US3060522A - Packaged door assembly and method for prefabricating and installing the same - Google Patents

Description

Oct. 30, 1962 PARKER 3 060,522

J H. PACKAGED DOOR ASSEMBLY AND METHOD FOR PREFABRICATING AND INSTALLING THE SAME Filed Nov. 5, 1958 FIG. 1.

FIG. 3.

INVENTOR. John H. Parker ATTORNEYS United States Patent 3,060,522 PACKAGED DOOR ASSEMBLY AND METHOD 50R PREFABRICATING AND INSTALLING THE John H. Parker, 743 E. Hayward Ave., Phoenix, Ariz. Filed Nov. 3, 1958, Ser. No. 771,658 6 Claims. (Cl. 2011) This invention relates to a packaged door assesmbly and method for prefabricating and installing the same.

Doors have, in the past, been hung by shimming the door frame around the rough openings with wooden shims so that it is plumb and square and held tightly in place, after which the door is cut to the plumbed door frame. Various attempts have been made to simplify this timeconsuming shimming operation, illustrative of which is the method disclosed in US. Patent No. 2,730,773 to G. I. Logue, January 17, 1956 wherein shiming is accomplished by means of pressure screws.

It is an object of this invention to provide a packaged assembly for installing a complete shop-hung door which requires no shimming and consequently can be installed in a minimum of time and with a minimum of effort.

Further objects are to provide a method for installing a packaged door assembly in a few simple steps by a person unskilled in the art of hanging doors, the operation requiring no special tools; to provide a method for prefabricating a packaged door assembly in which the various pieces of wood making up the component parts are first assembled in rough lengths and then machine cut and mitered together to insure a perfect fit when installing the door; to provide a packaged door assembly comprising a hinge jamb, strike jamb, header and door, all prefabricated and precut as one-piece units, which are readily assembled on the job into a door frame of superior strength; to provide a packaged door assembly of the character described, in which the casing is permanently secured to the frame; and to provide a packaged door assembly including pressure screws for positively positioning the hinge jamb, strike jamb and header.

Other objects of the invention will be manifest from the following description of the present preferred formof the invention, taken in connection with the accompanying drawings, wherein:

FIG. 1 is a perspective view of the component parts of the packaged door assembly of the present invention;

FIG. 2 is a fragmentary elevational view of a door frame illustrating the application of the present invention, portions thereof being broken away to disclose details of construction;

FIG. 3 is a transverse sectional view taken through one of the jambs and illustrating to advantage the manner of installing the same; and

FIG. 4 is a plan view of the header forming a part of the present invention.

Referring now in greater detail to the drawing, there is shown in FIG. 1, a prefabricated packaged door assembly which includes a hinge jamb 5, a strike jamb 6, a header 7, a door 8 and pressure screws 9.

Hinge jamb includes a frame member 11 the upper terminal of which is mitered at 11. A door stop 12, the upper edge of which is mitered at 13, is affixed to one face of frame member and extends longitudinally thereof. A pair of opposed casing members 14 having their upper margins mitered at 15 are permanently glued and stapled to the lateral margins of frame member 10 to provide a jamb of unitary construction. The mitered upper edges of frame member 10, door stop 12 and casing member 14 lie in the same plane. Conventional butt hinges are indicated at 16.

Adjacent the upper terminal of frame member 10 are a pair of spaced openings 17 preferably located one on each 3,959,522 Patented Oct. 30, 1962 "ice side of door stop 12, which are adapted for the reception of pressure screws 9 which will be hereinafter more fully described.

Strike jamb 6 comprises frame members and casing members which are of the same construction as hinge jamb 5 and consequently the parts thereof are identified by like primed numbers. One face of frame 10' may be suitably machined to provide a recess for the reception of a lock unit adapted to cooperate with hardware connected to door 8.

Header 7 includes a frame member 18, the lateral edges of which are mitered at 19. A door stop 20 having mitered terminals 21 is affixed longitudinally of frame 18. A pair of casing members 22 having mitered terminal portions 23 are nailed and stapled to the lateral margins of frame 18 in the manner of jambs 5 and 6. Pairs of openings 24 and 25, adapted for the reception of pressure screws 9, are provided in frame 18 adjacent the terminals thereof and on opposed sides of door stop 20.

Door 8 may be of conventional construction, having along one lateral edge, spaced butt hinges 26 adapted to be engaged with butt hinges 16 of door jamb 5 by means of pintles 27. Door 8 is further provided, along the edge thereof, remote from hinges 2.6, with openings 28 and 29 adapted to receive a door knob and lock unit which may form a part of the present assembly. Pressure screws 9 are designed to position the jambs 5 and 6 and header 7 and to close and match the miter joints between these parts. Each pressure screw 9 includes a T nut comprising a sleeve 30 which is internally threaded'at 31, one terminal of the nut being provided with a flange 3'2 portions of which, adjacent the outer periphery, are struck to provide barbs 33 adapted for engagement with the wood adjacent the openings in which the pressure screws are placed. The T nut is adapted for threaded engagement with a machine screw having a threaded shank 34, one terminal of which is enlarged to provide a flat head 35. The opposite end of threaded shank 34 is provided with a kerf 36 for adjusting the position of the machine screw with respect to the T nut. A plug for the pressure screw opening is indicated at 37.

In installing a packaged door assembly constructed in accordance with the present invention, the hinge jamb 5 is first slipped into place in the door opening so that casing members 14 are disposed on opposite sides of the vertical stud 38 which defines one side of door opening. Header 7 is next placed into position so that casing members 22 are on opposite sides of horizontal stud 3? forming the upper limit of the door opening. Strike jamb 6 is next slipped into position in the same manner as hinge jamb 5. Pressure screws 9 carried by jambs 5 and 6 and header 7 are then tightened sufficiently to hold the frame in place, making sure that the miters are matched exactly. Door 8 is next hung and the bottom of jambs 5 and 6 are manipulated until the frame fits the door. The door frame is then secured in place by means of nails 40 which are driven through the casing members into the studs. The pressure screws are tightened securely after which plugs 37 are inserted in screw openings 17, 17, 24 and 25.

In prefabricating the present packaged door assembly, the component parts of the hinge jamb, strike jamb and header are not individually handled and cut, but are assembled first in rough lengths and then machine cut at one time. The cutting of the assembled units results in a fully mitered door installation, which improves the appearance of the door assembly, lends to the ease of erection and is substantially less expensive to manufacture. Door assemblies constructed in accordance with this invention have been found to be of superior strength and meet the requirements of local and federal government inspectors. Prefabrication in the present manner additionally enables the component parts of the door frame to be packaged back to back for compact shipping, thereby etfecting a saving of space and considerably reducing any likelihood of damage.

It has also been found that with the device and method of the present invention, the door assembly may be hung by one possessing no special skill in the art of hanging doors, in approximately fifteen minutes and without special tools. The use of wooden shims is eliminated by the expediency of permanently affixing the casings to the frames to form an integral unit. To further reduce the cost of this assembly, stock T nuts and machine screws comprise the pressure screws forming a part of the present invention, thereby eliminating the high cost of specially designed pressure screws.

It is of course to be understood that the method and apparatus of the present invention may be employed in installing various types of doors such as sliding doors, swinging doors, etc. Various other changes may be made therein, without departing from the spirit and scope of the claims hereto appended.

What -I claim is:

1. A packaged door assembly for installation in a rough door opening comprising a pair of jambs and a header including a frame member and easing members preassembled and cut to the desired lengths, said jambs and header being complementally mitered at adjacent edges when in erected position, and adjustable positioning members mounted in said jambs and header and adapted for engagement with the rough door opening, to position the jambs and header and match the mitered edges thereof, said adjustable positioning members being located in each of said jambs and header in spaced pairs on each side of the mitered joints proximate the mitered edges thereof.

2. A packaged door assembly, as set out in claim 1, wherein said members comprise a plurality of T-nuts, each of which includes an internally threaded sleeve, one terminal of the sleeve being provided with a flange, portions of said flange being struck to provide barbs adapted for engagement with the jambs or header at the locus of openings therein in which the T-nut is received, and a screw threadedly engaged with said sleeve, the inner end of said screw being adapted to engage the rough door opening.

3. A packaged door assembly, as set out in claim 2, wherein the inner terminal of said screw is enlarged to provide a flat head and the opposite end thereof is provided with a kerf to permit adjustment of said screw.

4. A packaged door assembly for installation in a rough door opening comprising a pair of jambs and a header of wooden construction, each of which includes a frame member and casing members pre-assembled and cut to the desired lengths, adjacent terminals of said jambs and header being complementally and uniformly mitered throughout their widths, and adjustable positioning members mounted in said jambs and header and adapted for engagement with the rough door opening, to position the jambs and header and match the mitered edges thereof said adjustable positioning members being located in each of said jambs and header proximate the mitered edges thereof.

5. A packaged door assembly, as set out in claim 4, wherein each of said adjustable positioning members comprises a threaded sleeve, anchoring means on said sleeve for holding the latter in fixed position, and a positioning screw threadedly engaged with said threaded sleeve, one terminal of said screw being adapted to engage the rough door opening.

6. A packaged door assembly as set out in claim 5, wherein the inner terminal of said positioning screw is enlarged to provide a fiat head and the opposite end thereof is provided with a kerf to permit adjustment of said screw.

References Cited in the file of this patent UNITED STATES PATENTS 2,169,985 Hiza Aug. 15, 1939 2,706,837 Jackson Apr. 26, 1955 2,730,773 Logue Ian. 17, 1956 2,835,933 Evans May 27, 1958 2,859,491 Morris Nov. 11, 1958 2,874,420 Henderson Feb. 24, 1959 2,914,817 Jackson Dec. 1, 1959 FOREIGN PATENTS 478,022 Canada Oct. 23, 1951

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