the blocks to one of the jamb sections being disposed within the notch in each block, said corner wall pieces being secured to said securing blocks.

2. A packaging assembly for preformed door and frame constructions including side frame members joined by a header with a door hingedly secured to one of the side frame members, the side frame members and header being longitudinally separable, the side frame members and header including molding strips joined by jamb sections to provide a channel-like cross section, said assembly comprising corner packing means for each of the corners of the construction to be packaged, said means including spaced side wall pieces joined along adjacent, right angularly disposed edges -by corner wall pieces, securing blocks fastened to the jamb sections adjacent each corner of the preformed door and frame construction, said securing blocks being notched in a direction toward one of `the molding strips, with the means fastening the blocks to one of the jamb sections being disposed within the notch in each block, fasteners projecting through said corner wall pieces into said securing blocks whereby to fix the corner packing means to the door and frame construction in enveloping and protecting relation to the corners thereof.

3. A packaging assembly for preformed door and frame constructions including side frame members intcr connected by a header with a door hingedly secured to one of said side frame members, the side frame members and header being longitudinally separable and each including spaced molding strips connected by telescopically joined jamb sections to provide a channel-like cross section, the packaging assembly comprising means embracing the corners of the door and frame construction, said means including spaced side wall pieces having a pair of intersecting right angular edges and corner pieces interconnecting the side wall pieces along said intersecting edges, and securing blocks fastened on the jamb sections and extending between the molding strips, said securing blocks being notched in a direction toward one of the molding strips, with the means fastening the blocks to one of the jamb sections being disposed within the notch in each block, said corner pieces being secured to the securing blocks.

4. A packaging assembly for preformed door and frame constructions including side frame members interconnected by a header with a door hingedly secured to one of said side frame members, the side frame members and header being longitudinally separable and each including spaced molding strips connected by telescopically joined jambsections to providea channel-like cross `section, the packaging assembly comprising means embracing the corners of the door and frame construction, said means including spaced side wall pieces having a pair of intersecting right angular edges andcorner pieces interconnecting the side wall pieces along said intersecting edges, and securing blocks fastened on the jamb sections and extending between the molding strips, said securing blocks being notched in a direction toward one of the molding strips, with the means fastening the4 blocks to one of the jamb sections being disposed `Within `the notch in each block, fasteners projecting through said corner wall pieces into said securing blocks whereby to fix the corner packing means to the door and frame construction in enveloping and protecting relation to the corners thereof.

5. A packaging assembly `for preformed door and frame constructions including side frame members interconnected by a header lwithva door hingedly secured to one of said side frame members, the side frame members and header being longitudinally separable and each including spaced molding strips connected by telescopically joined jamb sections to provide a channel-like cross section, the packaging assembly comprising means embracing the corners of the door and frame construction, said means including spaced side wall pieces having a pair of intersecting right angular edges and corner pieces interconnecting the side wall pieces along said intersecting edges, and securing blocks fastened on the jamb sections and extending between the molding strips, said securing blocks being notched in a direction toward one of the molding strips, with the means fastening the blocks to one of the jamb sections being disposed within the notch in each block, said corner embracing means being secured to said securing blocks.

6. A packaging assembly for preformed door and frame constructions including side frame members joined by a header with a door hingedly secured to one of the side frame members, the side frame members and header being longitudinally separable, the side frame members and header including molding strips joined by jamb sections to provide a channel-like cross section, said assembly comprising corner packing means for each of the corners of the construction to be packaged, said means including spaced side wall pieces joined along adjacent, right angularly disposed edges by corner wall pieces, securing blocks fastened to the jamb sections adjacent each corner of the preformed door and frame construction, said securing blocks being notched in a direction toward one of the molding strips, with the means fastening the blocks to one of the jamb sections being disposed within the notch in each block, said corner wall pieces being secured to said securing blocks, and a sheet of protective material disposed on each side of said door and frame construction, each sheet being of substantially the same area as the door and frame construction and having its corner portions disposed between one side piece of a corresponding corner packing means and] an adjacent molding strip.

7. A packaging assembly for preformed door and frame constructions including side frame members joined by a header with a door hingedly secured to one of the side `frame members, the side frame members and header being longitudinally separable, the side frame members and lheader including molding strips joined by jamb sections to provide an outwardly facing channel, said assembly comprising corner packing means for each of the corners of the construction to be packaged, said means including spaced side wall pieces joined along adjacent, right angularly disposed edges by corner wall pieces with said side wall pieces disposed closely adjacent the outer sides of opposite molding strips, securing blocks fastened to the jamb sections within said channel and adjacent said corners of the preformed door and frame construction and extending between the opposed faces of the molding strips such that said molding strips are sandwiched between the side Wall pieces` and the securing blocks, said securing blocks being notched in a direction toward one of the molding strips, with the means fastening the blocks to one'of the jamb sections being disposed within the notch in each block, said securing blocks underlying corresponding corner wall pieces and said corner wall pieces being fastened to said securing blocks.

8. A packaging assembly for preformed door and frame constructions including side vframe members joined by a header with a door hingedly secured to one of the side frame members, the sideframe members and header being longitudinally separable, the side frame members and header including molding strips joined by jamb sections to provide a channel-like cross section, said assembly comprising corner packing means rfor each of the corners of the construction to be packaged, said means including spaced' sidewall pieces joined along adjacent,

right angularly disposed edges by corner wall pieces, y

securing blocks adjacent the upper corners of saidl frame extending between the molding strips, each of said securingblocks having a vertical notch in one side face thereof and a Vertical notch in one end face thereof, fasteners extending through each of said notches and into the adjacent jamb sections for rigidly retaining the securing blocks in place, said corner Wall pieces being secured to said securing blocks.

References Cited in the ile of this patent UNITED STATES PATENTS 1,910,781 Way May 23, 1933 2,290,990 Pagel July 28, 1942 2,331,753 Wohlers Oct. 12, 1943 2,489,029 Guerrant Nov. 22, 1949 2,651,814 Lester Sept. 14, 1953 2,711,564 Jackson June 28, 1955 2,753,602 Ringle July 10, 1956